Piping
components
PC L1 (Basic Module)
Basic level
Piping components
OUT LINES
• Introduction
• Components classification
(components function, types and manufacturing process)
Piping Bulk
Pipes
Flanges & accessories (bolts & gaskets)
Fittings
Piping valves
1. Gate
2. Glob
3. Check
4. Ball
5. butterfly
Basic level
In any plant various fluids flow through
pipes from one end to other.
We have to transfer the content of Tank no.
1 to the other two tanks.
We will need to connect pipes to transfer the
fluids from Tank-1 to Tank-2 and Tank-3
We have just brought the pipes, now
To solve these we need to solve some more
problems we need problems.
the pipe
Pipes are all straight pieces.
components, which
are called
PIPE FITTINGS
We need some
branch
connections
We need some
bend connections
,
There are various types of fittings for
various purposes, some common types are -
Elbows/Bends, Tees/Branches,
Reducers/Expanders, Couplings, Olets, etc.
Anyway, the pipes and
fittings are in place, but
the ends are yet to be
joined with the Tank
nozzles.
We now have to complete the
end connections.
These, in piping term, we call
TERMINAL
CONNECTIONS.
But if we want to control the flow from Tank-1 to
other tanks.
We need some arrangement to stop the
flow if needed
These are flanged
joints
This is a welded joint
To control the flow in a pipe line
we need to fit a special
component.
That is called - VALVE
There are many types of valves, categorized
based on their construction and
functionality,
Those are - Gate, Globe, Check, etc.
Other than valves another
important line component of pipe
line is a filter, which cleans out
derbies from the flowing fluid.
This is called a STRAINER
When some fluid is flowing in a pipe we
may also like know the parameters like,
pressure, temperature, flow rate etc. of
the fluid.
Here are some of the pipe supporting
arrangements. There can be numerous variants.
All depend on piping designer’s preference and
judgement.
Introduction
Manufacturing process types
• Forging ( used mainly for flanges and small sizes fittings and valves)
• Casting ( used mainly for large size valves and very large flanges)
• Machining (used mainly for large size fittings and bolts)
• Welding (used for large size pipes and very large fittings)
• Extrusion (used for small and large size pipes)
Basic level
Piping components
OUT LINES
• Introduction
• Components classification
(components function, types and manufacturing process)
Piping Bulk
Pipes
Flanges & accessories (bolts & gaskets)
Fittings
Piping valves
1. Gate
2. Glob
3. Check
4. Ball
5. butterfly
Basic level
Components classification
Piping components
Piping Bulk Piping valves
Pipes Flanges & Fittings Specialties Gate
accessories
(bolts & Connection
gaskets) Globe
fittings
Reducing
Check
fittings
Brunched
Ball
fittings
Butterfly
Basic level
Piping components
OUT LINES
• Introduction
• Components classification
Piping Bulk
Pipes
Flanges & accessories (bolts & gaskets)
Fittings
Piping valves
1. Gate
2. Glob
3. Check
4. Ball
5. butterfly
Basic level
Pipes
• Pipe is customarily identified by "Nominal Pipe Size" (NPS),
with wall thickness defined by "Schedule number" (SCH).
• Tube is customarily specified by its outside diameter (O.D.)
and wall thickness (WT), expressed either in Birmingham wire
gage (BWG) or in thousandths of an inch.
• Diameter nominal (DN) is used in the metric unit system. It
indicates standard pipe size when followed by the specific size
designation number without a millimeter symbol. For
example, DN 80 is the equivalent designation of NPS 3. Below
a table with equivalents for NPS and DN pipe sizes.
NPS 1/2 3/4 1 1¼ 1½ 2 2½ 3 3½ 4
DN 15 20 25 32 40 50 65 80 90 100
Basic level
Pipes (Manufacturing)
STEEL PIPES ARE MANUFACTURED IN 2 VERSIONS:
• SEAMLESS
– SEAMLESS PIPE PLUG MILL PROCESS
– SEAMLESS PIPE MANDREL MILL PROCESS
– SEAMLESS PIPE EXTRUSION PROCESS
• WELDED
– SPIRAL WELDED
– LONGITUDINALLY WELDED SAW
– ELECTRIC RESISTANCE WELDED (ERW)
Basic level
Pipes (Manufacturing)
SEAMLESS
SEAMLESS PIPE PLUG MILL
PROCESS
• This process is used to
make larger sizes of
seamless pipe, typically 6
to 16 inches
• solid round (billet) is used.
heated in the rotary hearth
heating furnace and rolled
by a plug mill
Basic level
Pipes (Manufacturing)
SEAMLESS PIPE MANDREL
MILL PROCESS
• This process is used to
make smaller sizes of
seamless pipe, typically
1 to 6 inches
• rolled by a mandrel mill
SEAMLESS PIPE
EXTRUSION PROCESS
• This process is used for
small diameter tubes
only.
Basic level
Pipes (Manufacturing)
WELDED PIPE
SPIRAL WELDED
• The defects that occur in
spiral welded pipe are
mainly those associated
with the SAW
Basic level
Pipes (Manufacturing)
LONGITUDINALLY WELDED (SAW)
Basic level
Pipes (Manufacturing)
ELECTRIC RESISTANCE
WELDED (ERW) AND HIGH
FREQUENCY INDUCTION
(HFI) WELDED PIPE
• the product is still often referred to
as ERW pipe, even though the weld
may have been produced by the HFI
process.
• ERW pipe was generally regarded as
a second-grade pipe suitable only for
low pressure applications.
• lowe cost of ERW pipe, suppliers and
end users directed a major effort
toward improving the pipe mill by
the automatic ultrasonic inspection
equipment In addition, the standard
of heat treatment of the weld line
Basic level
Piping components
OUT LINES
• Introduction
• Components classification
Piping Bulk
Pipes
Flanges & accessories (bolts & gaskets)
Fittings
Piping valves
1. Gate
2. Glob
3. Check
4. Ball
5. butterfly
Basic level
Flanges & accessories
FLANGE TYPES
• Welding neck: for high pressure
process conditions
• Socket weld: for low pressure
process and utilities
• Screwed: for small pressure
utility conditions and small sizes
Basic level
Flanges & accessories
FLANGE TYPES
• Slip-on: for large sizes and
limited pressures
• Lap joint: for special
corrosive commodities
• Blind Orifice
Basic level
Flanges & accessories
FLANGE FACING
• Flat face (FF) : for low Pressures
applications
• Raised face (RF): for moderate & high
Pressures applications
• Ring joint (RJ): for very high
Pressures applications
Basic level
Flanges & accessories (Manufacturing)
The majority of the flanges are forged
Basic level
Flanges & accessories
GASKETS
Non metallic gasket
ASBESTOS Free Synthetic Fibres
Used for FF flanges
Metallic Gaskets
Spiral Wound Gasket
Used for RF flanges
Ring Gaskets
Used for RJ flanges
BOLTING
Stud bolt:
Machine bolt
Basic level
Piping components
OUT LINES
• Introduction
• Components classification
Piping Bulk
Pipes
Flanges & accessories (bolts & gaskets)
Fittings
Piping valves
1. Gate
2. Glob
3. Check
4. Ball
5. butterfly
Basic level
Fittings
Connection fittings
Directional fittings : 1. 90 Deg Elbow 2. 45 Deg Elbow
In-Line fittings : 1. Coupling 2. Union 3. bushing 4. Nipple
End- line fittings : 1. Cap 2. Plug
Reducing fittings
Reducers : 1. Concentric 2. eccentric
Swages: 1. Concentric 2. eccentric
Brunched fittings
Brunched tee: 1. Equal tee 2. Lateral tee 3. Reducing tee
Brunched O-lets: 1. Weldolet 2. Sockolet 3. Thredolet:
Advanced module
Fittings (Connection fittings)
Directional fittings:
Change the flow direction
1. 90 Deg Elbow (LR & S.R) 2. 45 Deg Elbow (LR & S.R)
In-Line fittings:
Connect two smiler size pipes and/or fittings
1. Coupling 2. Union 3. Bushing 4. Nipple
Basic level
Fittings (Connection fittings)
End- line fittings :
Closing pipe spools
1. Cap 2. Plug
Basic level
Fittings (Reducing fittings)
Reducers :
Connect two dis-smiler size pipes (2” and above)
1. Concentric 2. eccentric
Swages:
Connect two dis-smiler size pipes (1.5” and below)
1. Concentric 2. eccentric
Basic level
Fittings (Brunched fittings)
Brunched tee: (2” and above)
1. Equal tee:
Connect three smiler size pipes
( two in line – one in 90 Deg)
2. Lateral tee:
Connect three smiler size pipes
( two in line – one in 45 Deg)
3. Reducing tee:
Connect three dis-smiler size pipes
( two in line – one in 90 Deg)
Basic level
Fittings (Brunched fittings)
Brunched O-lets: (1.5” and below)
1. Weldolet:
Connect small size brunch pipe to header pipe
(brunch pipe butt welded)
2. Sockolet:
Connect three smiler size pipes
(brunch pipe socket welded)
3. Thredolet:
Connect three dis-smiler size pipes
(brunch pipe threaded)
Basic level
Fittings (Manufacturing)
The fittings are forged for small sizes smiler to flanges and machined for large sizes
Basic level
Piping components
OUT LINES
• Introduction
• Components classification
Piping Bulk
Pipes
Flanges & accessories (bolts & gaskets)
Fittings
Piping valves
1. Gate
2. Glob
3. Check
4. Ball
5. butterfly
Basic level
Piping valves
1- Gate valve
Advantages:
• Could be use for the high temperature service .
• Cheap when comparing with the ball valve.
• Give a tight shut off for small sizes.
• Metal seat enable to use it with dirt fluid.
Disadvantages:
• It is not suitable for throttling applications.
• It is prone to vibration in the partially open state.
• It is more subject to seat and disk wear than a
globe valve.
• Repairs, such as lapping and grinding, are
generally more difficult to accomplish.
Basic level
Piping valves
2- Globe valve
Advantages:
• good throttling capability
• Shorter stroke (compared to a gate valve)
• Available in three patterns, each offering unique
capabilities
• Easy to machine or resurface the seats
Disadvantages:
• Higher pressure drop (compared to a gate valve)
• Requires greater force or a larger actuator to seat the
valve
• Throttling flow under the seat and shutoff flow over
the seat
Basic level
Piping valves
3- Check valve
• Check valves are designed to prevent the reversal of
flow in a piping system.
• The pressure of the fluid passing through the system
opens the valve, while any reversal of flow will close
the valve. (self operated)
Basic level
Piping valves
4- Ball valve
Advantages:
• Quick quarter turn on-off operation
• Tight sealing with low torque
• Smaller in size than most other valves
Disadvantages:
• In slurry or other applications, the suspended
particles can settle and become trapped in body
cavities causing wear, leakage, or valve failure.
Basic level
Piping valves
5- Butterfly valve
• Butterfly valves have many advantages over gate,
globe, plug, and ball valves, especially for large
valve applications.
• Savings in weight, space, and cost are the most
obvious advantages.
Basic level
Piping valves (Manufacturing)
• For valves 1.5” & blow forged.
• For valves 2” & above majority of the valve components are canting such as valve
body , valve disc, valve bonnet , valve hand-wheel, valve flange and valve seat.
Casting process
1. Sand Casting Method: Suitable to do cast iron casting, especially ductile iron casting
and gray iron casting valve products. This method is also suitable to get big size valve
parts with steel material or cast iron material. We can cast to 64 inch (DN1600) valve
body and valve disc, and the max weight to 2tons / per piece.
Basic level
Piping valves (Manufacturing)
2. Investment Casting Method: this method is suitable to do carbon steel and stainless
steel valves, especially ball valves. it can get a good surface finish and dimensions.
Basic level
Piping valves (Manufacturing)
3. Die Casting Method: we mainly do cast iron valve parts by lost foam casting, it can get
good surface finish and good dimension, you only machine little allowance
Basic level