Unit 5

Pipes, fittings and valves

Pipe:-
The pipe is pressure tight circular hollow section that used in piping systems to transport gases or fluids.

Pipe Material
Piping components are used to transporting various liquids that can be Flammable, Corrosive, Explosives,
Volatile, Reactive and sometime Hazardous to human health that is why selection of proper pipe material is
important.
Piping material selection mainly depends on process conditions such as

▪ Fluid it transports;
▪ at what temperature
▪ At what pressure it transports.
▪
Let’s try to understand this condition in depth.
1st, Process condition that will impact the selection of material is type of fluid it transport. For corrosive
fluids, you have to go for higher corrosion resistance material as compared to non-corrosive service

▪ Corrosive fluids such as – crude oil, Sea Water, H2S, Ammonia, Acids etc. required high corrosion
resistance material.
▪ On the other hand, normal carbon steel is enough for Non-Corrosive fluids such as – Lube oil, Air,
Nitrogen etc.

2nd Process condition that will impact the selection of material is the Temperature of fluids

▪ Cryogenic
▪ Low temperature
▪ Medium temperature
▪ High temperature

Increase or decrease in the service fluid temperature will greatly affect mechanical properties of
the pipe material such as impact resistance, elongation, and tensile strength; hence, you required special
material for both high temperature & Cryogenic services.

3rd Process condition that will impact the selection of material is the Pressure of service fluids. You required
high strength material or higher thickness material for high-pressure services compare to normal pressure
services.

Others non-process factor that also considered during material selection are

▪ Cost of material
▪ Availability – whether the material is locally available or import is required.
▪ Weld ability and Manufacturability of material also play a vital role in selection. Preference is
always given to the material which does not require any special requirement during welding and
manufacturing.
Material Properties

Similar to process fluid properties, there are certain material properties that also consider while selecting
pipe material. Some of them are

▪ Ultimate Tensile Strength – that is the capacity of a material to withstand when subjected to tension.
▪ Yield Strength – that is the load at which plastic deformation or you can say permanent deformation
start.
▪ Elasticity – is the ability of a material to resume its normal shape after the load is removed just like
rubber.
▪ % Elongation – Percent elongation is a measure of ductility.
▪ Hardness – is ability of a material to resist plastic deformation.
▪ Toughness– ability of a material to absorb energy before fracture.
▪ Creep resistance – ability to resist any kind of distortion when under a load over an extended period.
▪ Fatigue Resistance – is ability of material to withstand cyclic load for a given number of cycles
before it fails.

Piping material broadly classified into three categories. Metal, Non-metal, and composite, which is a
combination of metal to metal or metal to non-metal.

Metals. (Ferrous and Non-ferrous)

Ferrous Metal

▪ Carbon Steel
▪ Alloy Steel
▪ Stainless Steel

Non-ferrous Metal

▪ Copper and Copper Alloys

▪ Nickel and Nickel Alloys
▪ Aluminum and Aluminum Alloys
▪ Titanium and Titanium Alloys
▪ Zirconium and Zirconium Alloys

Non – metals.

▪ PVC/CPVC
▪ HDPE
▪ GRE/GRP
▪ Cement pipes

Tubes:

Tube refers to round, square, rectangular, and oval hollow sections used for pressure equipment, for
mechanical applications, and for instrumentation systems.
 Difference between pipes and tubes

PIPES TUBES
➢ Pipe Size Specified in Nominal Pipe Size ➢ Tubes sized are specified in millimetre or
(NPS) or Nominal Bore (NB) or in inches by outside diameter
Diameter Nominal (DN) ➢ Wall thickness is expressed in millimetre,
➢ Wall thickness is expressed in schedule or inches, or BWG (Birmingham wire
number gauge.)
➢ The outside diameter of pipe up to size ➢ Outside diameter of tubes is numerically
12” are numerically larger than equal to the corresponding size.
corresponding pipe size
➢ Used in all process & utility lines ➢ Generally used in tracing lines, tubes for
heat exchanger & fired heater & in
instrument connection.
➢ Available in the small bore as well as the ➢ Normally small-bore tube is used in
big bore. process piping. For structural use, tubs
are available in custom sizes.
➢ Shape- Round only ➢ Shape- Round, rectangular, square, oval
➢ Delivery time can be short. ➢ Delivery time can be short.
➢ Material - A wide range of materials is ➢ Material - Tubing is available in carbon
available steel, low alloy, stainless steel, and
nickel-alloys.

Schedule number (SCH): - The schedule number on pipe products relates to the thickness of the wall
on the pipe: as the number increases, the thicker the wall thickness becomes. Also, while the
schedule number can be the same on different sized pipes, the actual wall thickness will be different.
Here are a few examples:

▪ Pipe size 1.000” Schedule 40 – The actual wall thickness is 0.133”

▪ Pipe size 2.000” Schedule 40 – The actual wall thickness is 0.154”

▪ Pipe size 1.000” Schedule 80 – The actual wall thickness is 0.179”

▪ Pipe size 2.000” Schedule 80 – The actual wall thickness is 0.218”

The higher the schedule number is, the thicker the pipe is. Since the outside diameter of each pipe
size is standardized, a particular nominal pipe size will have different inside pipe diameter depending
on the schedule specified.

NPS (nominal pipe size)

The NPS size represents the approximate inside diameter (not outside) of the pipe; if the schedule
number on a set size is changed, it does effect the inside diameter (ID) but not the outside diameter
(OD). In 1927 the American Standard Association replaced the previously used Iron Pipe Sizing
(IPS) with Nominal Pipe Sizing (NPS). This North American standard is used on pipes for high or
low pressures and temperatures. Example:
NPS OD Schedule # Wall Thickness ID
1.000” 1.315” SCH 40 0.133” 1.049” (approx.)
 1.000” 1.315” SCH 80 0.179” 0.957” (approx.)
All pipes are specified using the NPS and schedule numbers. It is the schedule number that
determines the approximate inside diameter.

Selection of pipe sizes:-

• The pipe size selected for a particular installation depends mainly on the cost of the pipe and
fittings and the cost of energy needed for pumping the fluid.
• The cost of the pipe and the annual capital charges increase with about the 1.5 power of the
pipe diameter.
• While the power cost for turbulent flow varies with the 4.4 power of the diameter.
• The optimum pipe diameter as a function of flow rate and fluid density.

dopt = 293 (m) 0.53 () -0.37

dopt = Optimum pipe size (mm)

m = Flow Rate (kg/sec)
 = Density of fluid (kg/m3)

Fittings:-
Pipe Fittings are piping component that helps in Changes the direction of the flow such as elbows,
tees. Changes the size of the pipe such as reducers, reducing tees. Connect different components such
as couplings and stop the flows such as Caps.
There are different types of pipe fitting used in piping. Pipe Fittings used in piping work are mainly
Elbow, Tee, Reducer, Union, Coupling, Cross, Cap, Swage Nipple, Plug, Bush, Expansion Joint,
Steam Traps, Long Radius Bend, Flanges and Valve.
• Joining two pipe pieces – coupling / socket, union, nipple.
• Changing the pipeline diameter – reducer.
• Termination of the pipeline – plug.
• Changing the direction of the flow – elbow, bend.
• Branching of the pipeline – Tee, cross.
• Controlling a flow rate through a pipe – Valve.

Pipe Elbow

The Elbow is used more than any other pipe fittings. It Provides flexibility to change the pipe direction.
Elbow mainly available in two standard types 90° and 45°. However, it can be cut to any other degree.
Elbows are available in two radius types, Short radius (1D) and Long radius (1.5D).
90 Degree elbow is installed between the pipe to change the direction of the pipe by 90 Degree. Available in
long and short radius form.
45 Degree elbow is installed between the pipe to change the direction of the pipe by 45 Degree.

Pipe Bend

Long radius pipeline bends are used in fluid transportation line which required pigging. Due to their long
radius and smooth change of direction, pipe bend has very less pressure drop, and smooth flow of fluid &
pig is possible. 3D and 5D Pipe bends are commonly available. Here, D is the pipe size.

Pipe Tee

Pipe tee is used for distributing or collecting the fluid from the run pipe. It is a short piece of pipe with a 90-
degree branch at center. There are two types of Tee used in piping, Equal / Straight Tee and Reducing /
Unequal Tee.

In straight tee, the diameter of the branch is same as the diameter of the Run (Header) Pipe.

In reducing tee, diameter of the branch size is smaller than the diameter of the Run (Header) Pipe.

Wye Tee / Lateral

It is a type of Tee which has the branch at a 45° angle, or an angle other than 90°. Wye tee allows one pipe
to be joined to another at a 45° angle. This type of tee reduces friction and turbulence that could hamper the
flow. Wye tee is also known as a lateral.
Cross

Cross is also known as four-way pipe fitting. A cross has one inlet and three outlets (or vice versa).
Generally, crosses are not used in process piping to transport fluid. But forged crosses are common in the
fire water sprinkler line.

Pipe Reducers

A pipe reducer changes the size of the pipe. There are two types of reducer used in piping Concentric &
Eccentric.

Concentric Pipe Reducer or Conical Reducer

In Concentric reducer which is also known as a conical reducer, the center of both the ends is on the same
axis. It maintains the centerline elevation of the pipeline. When the center lines of the larger pipe and
smaller pipe are to be maintained same, then concentric reducers are used.

Eccentric Reducer

In Eccentric reducer, the center of both the ends is on different axis as shown in the image. It maintains BOP
(bottom of pipe) elevation of the pipeline. When one of the outside surfaces of the pipeline is to be
maintained same, eccentric reducers are required.

Offset = (Larger ID – Smaller ID) / 2

Pipe Coupling

There are three types of coupling available;

▪ Full Coupling
▪ Half Coupling
▪ Reducing Coupling

Full Coupling

Full Coupling is used for connecting small bore pipes. It used to connect pipe to pipe or pipe to swage or
nipple. It can be threaded or socket ends types.

Half Coupling

Half Coupling is used for small bore branching from a vessel or large pipe. It can be threaded or socket type.
It has a socket or thread end on only one side.

Reducing Coupling

Reducing coupling is used to connect two different sizes of pipe. It is like concentric reducer that maintains
a center line of the pipe but small in size.

Pipe Nipple

Nipple is a short stub of pipe which has a male pipe thread at each end or at one end. It used for connecting
two other fittings. Nipples are used for connecting pipe, hoses, and valves. Pipe nipples are used in low-
pressure piping.
Flanges
The pipe flanges are the second most used joining method after welding. They are used when joints need
dismantling. It provides flexibility for maintenance. Flange connects the pipe with various equipment and
valves. Breakup flanges are added in the pipeline system if regular maintenance is required during plant
operation. The flange is also the most common source of leak and fire in a process plant. There are a variety
of flanges available to suit the requirements. A flange can be classified in several alternate ways as follows:

1. Based on Types of Connection

2. Based on Flange facing Types
3. Based on Pressure Temperature Ratings
4. Based on Material Types

Flange Types

Threaded Flanges

Threaded Flanges are also known as screwed flange, and it is having a thread inside the flange bore which
fits on the pipe with matching male thread on the pipe. This type of joint connection is Speedy and simple
but not suitable for high presser and temperature applications. Threaded Flanges are mostly used in utility
services such as air and water.

Socket-Weld Flanges

Socket-Weld Flanges has a female socket in which the pipe is fitted. Fillet welding is done from outside on
the pipe. Generally, it is used in small bore piping and only suitable for low pressure and temperature
application.
Slip-On Flanges

Slip-On flange has a hole with matching outside diameter of pipe from which pipe can pass. The flange is
placed on pipe and fillet welded from both inside and outside. Slip-On Flange is suitable for low pressure
and temperature application. This type of flange is available in large sizes also to connect big-bore piping
with storage tank nozzles. Sometimes, these flanges are fabricated from plates and are not provided with the
hub.

Lap Joint Flanges

Lap flange is having two components, a stub end, and a loose backing flange. Stub end is butt-welded to the
pipe and Backing flange freely moves over the pipe. The backing flange can be of a different material than
stub material and normally of the carbon steel to save the cost. Lap flange is used where frequent
dismantling is required, and space is constrained.

Weld Neck Flanges

Weld neck flange is the most widely used type in process piping. It gives the highest level of joint integrity
due to Butt-welded with a pipe. These types of flanges are used in high pressure and temperature
application. Weld neck flanges are Bulky & costly with respect to other types of the flange.
Blind Flanges

The blind flange is a blank disc with a bolt hole. These types of flanges are used with another type of flange
to isolate the piping system or to terminate the piping as an end. Blind flanges are also used as a manhole
cover in the vessel.

Prevention of leakage:-
In many processing equipment, it is necessary to have one part move in relation to another part without
excessive leakage of a fluid around the moving member.
Common devices for minimizing leakage:-
i.Stuffing boxes.
ii.Mechanical Seal.
Valves and its classification
Definition: A valve is a device for isolating or regulating the flow rate of gases, liquids and slurries
through Pipe work and launder systems.

Mode of Operation
1. The force required to operate a valve can be carried out either manually (by hand) or mechanically.
2. Mechanical attachments (actuators) to a valve are usually either electrically or pneumatically
operated.
3. The actuators can be controlled manually (i.e. a technician pushing a button/switch) or by the plant
control system.

Valves Functions
Valve serves a various function within the piping system. Such as

1. Stopping and starting a fluid flow. Depending on whether a valve is open or closed, it let pass the
process fluid or halt the fluid.
2. Throttling the fluid flow. Some of the valves let you throttle the fluid depending open % of total
opening. Lesser the opening higher the throttling and otherwise.
3. Controlling the direction of a fluid flow. Multiport
4. Regulating a flow or pressure within the piping system. Some of the automatic control valves
maintain the flow and pressure within the system by adjusting opening and closing.
5. Relieve pressure or vacuum from the piping system and equipment. Pressure and vacuum relief valve
safeguard the process system from overpressure and during vacuum condition.

Classification of valves
The following are some of the commonly used valves classifications, based on the
mechanical motions.
1. Linear motion valves: the valve in which closure member, as in gate, globe, diaphragm, pinch moves
in a straight line to allow, stop, or throttle the flow.
2. Rotary motion valves: when the valves closure member travels along an angular or circular path, as
in butterfly, ball, plug valves.
3. Quarter turn valves: some rotary motion valves require approximately a quarter turn, 0 through 90,
motion of the to go to fully open from a fully position or vice versa.
 Classification of valves based on motion
Valves types Linear motion Rotary motion Quarter turn
Gate valve X
Globe valve x
Plug valve X X
Ball valve X X
Butterfly valve x X
Diaphragm valve X
Pinch valve x

Material selection
There are factors govern the basic material selection
1. Corrosion – resistance requirement.
2. Thermal shock.
3. Piping stress.
4. Fire hazard.

Types of materials typically available includes

1. Ductile iron.
2. Carbon steel.
3. Cast iron.
4. Stainless steel.
5. Brass.
6. Bronze.
7. Poly vinyl chloride (PVC) plastics.

Body materials,
1. For small valves are usually brass, bronze, or forget steel.
2. For large valves, cast iron, cast ductile iron or cast steel as required for the pressure and service.
3. The valve seat and valve disk are sometimes referred to as the valve trim and usually constructed of
the same material to meet the service requirements.
4. Valve stem material should be selected to meet service conditions. Stainless steel is commonly used
for most HVAC (heating, ventilation, and air conditioning) applications, and bronze is commonly
used in ball valve constructions.

Valve selections
1. Pressure.
2. Temperature.
3. Types of fluid. A) Liquid, B) Gas, i.e. steam or air. C) Dirty or abrasive (erosion), D) Corrosive.
4. Flow considerations. A) On- off throttling, B) Is the valve needed to prevent back flow, C) Concern
for pressure drop, D) Velocity.
5. Operating conditions. A) Frequency of operation, B) Accessibility, C) Overall space/ size available,
D) Manual or automated control, E) Need for bubble – tight shut – off, F) Concerns about body joint
leaks,
G) Fire safe design, H) Speed of closure.
Valves types.
In piping following types of valves are used depending on the requirements. The cost of Valve in the piping
system is up to 20 to 30% of the overall piping cost. And the cost of a given type and size of the valve can
vary 100%. It means that if you choose ball valve over butterfly valve for the same function. It can cost you
more. So, the selection of valves is essential to the economics, as well as operation, of the process plants.
1. Globe valve.
2. Gate valve.
3. Plug valve.
4. Ball valve.
5. Needle valve.
6. Butterfly valve.
7. Diaphragm valve.
8. Pinch valve.
9. Check valve.
10. Safety/relief valve.
11. Reducing valve.
12. Check ( non- returning) valves

Globe valve: are linear motion valves that are widely employed to stop, start and throttle flow. Globe
valves are designed with a stem that moves up and down to regulate flow inside the valve, a disc (ball,
composition, or plug) and seat, which is generally screwed into the valve body. Seats are designed in plane
parallel or inclined to the line of the flow. These types of modulating valves are most commonly used to
valve throttle, open or close flow in a system. The three basic globe valve body designs are Wye, Tee and
Angle.

Advantages:
1. Good shutoff capability.
2. Moderate to good valve throttling
3. Shorter stroke (compared to a gate valve).
4. Easy to machine or resurface the seats.
Disadvantages:
1. Large circulation resistance
2. It is more difficult to open and close
3. Higher pressure drop (compared to a gate valve).
4. Requires greater force or a larger actuator to seat the valve.
APPLICATIONS

The following are some of the typical applications of globe valves:

1. Cooling water systems.
2. Fuel oil systems.
3. Feed water or chemical feed systems.
4. Boiler and main steam vents and drains.
5. Turbine lubes oil system and others.

Gate valves:
Gate valve (also known as knife valves or slide valves) Gate valve is the most common type of valve in any
process plant. It is a linear motion valve used to start or stop fluid flow. In service, these valves are either in
fully open or fully closed position. Gate valves are used in almost all fluid services such as air, fuel gas, feed
water, steam, lube oil, hydrocarbon, and all most any services. Gate valve provides good shutoff. Gate
valves are advantageous in applications involving slurries, as their ‘gates’ can cut right through the
slurry.They are also used in applications that involve viscous liquids such as heavy oils, light grease,
varnish, molasses, honey and cream.

Advantages
1. They have good shutoff characteristics.
2. They are bidirectional.
3. The pressure loss through the valve is minimal.

Disadvantages
1 They cannot be opened and closed quickly. To fully open or closed wheel or gearbox actuators, the
shaft should be rotated as many as the full open revolution number. The full open revolution number
is equal to the pitch
2 Assembly, start-up, and maintenance require large space.
3 In the fully closed position, the slow movement of the slide causes high flow speed. Due to
vibration and collision, abrasion and deformation occur in the seating surfaces and the surface gets
damaged from friction.
4 At the place of operation, repair and maintenance of seating surfaces are difficult.
Application
1. Socket or butt-welding end-gate valves in air, fuel gas, feed water, steam, lube oil, and other systems
are typical applications. Threaded-end gate valves may be used in air, gaseous, or liquid systems.
2. Concern for leakage from threaded connection can be addressed by seal welding the threaded
connection or by using thread sealants, as appropriate. In low-pressure and low-temperature systems such
as fire protection systems’ water piping or water distribution pipelines, flanged gate valves are
commonly used.

Ball valve:
Ball valves are rotational motion valves and are used for on/off and throttling service. The flow control
element is a sphere with a round opening rotating in a spherical seat.
Flow is regulated from closed to open during a 90° turn. Full port ball valves create a minimum pressure
loss when fully open. A disadvantage of the ball valve is its poor throttling characteristics.

ADVANTAGES

1. Quick quarter turn on-off operation

2. Tight sealing with low torque
3. Smaller in size than most other valves

DISADVANTAGES
1. Conventional Ball valves have poor throttling properties
2. In slurry or other applications, the suspended particles can settle and become trapped in body
cavities causing wear, leakage, or valve failure.

Applications
The following are some typical applications of Ball valves:
1. Air, gaseous, and liquid applications
2. Drains and vents in liquid, gaseous, and other fluid services
3. Steam service.
Diaphragm valve:
A diaphragm valve is a linear motion valve that is used to start, regulate and stop fluid flow. The name
is derived from its flexible disk, which mates with a seat located in the open area at the top of the valve
body to form a seal.The diaphragm valve is used primarily for handling viscous and corrosive fluids as
well as slurries.

Advantages
1. Valve components can be isolated from the process fluid.
2. Valve construction prevents leakage of the fluid without use of a gland seal ( packing)

Disadvantages
1. The diaphragm becomes worn more easily and regular maintaince is necessary.
2. These types of valves are generally not suited for very high temperature fluids and are mainly
used on liquids systems.

Applications
1. Clean or dirty water and air service applications.
2. De- mineralized water systems.
3. Corrosive applications.
4. Vaccume services.
5. Food processing, pharmaceutical, and brewing systems.

Plug valve:
Plug valve is Quarter-turn rotary motion Valve that uses a tapered or cylindrical plug to stop or start the
flow. The disk is in plug shape, which has a passage to pass the flow. Plug valve used as on-off stop
valves and capable of providing bubble tight shutoff. Plug valve can be used in vacuum to high-pressure
& temperature applications Plug valves are similar to Ball valves in operation.
Type of Plug Valve
1. lubricated plug valve
2. non-lubricated plug valve
3. eccentric plug valve
4. lift-type plug valve

Advantages
1. One-piece valve body, top-loading design, simple structure, convenient maintenance, no leakage,
supporting higher-strength pipe system.
2. The medium in the chemical process has strong corrosion resistance. the valve in the application of
chemical process must have strong permeability and resistance to intergranular corrosion. The body
of plug valve should be high-level casting.
3. Really simple internals. The plug is completely covered by the bushing. Body and plug have no
wear. Plug valve can reach long-term use requirement of 300 ℃,
4. Comparing with the ball valve, it has the advantages of lower machining allowance.
5. It is a good choice for a lot of corrosive, abrasive and toxic fluid as well as continuously operated
device. It has the application advantages and extensive applicability in the field of chemical industry.

Disadvantages
1. The design of face sealing improves the requirements for driving torque. In the case of needing to be
equipped with pneumatic actuators, compared with ball valve, it will cost much more.
2. Though the investment of plug valve is more than ball valve.

Butterfly valves:

A Butterfly valve is a quarter-turn rotary motion valve, which is used to stop, regulate, and start the flow.
Butterfly valve has a short circular body. Butterfly Valve is suitable for large valve applications due to
compact, lightweight design that requires considerably less space, as compared to other valves. Butterfly
valves are well suited to handle large flows of liquids or gasses as well as slurries and liquids with large
amounts of suspended solids

.
APPLICATIONS OF BUTTERFLY VALVES
1. Butterfly valves are widely used in automobile systems. For example, you can detect the butterfly valve
in the car carburettor. Accordingly, the valve is used here to regulate the air flow towards the car’s
engine.
2. The application of butterfly valves in firefighting pipes and tubes is best known due to their easy
throttling facilities and adequate pressure limits.

Pinch valve:
The pinch valve is also known as clamp valve. It is a linear motion valve. Used to start, regulate, and stop
fluid flow. It uses a rubber tube, also known as a pinch tube and a pinch mechanism to control the fluid.
Pinch Valve is ideally suited for the handling of slurries, liquids with large amounts of suspended solids, and
systems that convey solid material pneumatically. Pinch valves are ideally suited for the handling of slurries,
liquids with large amounts of suspended solids and corrosive chemicals.

Advantages
1. Low & easy maintenance
2. Low weight
3. Very fast opening/closing times
4. Less air consumption
5. Self cleaning
6. Minimal turbulence & friction

Disadvantages
1. Temperature range is limited
2. Medium operating pressure is limited

Needle valve:

A needle valve, shown in Below Figure, is used to make relatively fine adjustments to the fluid flow and
can be used for on/off and throttling service. They are linear motion valves with a tapered ‘needle like’ cone
shaped plug that acts as the flow control element. The fluid enters from below into the seat which forms part
of the flow path. The needle plug permits the flow opening in this channel to be increased or decreased very
gradually. Needle valves are widely used for steam, air, gas, water or other non-viscous liquids.

The advantages of a needle valve include good flow control and the ability to allow high pressure ratings.
Disadvantages of the needle valve are a large pressure loss and possible clogging of the flow orifice.