PIPING PIPING PIPING - Piping-Components-Guide-for-Oil-and-Gas-Engineer
PIPING PIPING PIPING - Piping-Components-Guide-for-Oil-and-Gas-Engineer
PIPING PIPING PIPING - Piping-Components-Guide-for-Oil-and-Gas-Engineer
COMPONENTS
GUIDE
LEARN ABOUT PIPING COMPONENTS USED
IN PROCESS PIPING
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PIPING
COMPONENTS
GUIDE
LEARN ABOUT PIPING COMPONENTS
USED IN PROCESS PIPING
H T T P S : / / H A R D H A T E N G I N E E R . C O M
VARUN PATEL
FOUNDER OF HARDHATENGINEER.COM
-3-
CONTENTS
1 PIPE
2 PIPE FITTINGS
3 FLANGES
4 GASKETS
-4-
1
C H A P T E R
PIPE
H T T P S : / / H A R D H A T E N G I N E E R . C O M
-5-
PIPE
Let’s learn about the first building block of the Oil & Gas
Industries.
WHAT IS A PIPE?
The pipe is a straight pressure-tight cylindrical hollow, used in the
piping system to transport liquid, gas, and sometimes solids.
TYPES OF PIPE
Different types of pipes are used in different design conditions,
considering technical and commercial parameters. For small &
medium sizes requirement seamless pipe is more popular whereas
for larger diameter welded pipes are more economical.
In the chart given on the next page, you can see the most
commonly used types of pipe in the Oil & Gas industries.
-6-
PIPE
FUNDAMENTAL OF
PIPE (PIPELINE)
FOR OIL & GAS
ENGINEER
-7-
PIPE
-8-
PIPE
MANNESMANN PLUG MILL PROCESS
Mannesmann was a German engineer who has invented this
method. The only difference between the Plug mill and the
Mandrel mill process is that inside diameter is achieved in a single
pass in the mandrel method, whereas in Mannesmann, a multi-
stage reduction is possible.
EXTRUSION PROCESSES
In an extrusion method, a heated billet is placed inside the die.
Then, a hydraulic ram pushes the billet against the piercing
mandrel, material flows from the cylindrical cavity between die and
mandrel.
This action produces the pipe from the billet. Sometimes billet
manufacturers produce pipe with a high thickness known as
mother hollow. Many secondary pipe manufacturers used this
mother hollow to produce pipe with different dimensions.
SEAMLESS PIPE
MANUFACTURING
PROCESSES –
EXPLAINED
-9-
PIPE
Once the circular section is rolled from the plate, the pipe can be
welded with or without filler material. A welded pipe can be
manufactured in large sizes without any upper restriction. Welded
pipe with filler material can be used to manufacture long radius
bends and elbows.
Welded pipes are cheaper than the seamless pipe and weak due to
the weld.
SAW pipes are also available in the spiral seam, which is continually
rolled from the single plate coil. As a result, the spiral SAW pipe's
production rate is very high compared to the Straight SAW pipe.
-10-
PIPE
Three different terms are used to define the size of the pipe.
NB – Nominal Bore
DN – Diameter nominal
In the table given on the next page, you can see the correlation
between size and OD.
-11-
PIPE
Common schedule nos. are 5, 10, 20, 30, 40, 60, 80, 100, 120, 140, 160.
Pipe Thickness is also expressed as STD, extra strong-XS, double
extra strong-XXS.
Higher the schedule no. higher the thickness of the pipe and
smaller the inside diameter of the pipe as the outside diameter of
each pipe size is standardized.
There are only four schedules are mentioned in the ASME code
which are 5S, 10S, 40S, 80S. So, please remember schedule no. 10
and 10S do not have the same thickness.
-12-
PIPE
Please note that carbon steel schedules equal stainless schedules
for the following;
Up to NPS 12, all Sch 10 and Sch 10S wall thicknesses are the
same.
Up to NPS 10, all Sch 40, Std Wt and Sch 40S wall thicknesses
are the same.
Up to NPS 8, all Sch 80, XS, and Sch 80S wall thicknesses are the
same.
PIPE LENGTH
(SINGLE RANDOM VS DOUBLE RANDOM PIPE)
Pipe length is mentioned in either meter or feet. However, during
production, a pipe is not manufactured in the same lengths, and
during construction of the process plant, you require various sizes
of pipe.
You can order fixed length pipe also, but it may cost you more.
-13-
PIPE
TYPES OF PIPE ENDS
The pipe comes in the following four end types;
-14-
PIPE
For example, ASTM A106 allows only killed steel made by the open-
hearth, basic-oxygen, or electric furnace, with preferred separate
degassing.
Normalizing
Quenching
Tempering
Solution Annealing
Stress relieving
Combination of above
-15-
PIPE
Macro Analysis for Weld will check proper fusion of weld material
with pipe material.
Some special tests are also carried out on pipe material when it will
be used in aggressive environments. These tests will ensure that
pipe material can withstand such aggressive environments also.
Some of the tests are listed below;
The tensile test is done to check the yield and ultimate tensile of
the pipe. High or low-temperature tensile tests are also
performed if required by the purchaser or standard.
Bend test / Guided bend test is used to check the integrity of
weld joint
The flattening test examines the ability of plastic deformation in
a pipe
Impact test / Charpy V-Notch Test, check the ability of a material
to withstand under low-temperature conditions
A creep test is done to check the long-term effect of
temperature under constant load.
-16-
PIPE
INSPECTION OF PIPE
P = 2St/D or S = PD/2t
Holding time for the hydro test is a minimum of 5 sec as per ASTM
A530. Pressure is monitored by the computerizing system.
-17-
PIPE
Visual Inspection
Dimension Inspection
-18-
PIPE
The mass of all carbon steel pipe and seamless stainless steel pipe
is limited to +10% and a minus limit that varies depending on size –
refer to standards for more details.
-19-
PIPE
Straightness
The carbon steel pipe standards require only that “the finished pipe
shall be reasonably straight”.
ASTM A312M (in ASTM A999M) requires welded stainless steel pipe
to be straight to within 3.2 mm over 3.0 m lengths. Generally, the
thumb rule is that 1 mm per meter is acceptable. However, most
purchasers clearly specified a maximum acceptable limit for
straightness.
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PIPE INSPECTION,
TESTING &
MARKING
MARKING REQUIREMENTS
Once the pipe is cleared all tests and inspections, it is marked as
per the standard requirements. The following shall be marked on
pipe;
Manufacturer logo
ASTM material code
Material Grade
Size
Thickness- schedule no.
Length
Heat No
Special marking WR for weld repair or NH for the non-hydro
tested pipe.
-20-
PIPE
For stainless steel, pipe stenciling is also used. Please note the
following;
PACKING
Pipe ends are covered with a cap to prevent damage during
transportation. Spider supports at the end of the pipe are also
installed in Large diameter pipe to protect the circularity of the
pipe.
SUPPLEMENTARY REQUIREMENTS
Supplementary requirements are optional requirements that the
purchaser must specify along with purchase requisition. Mainly
these requirements are related to additional testing of the product
such as low-temperature tensile, transverse tensile, restriction on
Carbon Equivalent, etc.
-21-
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C H A P T E R
PIPE FITTINGS
H T T P S : / / H A R D H A T E N G I N E E R . C O M
-26-
PIPE FITTINGS
ELBOW
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 if required during construction.
Elbows are available in two radius types, Short radius (1D) and Long
radius (1.5D).
-27-
PIPE FITTINGS
REDUCING ELBOW
The 90º reducing elbow is designed to change direction and reduce
the length of flow within a piping system. The reducing elbow
eliminates one fitting and reduces the welding by more than one-
third.
MITER BEND
Miter bends are not standard fittings. They are fabricated from
pipes. Usually, they are preferred for size 10” & above because large
size elbow is expensive.
-28-
PIPE FITTINGS
RETURNS
Retuning elbows are used to
make 180º changes in
direction. Available in short &
long patterns. They are
mainly used in heating coils,
heat exchangers, etc.
TEE
There are different types of Tee used in piping.
-29-
PIPE FITTINGS
CROSS
Cross is also known as four-way 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 fire water sprinkler lines.
REDUCER
There are two types of the reducer used in piping Concentric &
Eccentric.
SWAGE
Swage is like reducers used to connect
butt welded pipes to smaller screwed
or socket welded pipes. Like reducers,
they are concentric & eccentric types.
They are covered under the regulatory
code BS – 3799
-30-
PIPE FITTINGS
PIPE CAPS
Pipe caps are used at the dead-end of
the piping system. It is also used in
piping headers for future connections.
STUB ENDS
Stub ends are used with a lap joint
flange. In this type of flange, a stub is a
butt welded with pipe, whereas the
flange is freely moved over the stub
end.
UNION
Union is used to connect small bore
pipes. It can be a socket end or
threaded end.
-31-
PIPE FITTINGS
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TYPES OF PIPE
FITTINGS USED IN
PIPING
Fittings are sized with respect to pipe size. In Nominal pipe size
(NPS) & also as a Diameter nominal (DN)
Thicknesses are marked in schedule no. Fittings generally have
a higher thickness than pipes to avoid rejection due to thickness
reduction during manufacturing. To avoid mismatch of fittings
ID to pipe ID, the manufacturer bevel the inside edge of fittings.
Socket weld & Threaded end forged fittings are available from
NPS 1/8” to 4” size
Forged Fittings are available in the following pressure-
temperature rating class.
FITTING MATERIALS
Fittings are always connected with pipe hence, the Chemical and
Mechanical properties of these materials match with pipe
materials.
-32-
PIPE FITTINGS
-33-
PIPE FITTINGS
In this method, a pipe is cut into pieces and pushed with the help of
a hydraulic ram. Then, an induction heating coil heat the pipe and,
it is pushed over a die called "mandrel," which allows the pipe to
expand and bend simultaneously.
-34-
PIPE FITTINGS
UO METHOD
UO method is used to manufacture the medium size of the elbow,
tee, and reducers.
The plate is cut out into a specially designed shape. It is formed first
into a U-shape using a die and then into an O-shape or tubular
form using another die. That is why this method is known as the UO
method. Once the fittings are formed in shape, they are welded
from inside and outside the closing seam.
-35-
PIPE FITTINGS
-36-
PIPE FITTINGS
-37-
PIPE FITTINGS
Manufacturing
methods
Images from TK
Fittings.
-38-
PIPE FITTINGS
STUBEND MANUFACTURING PROCESS
Stub Ends or Lap Joints Flange are manufactured by the flaring
method. The pipe end is a flare or spared out to form a flange face.
Stub ends are also manufactured by forging in which forge block is
machined to the final dimension.
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MANUFACTURING
PROCESS
Normalizing
Quenching
Tempering
Solution Annealing
Stress relieving
Combination of above
-39-
PIPE FITTINGS
PROOF TEST
To qualify the pipe fitting design, the manufacturer performed
various tests, including a burst test, to ensure that the design would
meet all the standard & code requirements.
In this test, a pipe & fittings are welded, and a dummy pipe spool is
prepared. This pipe spool is then pressurized to pre-define
calculated burst test pressure. If the fittings withstand the test, all
the future products manufactured using that design will consider
safe to use.
Lap joint stub ends are exempt from the proof test because they
are used with flange assembly and design considering applicable
pressure-temperature ratings.
-40-
PIPE FITTINGS
Ultrasonic
Radiography (Only for Weld)
Magnetic particle test
Liquid penetrant test
Positive Material Identification
DESTRUCTIVE TESTING
Destructive testings are performed to check the strength of the
body and weld of the product. Few destructive tests are listed
below.
Tensile test
Impact test / Charpy V-Notch Test
Hardness test
METALLURGICAL TESTS
Metallurgical Tests are performed on fittings body and weld to
confirm standard requirements: Micro Analysis or Chemical
Analysis of raw material, product, and weld. And Macro Analysis for
weld is performed.
SPECIAL TESTS
Special tests are carried out on fittings to confirm their ability to
withstand corrosive environments. These tests are listed below.
-41-
PIPE FITTINGS
VISUAL INSPECTION
Visual Inspections are conducted on fittings to check any surface
imperfections. Both fittings body and weld are checked for visible
surface imperfections such as dents, die marks, porosity, undercuts,
etc. Acceptance as per applicable standard.
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INSPECTION –
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DIMENSION INSPECTION
Dimension of the fittings must meet the standard requirements.
-42-
PIPE FITTINGS
Diameter
Length
Thickness schedule no
Straightness & perpendicularity of the ends
Degree of elbows & bends
Concentricity of reducer
-43-
PIPE FITTINGS
Manufacturer logo
ASTM material code
Material Grade
Size, for tee size of branch & run pipe and for reducer size of
both ends
Thickness (Schedule No) for both the ends if they are connected
to different thickness pipe
Heat No.
Compliance - for standard fittings –WP, for Special fittings S58,
S8, SPLD, etc.
-44-
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C H A P T E R
FLANGES
H T T P S : / / H A R D H A T E N G I N E E R . C O M
-49-
FLANGES
The flange is the second most used joining method after welding.
Flanges are used when joints need dismantling. It Provides
flexibility for maintenance. Flange Connects the pipe with various
equipment and valves. Breakup flanges are added to the pipeline
system if regular maintenance is required during plant operation.
Types of Connection
Flange facing Types
Pressure-Temperature Ratings
Material Types
THREADED FLANGES
Socket-Weld flanges have a female socket in which pipe is fitted.
Fillet welding is done from outside on the pipe. Generally, it is used
in small bore piping and is only suitable for low pressure and
temperature application. Refer to the image on the next page.
SOCKET-WELD FLANGES
Socket-Weld flanges have a female socket in which pipe is fitted.
Fillet welding is done from outside on the pipe. Generally, it is used
in small bore piping and is only suitable for low pressure and
temperature application.
-50-
FLANGES
-51-
FLANGES
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 inside and outside. Slip-On Flange is suitable for low
pressure and temperature application.
-52-
FLANGES
-53-
FLANGES
BLIND FLANGES
The blind flange is a blank disc with a bolt hole. These flanges are
used with another type of flange to isolate the piping system or
terminate the piping as an end. Blind flanges are also used as a
manentery cover in the vessel.
-54-
FLANGES
Flat Face
As the name suggests, a flat face flange has a flat face. Flat face
flanges are used when the counter flanges are flat faces. This
condition occurs mainly in connection to Cast Iron equipment,
valves, and specialties. A full-face gasket is used when a flat face
flange is used.
Raised Face
Raised face flange has a small portion around the bore raised from
the face. The gasket seat on this raised face. The height of the
raised face depends on the flange pressure-temperature rating
known as a class of the flange. For example, for 150# & 300# height
of the raised face is 1/6”, and above 300#, it is 1/4”. The inside bore
circle type of gasket is used with raised face flange.
RTJ Face
Ring joint type face flange has a specially designed grove in which
metal gasket seats. This type of flange is used in high pressure and
temperature services.
-55-
FLANGES
-56-
FLANGES
-57-
FLANGES
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The higher the rating, the heavier the flange, and it can withstand
higher pressure and temperature. When the temperature goes up,
the pressure goes down, and vice versa. Please note that different
material has different pressure ratings.
FLANGE RATINGS
AND FLANGE
CLASSES FOR ASME
FLANGES
-58-
FLANGES
FLANGE MATERIAL
Flanges are manufactured from the following materials.
Carbon steel
Low alloy steel
Stainless steel
Combination of Exotic materials (Stub) and other backing
materials
FLANGE INSPECTION
Following to be confirmed during inspection of the flange.
-59-
FLANGES
MARKING
The following shall be marked on the flange body.
Manufacturer logo
ASTM material code
Material Grade
Service rating (Pressure-temperature Class)
Size
Thickness (Schedule)
Heat No
Special marking if any QT (Quenched and tempered) or W
(Repair by welding)
-60-
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C H A P T E R
GASKET
H T T P S : / / H A R D H A T E N G I N E E R . C O M
-65-
GASKET
WHAT IS GASKET?
A Gasket is sealing material placed between connecting Flanges to
create a static seal, which will Maintain the leak-proof sealing in all
operating conditions.
Temperature
Pressure
Corrosion resistance
Types of fluid
Robustness
Availability
Cost
Non-Metallic
Metallic
Composite
NON-METAL GASKET
The most common materials used for these gaskets are Rubber,
Teflon, and Compressed Non-Asbestos Fiber (CNAF).
-66-
GASKET
These gaskets are used with low-pressure class flanges such as 150
or 300 Class and in low-temperature services. They are not used in
hydrocarbon services. Non-Metallic gaskets are the cheapest and
most easily available.
You can see in the right-side image, which shows a full-face gasket,
and the left side is inside the bolt circle gasket. The image also
shows CNAF & PTFE gaskets.
Full face gasket can only be used with FF flange and is normally
used for temporary connection of utility lines.
-67-
GASKET
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WHAT IS A
GASKET? TYPES OF
GASKETS USED IN
PIPING
METAL GASKET
Metal gaskets are manufactured from soft iron, Low Carbon steel,
Stainless Steel, Monel, and Inconel. These gaskets are also known as
ring gaskets or RTJ gaskets.
Two types of the metallic gasket are frequently used with RTJ
flange. Octagonal and Oval. You can see the difference in their
cross-section view.
-68-
GASKET
COMPOSITE GASKET
Composite gaskets are a combination of metal and non-metal
materials. Different types of combinations of materials are possible
based on the service requirements.
You can see in the image a spiral wound gasket with and without
an inner ring on the next page. The inner ring is used to provide
additional support to the winding material. The winding is an
alternative layer of filler material and winding material.
The filler material is a soft material such as graphite and PTFE, and
the winding material is a thin sheet of metal. Winding can be a V-
type or W type, as shown in the image given on the next page.
-69-
GASKET
The above image is of Spiral Wound Gasket, and the below image is
of Metal Jacketed Gasket.
WHAT IS A
GASKET? TYPES OF
GASKETS USED IN
PIPING
-70-
GASKET
KAMM/ CAM PROFILE GASKET
Kamm/ Cam profile Gasket has a solid metal core with concentric
grooves. Filler material, either graphite or PTFE, is layered on this
grooved metal ring. It is costlier than the Spiral wound gasket but
provides better blowout resistance, and is easy to handle even in
large diameters.
Manufacturer logo
Manufacturing standard
Size and Pressure Class
Type of Filler Material
Type of Winding Material
Inner and Outer Ring material
You can see the sample marking in the image given on the next
page.
-71-
GASKET
-72-
GASKET
-73-
GASKET
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-74-
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5
C H A P T E R
PIPING INTERVIEW
QUESTIONS
H T T P S : / / H A R D H A T E N G I N E E R . C O M
-79-
PIPING INTERVIEW
QUESTIONS
PART-1
1. Which code and standard are used in Oil and Gas?
2. Which code is used for process piping and power piping?
3. What are the most commonly used ASME Sections?
PIPING INTERVIEW
QUESTIONS PART-1
(CODES AND
STANDARDS)
PART-2
1. Which code and standard are used to select Pipe, butt welding
fittings, flanges, gasket, Socket & Threaded fittings, and Valves?
-80-
PIPING INTERVIEW
QUESTIONS
PART-3
1. What are the commonly used material for Pipes, butt welding
fittings, flanges, and plates?
2. What is the basic difference between ASTM A106 Gr.A / Gr.B/
Gr.C.?
3. What is the basic difference between ASTM A312 TP 304,
TP304H and TP 304L?
4. What is low alloy steel and what is high alloy steel?
PIPING INTERVIEW
QUESTIONS PART-3
(MATERIAL
STANDARDS)
PART-4
1. What is the difference between the flange pressure class and
schedule? Flange Class Vs Flange Schedule
2. Types of flange used in piping?
3. What is the difference between a raised face and a flat face
flange?
-81-
PIPING INTERVIEW
QUESTIONS
PART-5
1. What is the height of the face in the raised face flange?
2. What is serration on the flange face?
3. What types of serration are used on flange faces?
4. What are AARH and RMS?
5. How to measure the serration?
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PIPING INTERVIEW
QUESTIONS PART-5
(FLANGE FACE)
PART-6
1. How many types of gaskets are used in piping?
2. What is the most commonly used gasket material for temporary
piping?
3. Which is the most commonly used gasket type for process
piping?
4. Which type of gasket is used for high-pressure piping?
5. What are the criteria for the selection of Gasket?
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QUESTIONS PART-6
(GASKETS TYPES
AND USED)
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PIPING INTERVIEW
QUESTIONS
PART-7
1. Can you explain some properties of gasket material?
2. What is a centering ring in a spiral wound gasket?
3. What are the most common materials used for winding in the
Spiral Wound metallic Gasket?
4. How to identify the type of winding material in a spiral wound
gasket?
5. On which type of flanges spiral wound gaskets are restricted by
code?
6. What type of gasket is used in the Heat Exchanger?
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PIPING INTERVIEW
QUESTIONS
WATCH ON CHECK ANSWERS CHECK ON
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WEBSITE -
PIPING INTERVIEW
QUESTIONS PART-8
(ESSENTIAL
QUESTIONS PART-1)
PART-9
1. What is the difference between a machine bolt and a stud bolt?
2. What is the thumb rule to calculate spanner size for a given
bolt?
3. What is a steam tracing?
4. Which piping items will you drop down before conducting
Flushing and Hydrotest?
5. Why do we provide a Dampener in the Piping of Reciprocating
Pump?
6. Why do we provide a Full Bore Valve in connecting the pipeline
of Launcher / Receiver?
7. What should be the relative hardness between the RTJ gasket
and flange groove?
8. Why do we provide Drip Leg in Steam Line?
9. What is the normal upstream and downstream straight length
of the orifice flowmeter?
10. What do you mean by Composite Flange?
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PIPING INTERVIEW
QUESTIONS
PART-10
1. What is the insulation gasket kit and where do you use it?
2. What is the insulation joint?
3. What is the minimum distance to be maintained between two
welds in a pipe?
4. What are the different types of insulation used in piping?
5. What is the difference between GRE and GRP Pipe?
6. What is the difference between the post-heating of weld and
PWHT?
-85-
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