This document provides an overview of piping fundamentals for fresher engineers. It discusses what piping is, piping components like pipes, fittings, valves and instruments. It covers piping layout considerations, stress analysis, supports, insulation, material selection and critical piping systems. The document uses examples and diagrams to illustrate piping system design, modeling in software, drafting of P&IDs, and compliance with codes like ASME and IBR.

1. Piping Fundamentals – For Fresher Engineers Piping System - What is that? Concept Layout Development Piping Components & their access requirement. Straight length requirements. Orientation of various tapings, components, etc. Piping Drains & Vents Insulation. Material & Sizing Critical piping system consideration. Pipe Stress Analysis. Pipe Supports

2. Let us first Discuss about WHAT IS PIPE! It is a Tubular item made of metal, plastic, glass etc. meant for conveying Liquid, Gas or any thing that flows. It is a very important component for any industrial plant. And it’s engineering plays a major part in overall engineering of a Plant. In next few pages we shall try to familiarize about pipe and it’s components. Piping Fundamentals – For Fresher Engineers

3. In any plant various fluids flow through pipes from one end to other. Now let us start with a plant where we see three tanks. Tank-1, Tank-2 and Tank-3 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 LET US BRING THE PIPES .

4. We have just brought the pipes, now we need to solve some more problems. Pipes are all straight pieces. To solve these problems we need the pipe components, which are called PIPE FITTINGS We need some branch connections We need some bend connections Even some pipes are of different sizes!

5. These are the pipe fittings, There are various types of fittings for various purposes, some common types are - Elbows/Bends, Tees/Branches, Reducers/Expanders, Couplings, Olets, etc. We now have to complete the end connections. These, in piping term, we call TERMINAL CONNECTIONS. Anyway, the pipes and fittings are in place, but the ends are yet to be joined with the Tank nozzles.

6. So far this is a nice arrangement. But there is no control over the flow from Tank-1 to other tanks. We need some arrangement to stop the flow if needed To control the flow in a pipe line we need to fit a special component. That is called - VALVE These are flanged joints This is a welded joint

7. There are many types of valves, categorized based on their construction and functionality, Those are - Gate, Globe, Check, Butterfly, 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

8. Here we see a more or less functional piping system, with valves and strainer installed. Let us now investigate some aspects of pipe flexibility. In such case we need to fit a flexible pipe component at that location, which is called an EXPANSION JOINT If this tank nozzle expands, when the tank is hot.

9. When some fluid is flowing in a pipe we may also like know the parameters like, pressure, temperature, flow rate etc. of the fluid. To know these information we need to install INSTRUMENTS in the pipeline.

10. There are various types instruments to measure various parameters. Also there are specific criteria for installation of various pipe line instruments. Next we shall look into how to SUPPORT the pipe/and it’s components.

11. Here are some of the pipe supporting arrangements. There can be numerous variants. All depend on piping designer’s preference and judgement. Let us see some OTHER types of supports

16. This is screen picture of P&ID made by SPP&ID If we click on any line it will show the Data embedded.

20. Let us have a look into a piping model done by PDS 3D This is a 3D model of Feed water line along with pumps and other accessories

22. INSULATION MATERIAL - The insulating material should be bad conductor of heat. There are two basic categories 1) Fibrous Material , which has large voids full of air between fibers - Cork, Glass Wool, Mineral Wool, Organic Fibers. Note stagnant air is a bad conductor. 2) Cellular Material , which has closed void cells full or air - Calcium Silicate, Cellular Glass (Foam Glass), Polyurethane Foam (PUF), Polystyrene (Thermocol), etc. Some times Cast material like Cement Plaster or Plaster of Paris are also used. INSULATION CLADDING - Insulation materials are generally soft or fragile. So the outer surface of insulation are protected with Aluminum sheet or GI sheet cladding. Have a look at how pipes are insulated, and general components of insulation

23. Piping Calculations Pipe Sizing Calculation - to select required pipe diameter based on velocity and pressure drop. Find out Flow volume per second Check Velocity Allowable per second Calc. flow area required and Pipe size Calc. Press. Drop for that Pipe size Check Press. Drop meets Press. Budget Pipe Size OK YES Increase Pipe Size NO Pipe Material Selection - to select appropriate pipe material based on flowing fluid property. Find out type of Fluid flowing Check Pipe life Expectancy Select suitable Material per practice (Note-1) Check Mat. Listed in Design Code Pipe Material OK YES See Note-1 NO Note-1 : Material is selected per past experience with cost in mind and per material listed in design code. If material is not listed in code we may select next suitable material listed. Find out Fluid Temp. & Pressure Pipe Thickness Selection - to select appropriate pipe thickness based on flowing fluid property. Select Mat. & Diameter as above Decide on Corrosion allowance Calc. Pipe Thickness per Code Find out Fluid Temp. & Pressure

29. We have come to the End of Session. Hope you have gathered the fundamentals on the subject of Piping