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أخواني في الله أحضرت لكم كتاب Process Piping Design Handbook Volume One The Fundamentalsof Piping Design Drafting and Design Methods for ProcessApplications Peter Smith
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Contents List of Figures xiii List of Tables xvii Foreword xix Preface xxi 1 Piping Codes, Standards, and Specifications . 1 1.1Introduction 1 1.2 Definitions 2 1.3 Codes 3 1.3.1 American Societyof Mechanical Engineers Boiler Pressure Vessel Codes 3 1.3.2 American Societyof Mechanical Engineers B31, Codes for Pressure Piping 14 1.4 Standards and Specifications 24 1.4.1 American Societyof Mechanical Engineers 26 1.4.2 American Petroleum Institute 30 1.4.3 American Society for Testing and Materials 32 1.4.4 American Societyfor Nondestructive Testing 39 1.4.5 American Society for Quality 39 1.4.6 American Welding Society 40 1.4.7 American Water Works Association 41 1.4.8 Copper Development Association 42 1.4.9 Compressed Gas Association 43 1.4.10 Canadian Standards Association 43 viiviii Contents 1.4.11 ExpansionJoint Manufacturers Association 43 1.4.12 Manufacturers Standardization Societyof the Valve and Fittings Industry 43 1.4.13 National Association of Corrosion Engineers 1.4.14 National Fire Protection Association 45 1.4.15 Pipe Fabrication Institute 46 1.4.16 Societyof Automotive Engineers 48 45 2 Piping Components 49 2.1 Introduction to Piping Components 50 2.2 Pipe 51 2.2.1 Pipe Sizes 62 2.2.2 Pipe Ends 67 2.3.1 Butt-Weld End Fittings 72 2.3.2 Socket-Weldand Threaded-End Fittings 73 2.3.3 Flanged Joints 74 2.4.1 Valve Codes and Standards 82 2.4.2 Classificationof Operation Valves 87 2.4.3 Valve Classification 92 2.4.4 Valve Components 94 2.5.1 The Process of Joint Integrity 102 2.5.2 FlangeJoint Components 103 2.5.3 The Flanged Joint System 111 2.3 Pipe Fittings 70 2.4 Valves 80 2.5 Bolts and Gaskets (Fastenersand Sealing Elements) 101 3 Metallic Materialsfor Piping Components 115 3.1 Propertiesof Piping Materials 117 3.1.1 Chemical Propertiesof Metals 117 3.1.2 Mechanical Propertiesof Metals 118 3.1.3 Elongation and Reduction of Area 119 3.1.4 Physical Properties of Metals 120 3.2 Metallic Materials 122 3.3 Alloying of Steel 122Contents ix 3.4 Types of Steel 125 3.4.1 Mild (Low-Carbon) Steel 125 3.4.2 Medium-Carbon Steel 125 3.4.3 High-Carbon Steel 125 3.4.4 High-Tensile Steel 125 3.4.5 StainlessSteel 126 3.5 Steel Heat-TreatingMethods 131 3.5.1 Annealing 131 3.5.2 Normalizing 132 3.5.3 Hardening 132 3.5.4 Tempering 132 3.6 Nonferrous Metals in Alloying 132 3.7 Material Specifications 133 3.7.1 American Society for Testing and Materials 133 3.7.2 Unified Numbering System of Ferrous Metals and Alloys 135 4 Roles and Responsibilities 137 4.1 The Lead Piping Engineer 4.2 Piping Materials Engineering Group 138 139 4.2.1 Project Lead Piping Materials Engineer 140 4.2.2 Senior Piping Materials Engineer 141 4.3.1 Project Piping Area/Unit Supervisor 4.3.2 Project Piping CAD Coordinator 143 4.3.3 Project Piping Designers-Checkers 144 4.4.1 Project Lead Piping Materials Controller 146 4.4.2 Project Piping Materials Controller 147 4.5.1 Project Lead Piping Stress Engineer 148 4.5.2 Project Piping Stress Engineer 148 4.6.1 Process Engineering 151 4.6.2 Mechanical Engineering 154 4.3 Piping Design Group 142 (Squad Boss) 143 4.4 Piping Materials Control Group 145 4.5 Piping Stress Engineering Group 148 4.6 Other Engineering Disciplines Involved 150x Contents 4.6.3 Instrument Engineering 155 4.6.4 Civil Engineering 155 4.6.5 Structural Engineering 155 5 Projects 157 5.1 Project Types 157 5.2 Project Phases 160 5.2.1 Feasibility Phase 160 5.2.2 Conception Phase 160 5.2.3 Front-End Engineering Development Phase 161 5.2.4 Detailed Engineering Phase 162 5.2.5 Construction Phase 166 5.2.6 Precommissioning and Commissioning 5.2.7 Startup and Handover to the Owner 169 Phase 169 6 Fabrication, Assembly, and Erection 171 6.1 Codes and Standards Considerations 6.2 Fabrication Materials for Piping Systems 6.3 Fabrication Drawings 173 6.4 Fabrication Activities 174 172 172 6.4.1 Cutting 174 6.4.2 Beveling 174 6.4.3 Forming 175 6.4.4 Bending 175 6.5,l Welding Processes 179 6.5.2 Preheating 181 6.5.3 Heat Treatment 181 6.6 Brazing and Soldering 183 6.7 Protection of Carbon Steel in Corrosive Services 6.7.1 Corrosion Allowance 184 6.7.2 Internal Galvanizing of Pipe and Piping Systems 184 6.7.3 Pipe Cladding 186 6.5 Welding 178 183Contents xi 7 A B 6.8 Assembly and Erection 186 6.8.1 Alignment 186 6.8.2 FlangedJoints 188 6.8.3 Threaded Joints 188 Inspection and Testing 191 7.1 Piping Codes 191 7.2 Types of Examination 196 7.2.1 Visual Examination 197 7.2.2 Liquid Penetrant Examination 197 7.2.3 Magnetic Particle Examination 198 7.2.4 Radiographic Examination 199 7.2.5 Ultrasonic Examination 200 7.3.1 Some Limitations on the Pressure Testing of Piping Systems 201 7.3.2 Special Provisions for Testing 202 7.3.3 Preparation for Leak Test 202 7.4.1 Hydrostatic Leak Test 202 7.4.2 Pneumatic Leak Test 204 7.4.3 Combination Hydrostatic-Pneumatic 7.4.4 Initial Service Leak Testing 205 7.3 Testing of Piping Systems 200 7.4 Leak-TestingMethods 202 Leak Test 204 7.5 Choice of Testing Medium 7.6 Test Pack 206 7.7 Punch List 206 205 Listed Material 209 A.O. 1 Ferrous Metals 209 A.0.2 Nonferrous Material 213 A.l American Petroleum Institute 217 General Engineering Data . 219 Index 231 INDEX Index Terms Links Numerics 100% examination 196 100% radiography 199 A alignment 186 alloying 117 aluminum (Al) 122 American Iron and Steel Institute (AISI) 25 American National Standards Institute (ANSI) 14 American Petroleum Institute (API) 25 30 American Petroleum Institute’s API 5L 63 American Society for Nondestructive Testing (ASNT) 25 39 American Society for Quality 39 American Society for Testing and Materials 25 32 133 American Society of Mechanical Engineers (ASME) 4 25 American Water Works Association (AWWA) 25 41 American Welding Society (AWS) 25 40 annealing 131 full annealing 131 process annealing 131 spheroidizing annealing 131Index Terms Links ASME B1.20.1 1983, Pipe Threads, General Purpose, Inch 67 B16.25, Butt Welding Ends 70 B16.34, Valves—Flanged, Threaded, and Welding End 94 B16.47, Large Diameter Steel Flanges 80 B16.5, 2003, Pipe Flanges and Flanged Fittings 79 B31, Codes for Pressure Piping 191 B31.3 116 186 B31.3, Process Piping Table 331.1 182 B31.4, Pipeline Transportation Systems for Liquid 175 B31.8, Gas Transportation and Distribution Piping Systems 175 B36.10M, Welded and Seamless Wrought Steel Pipe 63 B36.19M, Stainless Steel Pipe 63 ASME Boiler and Pressure Vessel Code 4 191 Boilers and Pressure Vessels 13 Fiber-Reinforced Plastic Pressure Vessels 12 Material Specifications 5 6 Nondestructive Examination 10 Nuclear Components 13 Power Boilers 5 Recommended Guidelines for the Care of Power Boilers 10Index Terms Links ASME Boiler and Pressure Vessel Code (Cont.) Recommended Rules for the Care and Operation of Heating Boilers 10 Rules for Construction and Continued Service of Transport Tanks 13 Rules for Construction of Heating Boilers 9 Rules for Construction of Nuclear Facility Components 7 Rules for Construction of Pressure Vessels 10 11 Rules for In-Service Inspection of Nuclear Power Plant Components 12 Welding and Brazing Qualifications 12 ASME Codes and Standards flanges 103 ASME Codes for Pressure Piping 14 Building Services Piping 18 Fuel Gas Piping 15 Gas Transmission and Distribution Piping Systems 17 Managing System Integrity of Gas Pipelines 18Index Terms Links ASME Codes for Pressure Piping (Cont.) Manual for Determining Remaining Strength of Corroded Pipelines 19 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids 16 Power Piping 15 Process Piping 15 19 Refrigeration Piping and Heat Transfer Components 16 Slurry Transportation Piping Systems 18 ASME Guide for Gas Transmission and Distribution Piping Systems 19 ASME Standard 26 Face-to-Face and End-to-End Dimensions of Valves 28 Factory-Made Wrought Butt Welding Fittings 28 Forged Fittings, Socket Welding and Threaded 28 Large Diameter Steel Flanges 29 Malleable Iron Threaded Pipe Unions 29 Metallic Gaskets for Pipe Flanges, Ring Joint Spiral Wound and Jacketed 28Index Terms Links ASME Standard (Cont.) Nonmetallic Flat Gaskets for Pipe Flanges 29 Orifice Flanges 29 Pipe Flanges and Flanged Fittings NPS ½ through 24 27 Pipe Threads, General Purpose, Inch 27 Stainless Steel Pipe 30 Steel Line Blanks 30 Valves Flanged, Threaded and Welding End 29 Welded and Seamless Wrought Steel Pipe 30 assembly and erection 177 autogenous welds 180 AWWA Standards Concrete Pipe 42 Ductile-Iron Pipe and Fittings 41 Plastic Pipe 42 Steel Pipe 42 Valves and Hydrants 42 B backseat 101 bending 175 buckling 175 and forming 77 ovality 175 thinning 175Index Terms Links beveled ends (BE) 72 beveling 174 boiler piessure vessel (BPV) 3 bolt 110 bolting 109 and gaskets 101 and nut selection 110 tightening 112 boron (B) 122 brazing and soldering 177 183 Brownfield project 158 buckling 175 butt-weld end fittings 72 C camprofile 108 Canadian Standards Association 43 carbon (C) 122 chemical properties of metals 117 chromium (Cr) 123 circumferential butt welds 196 civil engineering 155 closing element 98 code 2 ASME B31.3 3 codes and standards considerations 172 columbium (Nb) 123Index Terms Links Combination HydrostaticPneumatic Leak Test 204 commissioning 169 commissioning phase 169 compressed asbestos fiber (CAF) gaskets types of gaskets 107 compressed gas association 43 computer-aided design (CAD) 1 conception phase 160 construction 13 166 construction phase 166 continued service 13 copper (Cu) 123 Copper Development Association 42 Copper Tube Handbook 42 corrosion allowance (CA) 66 184 corrosion-resistant alloys (CRA) 62 cutting 174 D density 121 design code ASME B31.3 24 detailed engineering 162 detailed engineering phase 162 diarnktre nominal (DN) 52 63 64 92 double random length (DRL) 61 dye penetrant inspection (DPI) 75Index Terms Links E engineering and procurement (E&P) 162 engineering, procurement, and construction (EPC) 137 162 erection 171 exotic materials 66 Expansion Joint Manufacturers Association 43 F fabrication 171 fasteners 113 feasibility phase 160 ferrous materials 122 flange 74 103 blind 78 dimensional standards 79 lap-joint 78 188 screwed 188 slip-on 78 188 socket-weld 76 188 threaded 77 weld-neck 188 weldneck 75 flange faces 104 flat face 105 raised face 104 ring-type oint 104Index Terms Links flange specification 105 flange pressure class 105 material 106 nominal pipe size 105 standard 106 type and facing 105 flanged joint system 74 111 188 assembly 113 bolt condition 112 flange condition 111 gasket condition 111 gasket quality 112 flux 180 forming 175 front-end engineering development (FEED) phase 161 G gardening 132 gasket 106 glass-reinforced epoxy (GRE) 51 glass-reinforced plastic (GRP) 51 grade 21 grain 121 boundaries 121 size 121 grassroots project 157Index Terms Links H hardenability 121 hardness 119 health, safety, and environmental (HSE) requirements 1 heat treatment 176 181 heat-affected zone (HAZ) 181 high-carbon steel 125 high-tensile steel 125 hot cuts 174 hydrostatic testing 200 202 I industrial piping systems testing limitations 201 industrial pressure piping design 194 fabrication 194 196 inspection 194 testing 200 initial service testing 200 205 inside diameter (ID) 52 installation 171 instrument engineering 155 iron (Fe) 123 iron pipe size (IPS) 62 issued for construction (IFC) 162Index Terms Links J joint integrity 102 K Kammprofile gaskets 108 L lead (Pb) 123 leakage field 198 liquid penetrant examination 197 longitudinal welds 53 196 low-temperature carbon steel (LTCS) 66 M magnetic particle examination (MPE) 198 magnetic particle inspection (MPI) 75 manganese (Mn) 123 Manufacturers Standardization Society (MSS) 25 of the Valve and Fittings Industry 25 43 mechanical engineering 154 mechanical properties of metals 118 modulus of elasticity 119 molybdenum (Mo) 123Index Terms Links N National Association of Corrosion Engineers (NACE) 25 45 National Fire Protection Association (NFPA) 25 National Fire Codes 45 National Fire Protection Association (NFPA) 45 necks down 119 nickel (Ni) 123 nominal pipe size (NPS) 52 64 nondestructive examination (NDE) 72 nonferrous materials 122 132 normalizing 132 nuts 110 O outside diameter (O.D.) 52 ovality 175 P phase 161 162 166 construction 166 detailed engineering 162 front-end engineering development 161 precommissioning and commissioning 169 phonographic 76 phosphorus (Ph) 124Index Terms Links physical properties of metals 120 pipe 63 butt-weld ends 70 cladding 186 dimensional specifications 63 fabrication 172 fabrication 174 fittings 70 galvanizing 184 material specifications 66 sizes 62 threaded ends 67 pipe ends 67 dimensional standards 67 Pipe Fabrication Institute (PFI) 25 46 pipeline system 18 piping design group 142 flexibility analysis 168 isometrics 168 materials control group 145 stress engineering group 148 system 50 51 pneumatic testing 200 204 precommissioning 169 precommissioning and commissioning phase 169 precommissioning phase 169 preheating 176 181Index Terms Links process engineering 151 153 process flow diagrams (PFDs) 152 project lead piping engineer (PEL) 137 138 materials controller 146 materials engineer 140 stress engineer 148 project phases 160 project piping area/unit supervisor (squad boss) 143 CAD coordinator 143 designers-checkers 144 materials controller 147 stress engineer 148 project types 157 punch list 206 R radiographic examination 199 random examination 196 random radiography 200 random spot examination 197 reprepped 67 requests for quotation (RFQs) 165 required-on-site (ROS) date 166 revamp 158Index Terms Links S schedule (SCH) 62 senior piping materials engineer 141 silicon (Si) 124 single random length (SRL) 61 Society of Automotive Engineers (SAE) 25 48 specific heat 121 specification 2 spiral welding 60 spot examination 196 spot radiography 200 squad bosses 142 square cut 67 stainless steel 126 austenitic 126 127 duplex grades 128 ferritic grades 128 martensitic 127 precipitation hardenable 129 130 super stainless steels 130 standard 2 ASME B16.52 standard specifications 2 ASTM A1052 startup and handover to the owner 169 steel medium-carbon 125 mild (low-carbon) 125Index Terms Links stem packing 100 stem protector 101 stress isometrics 168 stress relief 131 structural engineering 155 sulfur (S) 124 T technical bid evaluation (TBE) 165 tempering 132 test pack 206 thermal conductivity 121 thermal expansion 121 thinning 175 threaded joints 188 titanium (Ti) 124 toughness 120 tube 63 tungsten (W) 124 types of gaskets 106 compressed nonasbestos fiber (CNAF) 107 nonmetallic gasket 107 semi-metallic gaskets 107 U ultimate tensile strength (UTS) 118 ultrasonic examination 200Index Terms Links unified numbering system of ferrous metals and alloys 135 unlisted material 66 V vacuum testing 200 valve 80 81 API specification 83 API standards 84 automatic 87 AWWA standards and specifications 83 codes and standards 82 linear 87 MSS standards 84 non-pressure-containing parts 99 plug-type 81 pressure class ratings 92 pressure containing parts 95 quarter-turn 87 rotary 87 seat 99 size 92 small-bore 92 valve stem 99 nonrising stem with inside screw 100 rising stem with inside screw 100 rising stem with outside screw and yoke 99 rotary stem 100 sliding stem 100Index Terms Links vanadium (V) 124 visual examination 197 W welding 176 178 gas metal arc (GMAW) 180 gas shielded arc 180 gas tungsten arc 180 metal inert gas (MIG) 180 shielded metal arc 179 submerged arc 180 tungsten inert gas (TIG) 180 weld repair 181 Y yield strength 119 yoke 101 Young’s modulus 119
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