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Piping andPipelineEngineeringDesign, Construction,Maintenance, lntegrity,and RepairGeorge A. AntakiAiken, South Carolina, U.S.A. Taylor & Francis'e] Taylor &. Francis GroupBoca Raton London New YorkA CRC title, part of the Tayfor & Francis ìmprìnt, a member of theTaylor & Francìs Group, the acad emic divìsion of T&F Informa pie.

ContentsPREFACEIIIC HAPTER l COD ES, STANDARDS AND PRACTICEll9131.1 A BriefHistory ofPiping Technology1.2 National Codes, Standards and Guides1.3 Piping and Pipeline Codes1.4 Scope of ASME B31 Codes1.5 Boiler and Pressure V essei Code1.6 Federai and State Laws1.7 ASME Council on Codes and Standards1.8 ASME Bl6 Standards1.9 API Standards and Recommended Practices1.10 Manufacturers Standardization Society1.11 Pipe Fabrication Institute Standards1. 12 American Institute of Steel Construction1.13 American Concrete Institute1.14 NACE1.15 Materia! Institutes1.16 National Board1.17 Flow Contro! Institute Standard1.18 Hydraulic Institute Pump Standards1.19 References14151721222326293030303132323333CHAPTER 2 FUNDAMENTALS342.1 Competence2.2 At the Engineering Leve12.2.1 Materials2.2.2 Design2.2.2.1 Systern Design2.2.2.2 Component Design2.2.3 Construction2.2.4 Quality Contro! Inspections2.2.5 Preoperational Testing2.2.5.1 Mechanical Testing2.2.5.2 Operational Testing2.2.6 Maintenance2.2.7 Operation2.3 At the Corporate Level3434353636363738383838393940v

viContentsCHAPTER 3 MATERIALS42Introduction: A Good Pastry3.1 FenousPipe3.1.1 Wrought Iron3.1.2 Cast Iron3.1.3 Steel Pipe and Fittings3 .1.3 .l Essential Characteristics3.1.3.2 Carbon Steels3. 1.3.3 Alloy Steels3.1.3.4 High Alloy Steels3 .1.4 Steel Line Pipe3.2 Non-Fenous Pipe3.2.1 Alurninum Alloys3.2.2 Nickel Alloys3.2.3 Copper Alloys3.3 Fabrication ofSteel Pipe3.3.1 Pipe Size3.3.2 Searnless Pipe3.3.3 Seam Welded Pipe3.3.4 Docurnentation3.3.5 Microstructure3.4 Fabrication ofPipe Fittings and Components3.4.1 Forging3.4.2 Casting3.4.3 Sheet Meta!3.4.4 Pipe Specifications3.4.5 Machining and Finishing3.4.6 Base Metal Imperfections3.5 Mechanical Properties3.5.1 Strength3.5.2 Hardness3.5.3 Toughness3.5.3.1 Charpy Y-Notch Toughness3.5.3.2 Drop Weight Test3.5.3.3 Fracture Toughness3.5.4 Fatigue Strength3.5.5 Physical Properties3.6 Procurement3.6.1 Procurement Specification3.6.2 Supplier Assessment3.7 5858596061616262636668687071737374747778CHAPTER 4 1NTER AL P RESSURE814.1 Pressure Design ofPiping81

Contents4.1.1 Thin Wall Approximation4.1.2 Pipe1ine Design Equation4.1.3 Yield and Wali Thickness4.2 Pressure Design of Plant Piping4.2.1 Lamé's Formula4.2.2 Early Design Equation4.2.3 Piping Design Equations4.2.4 Allowable Stress4.2.5 Wall Thickness Allowance4.3 Yield and Burst Pressure4.3.1 The Von Mises Yield Pressure4.3.2 Burst Pressure4.4 Pressure Design ofPlastic Pipe4.5 Pressure Rating4.5.1 Pressure Rating4.5.2 Malleable Iron Threaded Fittings4.5.3 Steel Butt Welded Fìttings4.5.4 Steel Flange Ratings4.5.5 Socket Weldìng and Threaded Fittings4.5.6 Valves4.5.6.1 Shell Strength4.5.6.2 Seat Tightness4.5.7 Unlisted Components4.6 Pressure Stress in Fittings4.6.1 Pipe Elbows and Bends4.6.2 Branch Connections and Nozz1es4.6.3 Reinforcement ofBranch Connections4.6.4 End Fillets4.7 High Pressure Design4.8 Design Pressure4.8.1 Design Scenarios4.8.2 Pressure Excursions4.9 Over-Pressure Protection4 .l OBurst Energy4.11 Pipe Specification4.12 Valve Specification4.1 3 APTER 5 EXTERNAL PRESSURE1215.1 Buckling Pressure5.2 ASME Code Design5.3 References121124124CHAPTER 6 LAYOUT AND SUPPORTS126

viii6.1 Spacing ofPipe Supports6.2 Sustained Stress6.3 Stress Indices6.4 Design Standards6.5 Selection ofPipe Supports6.5.1 Variable Spring6.5.2 Constant Load Hanger6.5.3 Rigid Frames6.5.4 Road Hangers6.5.5 Pipe Rolls6.5.6 Rigid Struts6.5.7 Vibration Dampers6.5.8 Snubbers6.5.9 Anchors6.5.10 Saddles6.6 Design of Standard Support6.7 Design ofSteel Frames6.7.1 Design6.7.2 Construction6.8 Anchorage to Concrete6.9 Layout Rules of Good Practice6.9.1 Equipment Elevations6.9.2 Equipment Spacing6.9.3 Piping6.9.4 Valves6.9.5 Pump Piping6.9.6 Compressor Piping6.1 O ReferencesCHAPTER 7 FLEXlBILITV AND FATIGUE7.1 Layout for Flexibility7.2 Simplified F1exibi1ity Analysis7.3 Fatigue7.4 Smooth Specimen Fatigue7.5 Pipe Component Fatigue7.6 Fatigue Strength ofSocket Welds7.7 Fatigue Strength ofButt Welds7.8 ASME B31 Fatigue Rules7.9 Fracture Mechanics Approach7.1 0 Corrosion Fatigue7. 11 Shakedown7.12 Cold Spring7.13 Through-Wall Temperatures7. 14 Creep 2152155157160165167168169171173173174175177

Contents7.15 Pipe lnsulation7 .16 Expansion J oints7. 17 ReferencesC HAPTER 8 VIBRATION8.1 Root Cause8.2 Mechanically Induced Vibration8.3 Vibration Analysis8.4 Hydraulic Induced Vibration8.4.1 Vane and Piston Motion8.4.2 Turbulence Induced Vibration8.4.3 Cavitation and Air Pockets8.4.4 Acoustic Resonance8.4.5 Breathing Mode8.4.6 Valve Noise8.5 Measuri.ng Vibration8.5.1 Measuring Displacement8.5.2 Measuring Velocity8.5.3 Measuring Acceleration8.5.4 Strain Gages8.5.5 Signal Conditioners and Analyzers8.6 Assessing Vibration Severity8.6.1 Severity Charts8.6.2 Pipe Vibration Analysis8.7 Prevention and Mitigation8.7.1 Eliminate the Source8.7.2 Good Layout and Supports8.7.3 Preoperational Testing8.7.4 Reducing Turbulence and Cavitation8.7.5 Pulsation Damper8.7.6 Damping8.7.7 Flexible Connections8.8 ReferencesCHAPTER 9 F'LUID TRANSlENTS9.1 Single Liquid Phase9.1.1 Bulk or Propagative Flow9.1.2 Pressure Change in Bulk Flow9 .1.3 Waterhammer9.1.4 Valve Characteristics9 .1.5 One-to-Two P base Transient9.1.6 Pump Fill Rate9.1.7 Prevention ofLiquid Waterhammer9.2 Two-Phase Vapor-Liquid 0210211211216216216219221223224225226226

x9.2. 1 Steam-Water Waterhammer9.2.2 Case Histories9.2.3 Predicting the Effects ofTwo-Phase Transients9.2:4 Steam System Layout9.3 Non-Condensable Two-Phase Waterhammer9.3.1 FlowRegime9.3.2 Analysis ofSlug Flow9.3.3 Trapped Air9.4 Stress Analysis9.5 APTER 10 WIND DESIGN24110.1 Wind Damagel O.2 W ind Pressure10.3 Vo11ex Shedding10.4 Wind-Bome Mìssilesl 0.5 References241242243CHAPTER 11 SEISMIC DESIGN AND RETROFIT24624624624724724824811 .1 The Seìsmic Challenge11.2 Seisrnic Specìfication11.2.1 Project Specification11.2.2 Seìsrnic Input11 .2.3 Seisrnic Qualification11.2.3.1 Operability11.2.3.2 Leak Tightness11.2.3 .3 Position Retention11.2.4 Materia! Conditìon11.2.5 Interactions11 .2.6 Documentation11.2.7 Maintenance11.2.8 Definition of Common TellilS11.3 Rules of Good Practice11.4 Seismic Analysis Techniques11 .5 Seismic Input Based on IBC11.6 Seisrnic Response Spectra11.6.1 Seisrnic Input11.6.2 Modal and Directìonal Combinations11.7 Seisrnic Qualification11.8 Shake Table Testìng11 .9 Seismic Interactions11.9.1 Description11.9.2 Interaction Revìew11.9.3 Falling 0260262263264265265266266

Contentsl 1.9.4 Rocking or Swing Impactl 1.9 .5 Significant Impactl l. l OReferencesxi267268268C IIAPTER 12 EXPLOSJONS27112.1 Deflagration and Detonation12.2 Dynarnic Loads12.3 Dynarnic Properties12.4 Pressure Lirnits12.5 Design Criteria12.5.1 Quasi-Static Load12.5.2 Impulsive Load12.5.3 Fracture12 .6 Explosion Protection12.7 Extemal Explosions12.8 References271272274276276276278278280281284C HAPTER 13 S UBSEA PIPELINES28713. 1 Subsea Pipeline Safety13.2 Design Process13.3 Internai Pressure13.4 Extemal Pressure13.5 Pipe Lowering13.6 On-Bottom Stability13.6.1 Objective13.6.2 Static Analysis13.7 Pipeline Flotation13.8 Fatigue Design13.9 Hook and Pull13.1 OReferences287288289289292294294295297298298299C HAPTER 14 BURJED PIPE30214.1 To Bury or not to Bury14.2 Internai Pressure14.3 Soil Loads14.4 Surface Loads14.5 Thermal Expansion and Contraction14.6 Ground Movement14.7 Seisrnic14.8 References302303303304305307309309C HAPTER 15 WELDING31115 .l Shop and Field Welding15.2 Welding Processes311313

xii15.2.1 Shielded Meta! Are Welding15.2.2 Submerged Are Welding15.2.3 Gas Meta! Are Welding15.2.4 Flux Core Are Welding15.2.5 Gas Tungsten Are Welding15.2.6 Welding Parameters15.2.7 Gas Purging15.2.8 Meehanized Welding15.3 Weld Defects15.3.1 Weld Metallurgy15.3.2 Porosities15.3.3 Cracks15.3.3.1 HotCracking15.3.3.2 Delayed Cracking15.3.4 Inclusions15.3.5 Root Concavity and Undercut15.3.6 Incomplete Penetration15.3.7 Laek ofFusion15.3.8 Shrinkage15.4 Codes, Standards and Praetiee15.4.1 ASMEB31 andAPI 110415.4.2 Arneriean We1ding Society15.4.3 Eleetrode Nomenclature15.4.4 Welder and Weld Procedure Qualifieation15.5 Post-W el d Heat Treatment15.6 In-Serviee Welding15.7 Surfaeing Techniques15.8 28CHAPTER 16 EXAMINATION32916.1 Visua1 Examination16.2 Magnetie Particles Testing16.3 Liquid Penetrant Testing16.4 Radiographic Testing16.5 Ultrasonic Testing16.6 Eddy Current Testing16.7 Acoustie Ernission Testing16.8 Thermography16.9 Measurement Aecuraey16.1 OType and Extent of Exarninations16.11 Aceeptance Criteria16.12 Personnel Certification16.13 Pipeline Pigs16.13.1 Utility Pigs329330331333334336336337338339340341341341

Contentsxiii16.13.2 Smart Pìgs16.14 References343344C HAPTER 17 PIPE FLANGE34917 .l Flange Standards17.2 Flange Types17.3 F lange Gaskets17.3.1 Selection Factors17.3.2 Non-Metallìc Gaskets17 .3.3 Semi-Metallic Gaskets17.3 .4 Metallic Gaskets17.4 Flange Faces17.5 Flange Ratings17.6 Flange Bolt Torque17.7 Extemal Loads17.8 Assembly ofPipe Flanges17.8.1 Assembly Steps17.8.2 Closing the Gap17.9 Nuts and Bolts17.9.1 Definitions17.9.2 Bolt Fabrication17.9 .3 Bol t Specìfications17.9.4 Nut, Washer Specifications17.9.5 Restrictions17.9. 6 Corrosion Preventìon17 . l OMaintenance17 .l 0.1 Flange Assembly Sequence17 .l O.2 Replacing a Gasket17.10.3 Welding a Slip-On Flange17 .l 0.4 Leakage Diagnostics17.10.5 Refmishing Flange Faces17. 11 67368368368368371371374374374CHAPTER 18 MECHANICAL JOINTS37718. 1 What they Are18.2 Swage Fitings18.3 Grooved Fittings18.4 In Conclusion377CHAPTER 19 LEAKAND PRESSURE TEST38219.1 Leak Test and Pressure Test19.2 Leak and Pressure Test Methods19.3 Choice ofTest Method19.4 Conduct ofTest383388372372372373373379380381382389

xivContents19 .4.1 Plan the Test19.4. 2 Conduct the Test19.4.3 Pian for Leaks19.4 .4 Drail1 an d Dry19.5 Isolation19.6 Locating Leaks Underground19.7 References389390391391391393394C HAPTER 20 DEGRADATION I N SERVI CE39620.1 A Criticai Decision20.2 Generai Corrosion20.2.1 Progressive Corrosion20.2.2 Passivating Coating20.3 Local Corrosion20.4 Galvanic Corrosion20.5 Erosion Corrosion20.6 Environmental Effects20.7 Microbiologically Influenced Corrosion20.8 High Temperature Effects20.9 Mechanical Damage20.1 O Lining and Coating20 .l O.l Properties20.10.2 Liquid Organics20.10.3 Multilayer Coating20.10.4 Metalli c Coatings20.11 Corrosion Inhibitors20.12 Materia! Selection20.13 References396397399400402403405405408410CHAPTER 21 F JTNESS-FOR- ERVICE21.1 Fitness-for-Service21.2 Wall Thinning21.2.1 Measurement21.2.2 Ductile Fracture Initiation21.2.3 Longitudmal Thinning2 1.2.4 Circumferential Thinning21.2.5 Cautions21.3 Crack Flaws21.3.1 Brittle and Ductile Fracture21.3.2 Fundamental Approach21.3.3 Stress Intensity21.3.4 Fitness-for-Service Evaluation21.3.5 CrackArrest21.3.6 Fatigue4114134134144144154154164 16419419421421422422428428429429431431434438438