MATERIALS AND COMPONENTS

KR30703
OIL AND GAS TRANSPORTATION AND STORAGE
TS DR NORZILAWATI MOHAMAD
 MATERIALS AND COMPONENTS

Steel Cast Iron Plastic Copper

Pipe Pipe Pipe Piping
 STEEL PIPE

MANUFACTURING PROCESS

 Steel pipes available in the market is normally classified by the

manufacturing process.

 Many producing countries of steel pipe have their own standard

specifications for steel such as BS, JIS, DIN, ASTM and API, etc.

 Nevertheless in the petroleum industry the American Petroleum Institute

(API) and American Society for Testing and Materials (ASTM) standard

specifications are commonly used.

(a) ELECTRIC RESISTANCE WELDED PIPE

 This pipe is produced in individual lengths or in continuous lengths from coiled skelp, and
subsequently cut into individual lengths
 This pipe having a longitudinal butt joint wherein coalescence is produced by the heat
obtained from resistance of pie to the flow of electric current in circuit of which the pipe is a
part, and by the application of pressure.
 Typical specifications are;
 ASTM A53
 ASTM A135
 API 5L
 API 5LX
(b) FURNACE BUTT-WELDED PIPE

 Butt Welded is furnace- welded pipe produced in individual lengths from cut skelp,
having its longitudinal butt joint forge welded by mechanical pressure developed in
drawing the furnace-heated skelp through a cone shaped die, which serves as a
combined forming and welding die. Typical specifications are ASTM A53 and API 5L.
 Continuous welded is furnace- welded pipe produced in continuous lengths from coiled
skelp and subsequently cut into individual lengths, having its longitudinal butt joint forge-
welded by mechanical pressure developed in rolling the hot-formed skelp through a set
of round pass welding rolls. Typical specification are ASTM A53 AND API 5L.
(c) ELECTRIC FUSION WELDED PIPE

 Pipe having a longitudinal butt joint wherein coalescence is produced in the preformed tube
by manual or automatic electric-arc welding.
 The weld may be single or double and maybe made with or without use of filler metal. Typical
applications are;

ASTM A134 ASTM A671

ASTM A139 ASTM A672

Single or double weld is permitted Requires both inside and outside

with or without use of filler metal welds and the use of filler metal
 Spiral welded pipe is also made by the electric fusion welded process with either a butt joint, a
lap joint , or a lock seam joint. Typical specifications are ;

ASTM A134
ASTM A139 Butt joint
API 5LS

Butt joint, lap joint or

ASTM A211 lock seam joint
(d) ELECTRIC FLASH WELDED PIPE

 This pipe have a longitudinal butt joint wherein coalescence is produced simultaneously over
the entire area of butting surfaces by the heat obtained from resistance to the flow of electric
current between two surfaces, and by the application of pressure after heating is substantially
completed,
 Flashing and upsetting are accompanied by expulsion of metal from the joint.
 Typical specifications are;
 API 5L
 API 5LX
(e) DOUBLE SUBMERGED ARC WELDED PIPE

 This pipe have a longitudinal butt joint produced by at least two passes,
one of which is on the inside of the pipe.
 Coalescence is produced by heating with an electric arc or arcs between
the bare metal electrodes and the work.
 The welding is shielded by a blanket of granular, fusible material on the
work.
 Pressure is not used and filter metal for the inside and outside welds is
obtained from electrode and electrodes.
 Typical specifications are;
 ASTM A381
 API 5LX
 (f) SEAMLESS PIPE

 This is a wrought tubular product made without a welded seam.

 It is manufactured by hot-working steel or, if necessary, by subsequently cold finishing the hot-
worked tubular product to produce the desired shape, dimension, and properties.
 Typical specifications are;
 ASTM A53
 ASTM A106
 API 5L
 API 5LX

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STEEL PIPING SYSTEM DESIGN REQUIREMENTS

In designing of any piping system, the following basic criteria must be fulfilled;

 The piping system should have sufficient life time at internal and external

 Material should be strong enough to be handled

 In case of failures, damage should be limited

 Investment as low as possible.

STEEL PIPE DESIGN FORMULA (ANSI B31.8)
DESIGN LIMITATION

 Pressure for furnace butt welded pipe shall not exceed 60% at the mill test pressure.
 Pressure shall not exceed 85% at the mill test pressure for all other pipes provided.
 Transportation, installation or repair of pipe shall not reduce the wall thickness less than 90%
 In determining temperature consideration shall also be given to other loading such as soil
loading, transport and handling loading, weight of water during testing.
 When pipe that has been cold worked for the purpose of meeting the Specified Minimum
Yield Stress (SMYS) is subsequently heated, other than welding or stress relieving as part of
welding to a temperature higher than 900℉, the maximum allowable pressure should not
exceed 75% of value obtained in the pipe thickness formula.
 CAST IRON PIPE

BACKGROUND

 One of the differences between cast iron and steel is the presence of large quantity
of carbon generally 2-4% and frequently high silicon content.
 While, carbon in ordinary steel exist as cementite (Fe3C).
 For iron its occur in two form stable form (graphite) and unstable form(cementite,
analyzed as combined carbon)
 Graphite is grey, soft, and occupies a large bulk, hence counteracting shrinkage,
while cementite is intensely hard with density of the same order as iron.
 In Japan and Hong Kong, they are still putting in new cast iron pipelines for their gas
mains due to availability, good corrosion resistance(does not required cathodic
protection) and do not require qualified welders
CAST IRON PIPE DESIGN

 The ANSI B31.8 requires that the cast iron pipe should be designed in accordance with the
method set by in AWWA C101(American Water Works Association)

Specification Type of Pipe S (psi) R (psi)

ANSI A21.3 Pit cast 11,000 31,000

ANSI A21.7 Centrifugal (metal mold) 18,000 40,000

ANSI A21.9 Centrifugal (sand-lined mold) 18,000 40,000

 Standard thickness for cast iron pipe are the wall thickness, diameter and maximum working

pressure permitted under AWWA C101 for the type and sizes of cast iron most commonly used

for gas pipe shown in table 7 and table 8

 For pipe size, pressure, thickness, or laying condition not shown in these tables, reference should

be made to AWWA C101 for the method of calculation.

CAST IRON PIPE JOINTS

(a) Caulked and spigot joint

 This type of joint shall not be used for pressures in excess of 25 psig; unless reinforced
with mechanical champs.
 Dimension shall conform to ANSI A21.3, A21.7, A21.9 and AAWA C110.
(b) Mechanical joint
 Shall utilize gaskets made of a resilient material as their sealing medium
 The material selected for gaskets shall be of a type of adversely affected by the gas
or condensates in the mains.
 The gasket shall be suitably confined and retained under compression by a separate
gland or follower ring.
(c) Flanged joint

 The dimension and drilling for flanges shall conform to ANSI B16.1

(d) Threaded joint

 The user of threaded joints to couple lengths of cast iron pipe is not
recommended.
INSTALLATION OF CAST IRON PIPE

 The AWWA C101 describes method of laying the underground cast iron pipe with the
applicable fields conditions
 Underground cast iron pipe shall be installed with a minimum cover of 24 ins. Unless prevented
by other underground structures. Where sufficient cover cannot be provided to protect the
pipe from external loads or damage and the pipe is not designed to withstand such external
loads, the pipe shall be cased or bridged for its protection.
 Cast iron pipe installed in unstable soils shall be provided with suitable support. Suitable
harnessing or buttressing shall be provided at points where the main deviates from a straight
line and the thrust, if not restrained, would part the joint.

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 PLASTIC PIPE

BACKGROUND

 Plastic pipe was introduced for gas distribution system more than thirty years ago and
now has permanently established itself as excellent to ferrous pipes.
 In fact for low pressure distribution system plastic pipe could offer overall advantages as
compared to ferrous piping in terms of;
 Low investment cost
 Corrosion resistance
 Light in weight and easily coiled
 Easy to joint
 Reduce installation time
 Currently types of plastics that were widely being used for gas distribution are

polyethylene(PE), polyvinyl chloride (PVC) and polyamide(Nylon).

 Polyethylene pipe is the most popular and at present being used in all parts of the world.

 Polyamide pipe has just recently being introduced in Australia and was claimed to be

more superior to polyethylene in many aspects.

 Types of pipe probably could be used as long as it meets the following criteria which were

considered essential for plastic pipe in gas distribution are long term strength, ageing
resistance, impact strength, chemical resistance, temperature resistance, impermeability,
pipe attributes ability to heat fuse for joining, coil for ease of handling and squeeze-off for
pressure control
DESIGN OF PLASTIC PIPING (ANSI B31.8)

 Provisions in ANSI B31.8 are intended to limit the use of plastic

piping primarily to mains and service lines in typical
distribution system operating at pressure of 100 psi or less

DESIGN FORMULA

The design formula for plastic gas piping system or the nominal
wall thickness for a given design pressure can be determined by
the following formula:
THERMOPLASTIC DESIGN LIMITATION

 The design pressure shall not exceed 100 psig.

 Thermoplastic pipe, tubing, and fitting shall not be used where the operating temperature of the

material will be;

 Below -20℉

 Above the temperature at which the long term hydrostatic strength used in the design

formula.
JOINT REQUIREMENTS FOR PLASTIC PIPE

 Pipe or tubing shall not be threaded

 Solvent cement joints, adhesive joint and heat fusion joint shall be made in accordance with
qualified procedures which has been established and proven by test to produce gas tight
joints at least as strong as the pipe or tubing being joint.
 Heat fusion or mechanical joint shall be used when joining polyethylene pipe, tubing or fitting.
 There are 3 methods of heat fusion jointing that currently are being used for polyethylene pipe
 Butt fusion
 Socket fusion
 Electrofusion
(i) BUTT FUSION

 This is the earliest technique known to joint polyethylene pipe that gives satisfactory
performances.
 Using this method the two ends of pipe to be jointed is heated up using hot plate and
fused together by applying some pressure.
 This technique rely heavily on skill and commitment of the operator
 Failure to achieve the recommended specifications for one of the parameters may
result in poor joint.
 Other important factors in getting good joints are the melt flow index(MFI) and pipe
roundness.
 A big difference in the value of melt flow index(MFI) between pipes to be jointed will
results in poor bonding.
 Unsatisfactory roundness of pipe will make it difficult to be aligned properly during
fusion operation and result to poor joint
(ii) SOCKET FUSION

 The two pipes ends are joint together by a socket made of the same of compatible material.
 The external wall area of the two pipes and the internal wall area of socket are heated by using
specially designed tool.
 Using this technique the secondary parameters which are necessary to make good joint could be
controlled to a certain extent
 The need to get good roundness of pipe and precision alignment are reduced. Nevertheless, the
skill of the operator is still necessary in maintaining the right temperature and holding time
 Socket joint produces stronger joint as compared to butt joint due to fusion surface area for this
type of joint is larger than the butt fusion.
 Experience showed that this type of joint is less susceptible to environmental stress cracking due to
reduction of ‘stress riser’ points.
(iii) ELECTROFUSION

 Single heating coil is incorporated in the interior of the sockets with the ends
passing through the wall of the sockets for connection to the welding
machine.
 When an electric current is applied, heat is generated in the coil which, being
directly adjacent to the contact surfaces of the fitting and pipe, ensure the
optimal transmission and flow of heat throughout the whole welding cycle.
 This result in the fitting being reliably and permanently welded to the pipe in
the shortest possible time.
 The heating coil is permanently embedded in the Polyethylene material to
provide additional strengthening against the effect of internal pressure.
 Electrofusion technique eliminates greatly the need of skillful and dedicated
welders to get good joint.
 With proper sizing, good fit between fitting and pipe could be achieved

 Disadvantages of this system are mainly due to over dependent of good performances

of the welding machines which require some calibration and proper maintenance.

 The other factor is cost, where compared to Butt fusion the acquisition cost for

electrofusion joint is about 20% higher.

 Nevertheless as in any other system, the total cost which includes investment on

machine, skilled operator, repair cost to be considered before deciding what system to

use.
STANDARD DIMENSION RATIO, SDR

 The Standard Dimension Ratio (SDR) system enables the user to select a number of different sizes
of pipe for a piping system, all of which will have the same design pressure.
 When plastic material of the same design strengths are used, the same SDR may be used for all
sizes of pipe instead of calculating a value of t for each size.

𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑒𝑑 𝑜𝑢𝑡𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟

𝑆𝐷𝑅 =
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑒𝑑 𝑤𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠
COPPER PIPING

PROCESS

 Type K tubing in coils, is used for underground work where the minimum number
of joint, combined with greater thickness is of distinct advantage.
 Type L tubing, usually in straight lengths sometimes used for gas plumbing in
home.
 Copper is preferred over G.I. pipes because of its appearance
 ANSI B31.8 limit the use of copper for main under the following circumstances;
 Mains pressure must not exceed 100 psig.
 Where the gas carried contain more than an average of 0.3 grains of
hydrogen sulphide per 100 scf.
 Copper tubing or pipe for mains shall have a minimum wall thickness of 0.065
in and shall be hard drawn.
 Copper pipe or tubing shall not be used for mains where strain or external
loading may damage the piping
JOINTING OF COPPER PIPE

 Copper pipe is required to be joined by using either a compression type coupling or a

brazed or soldered lap joint.
 The filler material used for brazing shall be a copper -phosphorus alloy or silver base alloy.
 Butt weld`s are not permissible for joining copper pipe or tubing.
 Copper tubing shall not be threaded, but copper pipe with wall thickness equivalent to the
comparable size of schedule 40 steel may be threaded and used for connecting screw
fittings or valves.
 Provision must be made to prevent harmful galvanic action where copper is connected to
steel.
INSTALLATION OF COPPER SERVICE LINES

The following requirements shall apply to copper service line within building:

 Copper service lines may be installed within building, provided the service line is not concealed
and is suitably protected against external damage.
 An underground copper service line installed through the outer foundation wall of a building shall
be either encased in a sleeve, or otherwise protected against corrosion. The annular space
between the service line and sleeve shall be sealed at the foundation wall to prevent entry of gas
and water.
 A copper service line installed underground under building shall be encased in a conduit designed
to prevent gas leaking from the service line from getting into the building
 Connection using a copper or cast bronze service line tee or extension fitting
sweat-brazed to copper mains.
 Butt welds and fillet- brazed joints are not recommended
 Some of the recommended specifications for copper pipe and tubing are given
below;
i. ASTM B88 - Seamless copper water tube. Type K and L
ii. ASTM B280 - Seamless copper tube for air conditioning

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END OF PART II