Becht Training Course & Workshop in Process Piping in Accordance With ASME B31.3 Design, Construction, And Mechanical Integrity

Training Course & Workshop in

Process Piping in Accordance with

ASME B31.3 B31.3 Design, Construction, and Mechanical Integrity May 25 -26, 2006 Singapore

Don Frikken Becht Engineering Company 5515 HWY 50 Gerald, MO 63037 573-764-6744 ([email protected])

Introduction to Process Piping in Accordance with ASME B31.3 Design, Construction, and Mechanical Integrity

May 25 -26, 2006 Singapore

Don Frikken Becht Engineering Company 5515 HWY 50 Gerald, MO 63037 573-764-6744 ([email protected])

i

Workshop Objectives The aim of this workshop is to provide the participants with an overview of the area of Piping Technology with an emphasis on process piping. The workshop covers design, fabrication, examination and testing requirements of ASME B31.3. It covers Code requirements from design through start-up of new piping systems, as well as standards for inspection and repair of piping systems that have been in service, as provided in API 570, Piping Inspection Code. This workshop provides a foundation of knowledge necessary for those responsible for assuring the mechanical integrity of existing piping systems, as well as those responsible for designing and constructing new piping systems.

Who Should Attend Engineers, senior designers, maintenance, quality assurance, inspection and manufacturing personnel who work with process piping (e.g., in the chemical, petroleum, plastic processing, pulp and paper fields) will find it a time-saving means to broaden and update their knowledge of piping.

Workshop Contents The workshop will review the basic requirements of the ASME B31 Code for Pressure Piping with emphasis on B31.3, Process Piping. General topics in the workshop include Code organization and intent, pressure design, design for sustained loads including support design, flexibility analysis, equipment loads, flanges, expansion joints, supports and restraints, materials, fabrication, examination, testing, and, for existing piping systems, mechanical integrity. Applications of these concepts, including simple hand analysis methods and computerbased analysis methods, will be demonstrated. Included will be comparisons between ASME B31.3 and ASME B31.1, Power Piping. Inspection and maintenance (mechanical integrity) of existing piping systems will be covered, as provided in API 570, Piping Inspection Code. Each session will be conducted in a lecture/discussion/problem solving format designed to provide intensive instruction and guidance on understanding Code requirements. The instructors will be available following each day’s session to provide participants with further opportunity for discussion and consideration of specific problems.

ABOUT THE INSTRUCTOR Don Frikken is an internationally recognized authority in piping design. Now employed by Becht Engineering, Don had been with Solutia, Inc. and Monsanto Company for 34 years; working on a wide range of activities including piping and mechanical design, project engineering, and engineering standards. However, Don’s principal specialty is piping design, including design of complex piping systems, piping flexibility analysis, selection of piping components including valves, development of piping standards and specifications, and developing and teaching numerous piping seminars and workshops. He is an ASME Fellow and has been active on various ASME standards committees. He is past Chair of the ASME B31.3 Process Piping Code committee, Chair of the B31 Standards Committee, which oversees all B31 Piping Code committees, member of the B16 Standards Committee, member of the Board on Pressure Technology Codes and Standards, member of the Codes and Standards Board of Directors, which oversees the development and

ii

maintenance of six hundred ASME codes and standards, and recently completed a three year term as an ASME Senior Vice President. Don has received a number of awards, and recently was awarded the ASME Melvin R. Green Codes and Standards Medal, which recognizes outstanding contributions to the development of documents used in ASME programs of technical codification, standardization and certification. Don graduated with a B.S.M.E. from Kansas State University and has a master’s degree in civil engineering from the University of Missouri-Rolla.

B31.3 Workshop Outline Section Title 1 Introduction

2

Metallic Pipe & Fitting Selection

3

Materials

4

Pressure Design (metallic)

Topics Covered ¾ General Definitions ¾ Piping Development Process ¾ Piping System Standards ¾ B31.3 Scope ¾ Organization of the Code ¾ Fluid Service Definitions ¾ Piping System Failure ¾ Bases for Selection ¾ Listed versus Unlisted Piping Components ¾ Fluid Service Requirements ¾ Pipe ¾ Fittings ¾ Branch Connections ¾ Flanges ¾ Gaskets ¾ Bolting ¾ Flanged Joints ¾ Strength of Materials ¾ Bases for Design Stresses ¾ B31.3 Material Requirements ƒ Listed and Unlisted Materials ƒ Temperature Limits ƒ Toughness Requirements ƒ Deterioration in Service ¾ Design Pressure & Temperature ¾ Quality Factors ¾ Weld Joint Strength Factor ¾ Pressure Design of Components ƒ Four Methods ƒ Straight Pipe ƒ Fittings ƒ Fabricated Branch Connections ƒ Flanges and Blanks ƒ Other Components ¾ Piping Material Specifications

iii

Section Title 5 Valve Selection

6 7

Introduction to Flexibility Analysis Layout and Support

8

Flexibility

9

Reactions

10

Flexibility Analysis

11

Designing with Expansion Joints

12

Fabrication and Installation

13

Inspection, Examination and Testing

Topics Covered ¾ Code Requirements ¾ Selection by Valve Type ƒ Gate ƒ Globe ƒ Check ƒ Butterfly ƒ Ball ƒ Plug ¾ What are we trying to achieve? ¾ Flexibility Analysis Example ¾ General Considerations ¾ Support Spacing ¾ Support Locations ¾ Support Elements ¾ General Considerations ¾ Friction ¾ Stress Intensification ¾ Thermal Expansion ¾ Spring Hangers ¾ The Displacement Load Analysis ¾ General Considerations ¾ Fabricated Equipment ¾ Rotating Equipment ¾ Supports ¾ Cold Spring ¾ When to Perform a Detailed Analysis ¾ Considerations ¾ Types of Expansion Joints ¾ Pressure Thrust ¾ Installation of Expansion Joints ¾ Metal Bellows Expansion Joints ¾ Welder/Brazer Qualification ¾ Welding Processes ¾ Weld Preparation ¾ Typical Welds ¾ Preheating & Heat Treatment ¾ Typical Owner Added Requirements ¾ Installation ¾ Flange Joints ¾ Inspection ¾ Examination ƒ Methods ƒ Requirements ƒ Acceptance Criteria ¾ Leak Testing ƒ Methods ƒ Requirements

iv

Section Title 15 Nonmetallic Piping Systems

16

Category M Fluid Service

17

High Pressure Piping

18

In-service Piping Inspection, Repair, Alteration and Rerating

19

What’s Different in B31.1

Topics Covered ¾ General ¾ Design, Fabrication and Installation for o Thermoplastics o Reinforced thermosetting resins o Reinforced concrete o Vitrified clay o Borosilicate glass o Piping lined with nonmetals ¾ Limitations ¾ General ¾ B31.3 Requirements o Design o Fabrication o Examination o Testing ¾ Typical Owner Added Requirements ¾ General ¾ Materials ¾ Pressure Design ¾ Limitations ¾ Fabrication ¾ Examination ¾ Testing ¾ API 570 Piping Inspection Code ¾ Responsibilities ¾ What to Inspect ¾ Types of Inspection ¾ Inspection Practices ¾ Frequency and Extent of Inspection ¾ Remaining Life Calculation ¾ Repairs and Alterations ¾ Rerating ¾ Scope ¾ Organization of the Code ¾ Fluid Service Requirements ¾ Bases for Allowable Stresses ¾ Material Requirements ¾ Pressure Design Requirements ¾ Valve Requirements ¾ Fabrication and Installation ¾ Inspection, Examination and Testing

v

ASME B31.3 Process Piping Course

1. Introduction

ASME B31.3 Process Piping Charles Becht IV, PhD, PE Don Frikken, PE Instructors BECHT ENGINEERING COMPANY, INC.

Introduction -

1

Scope of B31.3 Course This course covers piping as typically used in process plants. Not covered: ƒ Pipelines ƒ Plumbing ƒ Nuclear plant piping

BECHT ENGINEERING COMPANY, INC.

Introduction -

2

ASME B31.3 Process Piping Course

1. Introduction

Topics Covered 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Introduction Metallic Pipe & Fitting Selection Materials Pressure Design Valve Selection Flexibility Analysis Layout and Support Flexibility Support and Equipment Load Limits Flexibility Analysis Methods

BECHT ENGINEERING COMPANY, INC.

Introduction -

3

More Topics Covered 11. 12. 13. 14. 15. 16. 17. 18.

Designing with Expansion Joints Fabrication and Installation Inspection, Examination and Testing Category M Fluid Service Nonmetallic Piping Systems High Pressure Piping Inspection, Repair, Alteration and Rerating What’s Different in B31.1

BECHT ENGINEERING COMPANY, INC.

Introduction -

4

ASME B31.3 Process Piping Course

1. Introduction

1. Introduction ¾General Definitions ¾Piping Development Process ¾Piping System Standards ¾B31.3 Scope ¾Organization of the Code ¾Fluid Service Definitions

BECHT ENGINEERING COMPANY, INC.

Introduction -

5

Definitions: (300.2) piping: assemblies of piping components used…[for] fluid flows. Piping also includes pipe supporting elements, but does not include support structures…or equipment… piping system: interconnected piping subject to the same design conditions

BECHT ENGINEERING COMPANY, INC.

Introduction -

6

ASME B31.3 Process Piping Course

1. Introduction

More Definitions: piping components: mechanical elements suitable for joining or assembly into pressure-tight fluid-containing piping systems…pipe, tubing, fittings, flanges, gaskets, bolting, valves and devices such as expansion joints, flexible joints, pressure hoses, traps, strainers, inline portions of instruments and separators. BECHT ENGINEERING COMPANY, INC.

Introduction -

7

& More Definitions: design pressure: the pressure at the most severe condition of internal or external pressure and temperature expected during service design temperature: the temperature at which, under the coincident pressure, the greatest thickness or highest component rating is required BECHT ENGINEERING COMPANY, INC.

Introduction -

8

ASME B31.3 Process Piping Course

1. Introduction

Piping Development Process 1. Establish applicable system standard(s) 2. Establish design conditions 3. Make overall piping material decisions ƒ ƒ ƒ

Pressure Class Reliability Materials of construction

4. Fine tune piping material decisions ƒ ƒ ƒ

Materials Determine wall thicknesses Valves

5. Establish preliminary piping system layout & support configuration 6. Perform flexibility analysis 7. Finalize layout and bill of materials 8. Fabricate and install 9. Examine and test

BECHT ENGINEERING COMPANY, INC.

Introduction -

9

Piping System Standards Provide a set of requirements for obtaining a safe, reliable and economical installation. Are frequently called Codes; for example, B31 piping system standards are called Codes.

BECHT ENGINEERING COMPANY, INC.

Introduction -

10

ASME B31.3 Process Piping Course

1. Introduction

ASME Piping System Standards B31.1 B31.3 B31.4 B31.5 B31.8 B31.9 B31.11

Power Piping Process Piping Liquid Transportation Pipelines Refrigeration Piping Gas Transportation Pipelines Building Services Piping Slurry Transportation Pipelines

BECHT ENGINEERING COMPANY, INC.

Introduction -

11

More ASME Piping System Standards BPE-1 Bioprocessing Equipment PVHO-1 Pressure Vessels for Human Occupancy HPS High Pressure Systems B&PV Code, Section III for Nuclear Power Plants

BECHT ENGINEERING COMPANY, INC.

Introduction -

12

ASME B31.3 Process Piping Course

1. Introduction

Other Piping System Standards NFPA 13 – Installation of Sprinkler Systems NFPA 24 – Installation of Private Mains NFPA 50 – Bulk Oxygen Systems NFPA 54 – National Fuel Gas Code CGA – Handling of Anhydrous Ammonia (K61.1) Chlorine Institute #6 – Piping Systems for Chlorine See the longer list, pages 2-3 in the supplement.

BECHT ENGINEERING COMPANY, INC.

Introduction -

13

B31.3 Scope Rules for the Process Piping Code Section B31.3 have been developed considering piping typically found in petroleum refineries; chemical, pharmaceutical, textile, paper semiconductor, and cryogenic plants; and related processing plants and terminals. (300.1) BECHT ENGINEERING COMPANY, INC.

Introduction -

14

ASME B31.3 Process Piping Course

1. Introduction

B31.3 Scope

This Code prescribes requirements for ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ

materials and components design fabrication assembly erection examination inspection testing

of piping [300.1.1(a)] BECHT ENGINEERING COMPANY, INC.

Introduction -

15

B31.3 Scope This Code applies for all fluids, including: (1)raw, intermediate, and finished chemicals; (2)petroleum products; (3)gas, steam, air, and water; (4)fluidized solids; (5)refrigerants; and (6)cryogenic fluids. [300.1.1(b)] BECHT ENGINEERING COMPANY, INC.

Introduction -

16

ASME B31.3 Process Piping Course

1. Introduction

B31.3 Scope Exclusions: (300.1.3) ¾ Piping systems designed for ƒ ƒ ƒ ƒ ƒ

pressure >0 and