Piping Design, in this ppt you can learn about designing a pipe according to your requirements.

1. 20CH314T: Piping Design
Dr. Saket Kumar
Assistant Professor
Chemical Engineering Department

3. Text/References Books
1. Chemical Process Design and Simulation by Juma Haydary, 2019 John Wiley & Sons, Inc.
2. Process plant layout and piping design by Ed Bausbache and Rogur hunt, Prentice hall
3. Handbook of Piping Design by G.K. Sahu, New age international publishers.

4. Examination Scheme
1. Mid Semester – 25%
2. End Semester – 50%
3. Internal Assessments – 25%
• Internal assessments includes: Assignments, Attendance, Class Interactions

5. Piping Design
• Piping design is basis for every aspect for material flow with in/outside the plant. For example, in a
processing plant, movement of material within the different units must be optimized so that it can travel
minimum distance and curves to get processed quickly.
• In heavy scale industries, the heat or pressure in the pipe is very critical. A simple miscalculation of pipe
network’s capability can lead to a disastrous outcome, often resulting in casualties.

6. Piping Design
Piping designs are required for almost every establishments but the following are some
industries where piping designs is required frequently:
• Oil & Gas Extraction Plants
• Refining Plants
• Chemical Industry
• Pharmaceuticals Plants
• Water Resource Management
• Process Plants
• Fertilizers Manufacturing
• Waste managements
• Heavy Scale Industries

7. Piping Design
• Simply defined, pipes are pathways through which fluids are contained and flow in a system. A
network of pipes, fittings, joints, valves and supports is defined as a pipe system.
• There can be multiple pipe systems on a typical project and they can be segregated by
discipline such as civil (domestic water, storm water, sanitary, industrial waste, waste water,
etc.); mechanical or heating, ventilation and air conditioning (chilled water, condeser water, hot
water, steam, condensate, natural gas, fuel oil etc.); plumbing (domestic cold water, hot water,
waste, vent, etc); and fire protection (sprinkler water, compressed air, etc.)
• Piping system is dependent on the requirement and design criteria that are specific of each
discipline. The design of pipe systems is also governed by codes such as those published by
ICC and ASME, ASTM, NFPA, MSS, AWWA and ASHRAE.
ICC: International Code council
ASME: American Society of Mechanical Engineers
ASTM: American Society for Testing and Materials
NFPA: National Fire Protection Association
MSS: Manufacturers Standardization Society
AWWA: American Water Works Association
ASHRAE: American Society of Heating, refrigerating
& Air-conditioning Engineers.

19. Basics of Fluid Flow
Types of fluid flow
• Steady or unsteady flow
• Uniform or non-uniform flow
• One-dimensional, two dimensional flow or three-dimensional flow
• Rotational or irrotational flow
• Laminar or turbulent flow.
Steady flow
• If the fluid characteristics like velocity, pressure, density, temperature, etc., at any point in a fluid in
motion do not change with time, the flow of fluid is said to be steady. This means that the various
characteristics of fluid in motion are independent of time at any point.
• Thus, steady flow may be expressed mathematically as:
•
𝑑𝑣
𝑑𝑡
= 0;
𝑑𝑝
𝑑𝑡
= 0;
𝑑𝜌
𝑑𝑡
= 0;
𝑑𝑇
𝑑𝑡
= 0
• Most of the practical problems in engineering involve only steady flow conditions.

20. Basics of Fluid Flow
Uniform flow
• When the velocity of flow of a fluid does not change both in magnitude and direction from point to
point in the fluid for any given instant of time, the flow is said to be uniform. Thus, it expressed
mathematically as:
•
𝑑𝑣
𝑑𝑠
= 0;
• Where s represents any direction of displacement of the fluid elements and time is kept constant. Flow of
liquids under pressure through long pipelines of constant diameter is uniform.
Non-uniform flow
• If the velocity of flow of a fluid changes from point to point in the fluid at any instant, the flow is said to
be non-uniform. Thus, it expressed mathematically as:
•
𝑑𝑣
𝑑𝑠
≠ 0;
• Flow of liquids under pressure through long pipelines of varying diameter is non-uniform.

21. Basics of Fluid Flow
1-D, 2-D or 3-D flow
• When the various characteristics of the following mass of a fluid are the functions of one, two or three of
the coordinate directions respectively and time t (for unsteady state), then the flow is called 1-D, 2-D or
3-D.
Rotational flow
• A flow is said to be rotational if the fluid particles while moving in the direction of flow rotate about their
mass centres.
Irrotational flow
• A flow is said to be irrotational if the fluid particles while moving in the direction of flow do not rotate
about their mass centres.
Laminar flow
• A flow is said to be laminar when the various fluid particles move in layers with one layer of fluid sliding
smoothly over an adjacent layer.
Turbulent flow
• A flow is said to be turbulent when the fluid particles are in an extreme state of disarray, their velocity
fluctuations are erratic and they develop rotary movements.

22. Flow development in Pipe
• Reynolds Number:
• Osborne Reynolds discovered that the flow regime depends mainly
on the ratio of inertial forces to viscous forces in the fluid and the
ratio is called the Reynolds number.
𝑅𝑒 =
𝐼𝑛𝑒𝑟𝑡𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒𝑠
𝑉𝑖𝑠𝑐𝑜𝑢𝑠 𝑓𝑜𝑟𝑐𝑒𝑠
=
𝜌𝐷𝑉
𝑎𝑣𝑔
𝜇
Where D = Characteristic length of the geometry (diameter in case of
circular pipe).
• For the flow in a circular pipe, Recr = 2300.
• For flow in noncircular pipes, Re is based on the hydraulic diameter
Dh, defined as: 𝐷ℎ =
4𝐴𝑐
𝑝
Where Ac is the cross sectional area of the pipe and p is its wetted
perimeter.
• For circular pipe: 𝐷ℎ =
4𝐴𝑐
𝑝
=
4𝜋𝑟2
2𝜋𝑟
= 2𝑟 = 𝐷

23. Flow development in Pipe
• When the flow enters a pipe, a boundary layer develops along the walls of the pipe.
• Sufficiently far from the pipe entrance, the flow becomes fully-developed.
• Entrance length or developing length:
• The distance from the pipe entrance at which the flow becomes fully-developed.
• For laminar flows,
𝐿𝑑𝑒𝑣
𝐷
= 0.06 𝑅𝑒
• Re = 2300, entrance length = 138D
• For turbulent flows, the mean velocity profile becomes fully-developed within 25-40D.
• Other details of turbulent motion like fluctuations may take up to 80D or more to develop.

24. Head Loss
Total head loss
Major losses Minor losses
Losses due
to friction in
constant
area pipes
At inlets and exists
At enlargements
and contractions
At bends
At valves and
fittings

25. Major losses
• Major losses: Pressure for fully-developed flow through a horizontal pipe of constant cross-sectional
area
ℎ𝐿,𝑀𝑎𝑗𝑜𝑟 =
𝑃0
𝜌𝑔
+
𝑉0
2
2𝑔
+ 𝑍0 −
𝑃𝑖
𝜌𝑔
+
𝑉𝑖
2
2𝑔
+ 𝑍𝑖
• Horizontal pipe: Zo = Zi
• Constant cross sectional area: Vo = Vi
ℎ𝐿,𝑀𝑎𝑗𝑜𝑟 =
𝑃0
𝜌𝑔
−
𝑃𝑖
𝜌𝑔
=
∆𝑝
𝜌𝑔
• No minor losses present
ℎ𝐿,𝑇𝑜𝑡𝑎𝑙 = ℎ𝐿,𝑀𝑎𝑗𝑜𝑟 =
∆𝑝
𝜌𝑔

26. Flow development in Pipe
Laminar Flow:
• From Hagen-Poiseuille law:
• 𝑢 𝑟 = 2𝑉
𝑎𝑣𝑔(1 −
𝑟2
𝑅2)
• Umax = 2Vavg
• For fully-developed flow, from Hagen-Poiseuille law
• ∆𝑃 =
32𝜇𝐿𝑉𝑎𝑣𝑔
𝐷2
• In practice, it is convenient to express the pressure loss for all types of fully developed internal flows
(laminar or turbulent flow, circular or non circular, smooth or rough, horizontal or inclines pipes) as:
• ∆𝑃𝐿= 𝑓
𝐿
𝐷
𝜌𝑉𝑎𝑣𝑔
2
2
• f is Darcy Friction factor (f), for circular pipe: 𝒇 =
𝟔𝟒
𝑹𝒆
• Coefficient of friction or Fanning Friction factor = Darcy Friction factor/4.

27. Flow development in Pipe
Turbulent Flow:
• Pressure drop can not be evaluated analytically.
• We can use dimensional analysis and correlated with experimental data.
• In fully-developed turbulent flow, the pressure drop (ΔP) caused by friction can depend on
• Pipe diameter (D), pipe length (L), pipe roughness (e)
• Fluid density (ρ), fluid viscosity (μ)
• Mean or average flow velocity (𝑉)
• We can find the non-dimensional groups,
∆𝑝
𝜌𝑉2
= 𝜑1
𝜇
𝐷𝜌𝑉
,
𝐿
𝐷
,
𝑒
𝐷
• Darcy Friction factor (f): 𝑓 = 𝜑 𝑅𝑒,
𝑒
𝐷
ℎ𝐿,𝑀𝑎𝑗𝑜𝑟 = 𝑓
𝐿
𝐷
𝑉2
2𝑔
• Coefficient of friction or Fanning Friction factor = Darcy Friction factor/4.

28. Friction factor for commercial pipes
• In laminar flow in pipes
friction factor is observed
to function of Re only.
• f decreases with increase
in Re for laminar flow
• Sharp increase in f at
transition
• In turbulent regime, f
decreases gradually with
an increase Re and then
becomes independent of
Re at higher values.
• Curve accurate
approximately within
±10%

29. Friction factor in turbulent flow
Colebrook relation
von Karman Equation
Prandtl Equation
For fully rough zone (Re →∞)
For smooth pipe (Ɛ →𝟎)

30. Friction factor in turbulent flow
• Colebrook equation is implicit in f, and thus the determination of the friction factor requires iteration. An
approximate explicit relation for f given by S. E. Haaland as:
• To avoid tedious iterations in head loss, flow rate, and diameter calculation, Swamee and Jain proposed the
following relations, accurate to within 2% of Moody chart:

31. Exercise
Pressure Drop and Head Loss in a Pipe

32. Exercise
Determining the Head Loss in a Water Pipe

33. Head Loss
Total head loss
Major losses Minor losses
Losses due
to friction in
constant
area pipes
At inlets and exists
At enlargements
and contractions
At bends
At valves and
fittings

34. Head loss
ℎ𝐿,𝑇𝑜𝑡𝑎𝑙 = ℎ𝐿,𝑀𝑖𝑛𝑜𝑟 + ℎ𝐿,𝑀𝑖𝑛𝑜𝑟
ℎ𝐿,𝑀𝑎𝑗𝑜𝑟 = 𝑓
𝐿
𝐷
𝑉2
2𝑔
• f can be obtained from Moody’s chart.
• For laminar flow: 𝒇 =
𝟔𝟒
𝑹𝒆
• For turbulent flow:
1
𝑓
= −2.0 𝑙𝑜𝑔
𝑒/𝐷
3.7
+
2.51
𝑅𝑒 𝑓
(Colebrook relationship)

35. Minor losses
• Head loss in bends, contractions and expansions, fittings and valves.
• Generally caused by the flow separation and mixing
• Difficult to determine theoretically
• Can be represented by a general expression
ℎ𝐿,𝑀𝑖𝑛𝑜𝑟 = 𝐾𝐿
𝑉2
2𝑔
• KL is loss coefficient and determined experimentally for different situation.
• Minor losses are also expressed in terms of an equivalent length (Lequiv) of a section
of a pipe.
• ℎ𝐿,𝑀𝑖𝑛𝑜𝑟 = 𝐾𝐿
𝑉2
2𝑔
= 𝑓
𝐿𝑒𝑞𝑢𝑖𝑣
𝐷
𝑉2
2𝑔
• ℎ𝐿,𝑇𝑜𝑡𝑎𝑙 = ℎ𝐿,𝑀𝑎𝑗𝑜𝑟 + ℎ𝐿,𝑀𝑖𝑛𝑜𝑟
= 𝑖 𝑓𝑖
𝐿𝑖
𝐷𝑖
𝑉𝑖
2
2𝑔
+ 𝑗 𝐾𝐿,𝑗
𝑉𝑗
2
2𝑔

36. Minor losses
• Losses may occur due to sharp corners.
• Formation of vena contracta
• K = 0.5 for square edge inlet
• For a well-rounded pipe, the entrance loss coefficient is almost negligible.
• K= 0.03 for r/D= 0.2
• Reentrant inlet: pipe protruding in the reservoir
• K ~ 0.8 typically

37. Minor losses: Inlet and Exit
• On discharge in a large reservoir,
the fluid kinetic energy is
completely dissipated.
• ℎ𝐿,𝑀𝑖𝑛𝑜𝑟 = 𝛼
𝑉2
2𝑔
• 𝛼 = Kinetic energy coefficient, 2
for laminar flow and 1.05 for fully
turbulent

38. Minor losses: Sudden expansion and Contraction

39. Minor losses: Bends and Branches

40. Minor losses: Valves
Globe valve Fully open ball valve

41. Piping Networks
Series and Parallel Pipes
• For pipes in Series, the flow rate is the same in each pipe, and the head loss is the sum of the head losses
in the individual pipes.
• For pipes in Parallel, the head loss is the same in each pipe, and the total flow rate is the sum of flow rate
in individual pipes.
Series Parallel

42. Piping Networks

43. Minor losses
Head Loss and Pressure Rise during Gradual Expansion
KL = 1.33
α = 1.06

44. Minor losses

45. Pipe Codes, Standards, and Specifications
A common document with a certain guidelines so that all the individuals and institutions follow one document
called code and standards.
Code: Code is a group of general rules or systematic procedures for design, fabrication, installation, and
inspection that are adopted by legal jurisdiction and made into law.
Features covered in codes:
• General guidelines for design, Materials, Fabrication, Erection, Inspection, and Testing.
• Minimum engineering requirements for safe design.
• Indicates reference standards to be verified.
• American Society of Mechanical Engineers (ASME) develops and publishes engineering codes and standards.
Examples of codes:
• ASME BPVC: Boiler Pressure Vessel
• ASME B 31.1: Power Piping
• ASME B 31.3: Process Piping
• ASME B 31.4: Pipe Line Hydrocarbon

46. Pipe Codes, Standards, and Specifications
Definition of Standard:
A standard contains more-detailed design and construction parameters and standard dimensional and tolerance
requirements for individual piping components, such as various types of valves, pipe, tee, flanges, and other in-
line items to complete a piping system
Features covered in Standards:
• Rules and conditions for Design, Materials, Fabrication, Inspection, Testing, Examination, Certification and
Packing.
• Mandatory engineering practices and requirements.
Examples of Standards:
• ASME B 16.5: Steel Flanges
• ASME B 16.9: Buttweld Fitting
• API 600: General Use Gate Valves
• API 609: Standard for Butterfly Valves

47. Pipe Codes, Standards, and Specifications
Difference between codes and specifications
Codes Specification
General Guidelines and Procedure Rules and Conditions
Minimum Engineering Requirement Mandatory Engineering Practices
Used for engineering companies and
institution for the preparation of
engineering and specifications
Used by Manufacturers to design and
fabricate the component
Covers requirements for an industry Covers requirements for a specific
components
Codes shall specify the standards to
be used
Standards are not deemed to
authorize codes
Varies with industries Varies with type of components and
materials

48. Pipe Codes, Standards, and Specifications
Specification: It gives more specific information and data on the component; and ASTM’s are considered to be
material specifications, although they sometimes are ambiguously called standard specifications. ASTM A105
is the “standard specification for carbon steel forgings for piping applications.”
To conclude and combine these definitions, ASME B31.3 is a design code, with flanges designed to the ASME
B16.5 standard, which are constructed to the material specification ASTM A105.

49. Piping Components
To connect the various process and utility equipment contained within a process plant, it is necessary to use an
assortment of piping components that, when used collectively, are called a piping system.
• The individual components necessary to complete a piping system are:
• Pipe
• Pipe fittings
• Valves
• Bolts and gaskets (fasteners and sealing)
• Piping special items, such as steam traps, pipe supports, and valve interlocking.

50. Piping Components
• Pipe:
• Pipe is the main artery that connects the various pieces of process and utility equipment within a
process plant.
• Pipe used within a process plant designed to one of the ASME B31 codes generally is of a metallic
construction, such as carbon steel, stainless steel, duplex, copper, or to a lesser degree, one of the more
exotic metals like Monel or titanium.
• Nonmetallic pipe such as one of the plastics, like PVC, glass-reinforced epoxy, or glass-reinforced plastic,
are not prohibited, and each has its own set of characteristics.
• The plastic most commonly used is polyester or vinylester, but other plastics, such as epoxy, can be used
to make glass-reinforced epoxy (GRE).
• IPS (Iron pipe size): Inside diameter of the pipe in inches.
• NPS (Nominal pipe size): Outside diameter of the pipe in inches.

51. Piping Components
• Pipe Fittings:
Pipe fitting components are used for one or more functions:
• Change of direction- 90 and 45 elbows.
• Change of direction- equal tee
• Reduction in pipe size-eccentric and concentric reducers, swages
• Reduction in pipe size and change of direction-reducing tee.
• Pipe joint-flange, coupling, union.
• Reinforced branch fitting-Weldolet, Sockolet, Threadolet.
• Mechanical joints-flanges.
All these piping components can be joined together by several welding and mechanical methods: butt-
weld, socket weld or threaded ends, flanges (bolts and gaskets), or proprietary mechanical joints (Victaullic,
Butt-Weld hub ends).

52. Piping Fitting Components

53. Piping Components
Introduction of Valves:
• A valve is a device that regulates, directs or controls the flow of a fluid by opening, closing, or partially
obstructing various passageways.
• Valves can be operated manually or by remote control system.
• It is important to choose the right valve which will be trouble free in operation and economical to install
and operate.
Valves Functions:
• Starting and Stopping of Flow (On-off service)
• Regulating or Throttling Service
• Preventing Back flow
• Automatic Process Control
• Safety and Protection against Excessive Pressure

54. Valves
Manual Valves Check Valves Safety/Relief
Valves
Control Valves
Vertical
slide or
Gate valve
Stopper type closure
Rotary
Globe
Valves
Needle
Valves
Ball
Valves
Plug
Valves
Butterfly
Valves
Lift
Check
Valves
Tilting
Check
Valves
Swing
Check
Valves
Diaphragm
Check
Valves

55. Piping Components
• The most commonly used valves in projects designed to ASME B31 code are:
• Gate valves
• Globe valves.
• Check valves
• Ball valves
• Plug valves
• Butterfly valves
• Pinch or diaphragm valves
• Control valves
• Pressure relief valves
• Control valves
Common functions:
• Start/stop flow (butterfly valve) – isolating valve,
such as a gate, ball, or plug valve.
• Regulate flow (butterfly valve) – throttle or globe
valve.
• Prevent backflow – nonreturn or check valve.

56. Manual Valve
A Manual valve operates through a manual operator, which is primarily used to start and stop the flow.
Some designs can be used for basic throttling.

57. Vertical Slide Valve
Valve that opens and closes a passageway by sliding vertically over a port.

58. Gate Valve
These are best suited for services that require infrequent valve operation and where disc is kept either
fully opened or closed. Gate valve is not suitable for throttling applications because the disc can suffer
sever erosion.

59. Globe Valve
• As the name implies, globe valve has a body of oval (or bulbous) shape and a plug or disc, fitted with a
spindle and hand-wheel, which sits into a seat ring perpendicular to the axis of flow and it is either fitted
with the valve body or machined integral with the body.
• The fluid flowing through a globe valve changes its direction imposing a greater pressure drop than the
gate type.

60. Needle Valve
Long tipped needle like point that is used to make relatively fine adjustment in the amount of fluid flow.

61. Ball Valve
The valve use ball shaped disc with a hole in it. When the valve is open, the hole is in the
direction of flow.

62. Plug Valve
The simplest and the oldest device conceived in the valve family for the manual control of fluid flow is
the tapered plug valve, earlier known as stop cock. It is an on-off service valve.

63. Butterfly Valve
• Simple device used for on-off and throttling services. Normally, the valve does not provide
a bubble-tight condition but designs are available by which perfectly tight shut-off can be
achieved.
• It is easy to operate, only a quarter turn of the spindle changes the position of the disc
from fully closed to fully open condition.

64. Lift Check Valve
• Check valves are also known as non-return or reflux or retention valves are used to prevent back-
flow automatically in piping systems.
• Generally, check valves are kept open by the pressure of the flow and closed by the back pressure or
by weight of the checking mechanism.
• In lift check valves, the flow moves through the body in a changed direction as in globe valves.

65. Swing Check Valve
• In swing check valves the flow moves approximately in a straight line.
• Widely used for all pressure services (where low pressure drop is required) and especially
on pumped liquid lines.

66. Tilting Disc Valve
Full flow service as the gate valve.

67. Diaphragm Check Valve
• Diaphragm valve is used mainly for automatic on-off and limited throttling of very viscous and
abrasive fluids.
• Highly suitable for toxic, explosive, inflammable fluid, etc and vacuum services within its range of
pressures and temperature.

68. Safety Relief Valve
• Safety relief valve or pressure reducing valve is to effect a reduction in pressure of the passing fluid. The
pressure reduction is achieved mainly by throttling.
• There are two different types of pressure reducing valves available for different media of flow (i) lever and
weight loading type, (ii) spring-controlled diaphragm type.

69. Valve Coefficient
• The relationship between the pressure drop across the valve
and the corresponding flow rate is given by valve coefficient.
• The valve coefficient (also known as Flow coefficient) of a
valve is a relative measure of its efficiency at allowing fluid
flow.
• 𝐶𝑣 = 𝑄
𝑆𝐺
∆𝑃
• Where, Q is the flow rate (expressed in US gallon per
minute);
• SG is the specific gravity of the fluid (for water = 1).
• ∆P is the pressure drop across the valve (expressed in psi).
• Cv is technically defined as: The volume (in US gallons) of
water at 60 °F that will flow per unit through a valve with a
pressure drop of 1 psi across the valve.

70. Thank You