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Unit No. 1 - Piping 1 - Piping Unit No.

UNITS IN THIS COURSE


UNIT 1 UNIT 2 UNIT 3 PIPING PIPE FITTINGS VALVES

TABLE OF CONTENTS
Para 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 COURSE OBJECTIVE INTRODUCTION TO PIPING PIPING SIZES PIPE CODING METAL PIPING CORROSION ELECTROCHEMICAL CORROSION CORROSION PROTECTION INTERNAL CORROSION PIPELINE SAFETY Page 3 4 5 6 6 6 7 9 11 12 13 14 15 17 22 22 23

1.10 TUBING 1.11 USES OF TUBING

1.12 CONNECTING TUBING

Module No. 7 : Piping systems Module No. 7 : Piping systems

1.13 PIPING INSULATION 1.14 PIPE SUPPORTS 1. 15 PIPERACKS 1. 16 PIPE HANGERS 1.0 COURSE OBJECTIVE

This course introduces the students to all the main pieces of static equipment on a plant site. Upon completion of the course the trainees will be able to describe and Page 1/24

discuss the following: Equipment Terminology. Theory of operation. Equipment construction. Hands on operation. Safety features. How the equipment is used in the overall process.

Unit No. 1 - Piping

1.1

INTRODUCTION TO PIPING The piping system is important to all plant operations. Because it looks very simple it is sometimes overlooked. However, if the piping system does not operate properly a plant will shutdown. It is very important that the trainee understands what a piping system does. An operator must ensure that the equipment is installed, maintained and operated correctly. Every plant has large and small piping systems. These systems have many different uses in a plant. All fluids and gases in a plant are moved from place to place in piping systems. The piping system includes pipe, pipe fittings to control the direction of flow and valves to control the amount of flow. The size of the pipe, pipe fittings and valves will vary depending on the different processes. The material used to make up the piping system depends on the material being carried by the system. The piping systems in a plant carry hot and cold water, crude oil, refined products, chemicals, gases and other fluids at many different temperatures, pressures, and flow rates. All parts of a piping system must be properly inspected and maintained. The loss of a single piping system in one part of a plant may cause the shutdown of processes in the plant. It is very important that the trainee operator understands the operation and maintenance of the piping systems. The main functions of a piping system are: To contain, control, transport and transfer liquids through the plant processes. To transport and sales and transfer finished products to the storage facilities

Module No. 7 : Piping systems

1.2

PIPING SIZES Piping is manufactured (made) in standard lengths, diameters and wall thickness. The trainee must understand the correct pipe size to make sure the piping system is safe. There are four dimensions of a pipe which are used to indicate pipe size. These are shown in Figure 1-1

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Unit No. 1 - Piping

Figure 1-1 Pipe Dimensions

The inside diameter (ID) and outside diameter (OD) are the most common measurement of pipe. For pipe up to 300 millimeters in diameter, the inside diameter is used for the pipe size. For pipes over 300 millimeters the pipe size is given by the outside diameter. Wall thickness is also used to indicate pipe size. Piping is usually classed according to schedule. Schedule numbers range from 10 to 160. Low numbers mean thin walls and high numbers mean thick walls. Length : Wall Thickness: Inside Diameter (ID): outside Diameter (OD): Standard pipe lengths are 20' or-6.1 metres. By schedule number. Used to describe pipes from 0-300 mm in diameter. Used to describe pipes larger than 300 mm in diameter.

The most common schedule numbers are 40, 80, 120, and 160. Schedule 40 pipe has a thinner wall thickness than schedule 80 pipe. Schedule 160 pipe has the thickest wall. As well as inside diameter, outside diameter and wall thickness the length of the pipe is important. The length of a section of pipe is about 6 meters. It is also possible to get longer sections of pipe. 1.3 PIPE CODING Piping systems are classed as process lines or service lines. Process lines carry process fluids. Service lines carry water, steam, gas and air which are required for process or plant utility systems. Most piping is colour coded. The material inside can be identified by the colour of Page 3/24

Module No. 7 : Piping systems

the pipe. The pipe may also have letters on it to identify the contents. For example pipe which carries water for fire protection is usually painted red and is also identified with white lettering. Different companies may use different colour coding. 1.4 METAL PIPING There are many different types of metal piping. Some of these are pure metals such as aluminium or copper. Others are alloys such as stainless steel and carbon steel. An alloy is a metal made up of two or more metals which are melted together to form a new material. Metal piping may be ferrous or non-ferrous. A ferrous metal is a metal which contains iron. Wrought iron, cast iron, and carbon steel are all examples of ferrous metals. Special metal pipe may be required for certain uses. Corrosive materials may require special pipe. Highly corrosion resistant pipe is less common and more expensive then ferrous metal pipe. 1.5 CORROSION Corrosion is the breakdown or deterioration of a substance because of a chemical reaction with its environment. The substance does not necessarily have to be a metal to corrode. Wood, ceramics, plastic and other materials may also corrode. If a material corrodes its properties will change so it cannot do its job. All metals and alloys can corrode. There are 105 known elements. About 80 of these are metals. Each one has different mechanical, chemical and physical properties. All metals corrode in different way and at different rates. Some environments are more corrosive than others. There are always exceptions but it is generally true that: 1.6 No corrosion will occur in a vacuum. Salt water is more corrosive than fresh water. Hot water is more corrosive than cold water. Hot air is more corrosive than cold air. Moist air is more corrosive than dry air. Polluted air is more corrosive than clean air. Acids are more corrosive than bases.

Unit No. 1 - Piping

ELECTROCHEMICAL CORROSION Most of the corrosion which occurs in metals is electrochemical. This corrosion may occur on the inside or outside of a piece of metallic equipment.

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Unit No. 1 - Piping

Figure 1-2 Steel Corrosion From Brass If two unlike metals are present in an atmosphere or solution a chemical reaction takes place. One of the metals loses electrons and the other gains electrons.

The metal that loses electrons is the anode. This is the metal that is being corroded. The metal that gains electrons is the cathode. This does not corrode. It becomes plated with electrons. The electron movement from the anode to the cathode material is electrical current flow. The current flow is very small but over a long time this flow can severely corrode the anode material. A small electrical battery is formed by the two unlike metals and the environment. The environment may be the earth, gas or even the atmosphere (air). The temperature, surface conditions, time, mechanical forces and pressure all affect the amount and speed of corrosion. Figure 1-2 shows two steel pipes joined by a brass fitting. The brass valve acts as a cathode so it will not corrode. The steel pipe connected to the brass acts as an anode. The pipe will corrode in an atmosphere or environment where corrosion can occur. There are many corrosive environments in a chemical processing plant. Contact between two unlike metals is not the only condition which can cause corrosion.

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Unit No. 1 - Piping

Figure 1-3 Corrosion of New Pipe Connected to Old Pipe Figure 1-3 shows a section of new pipe welded between the two older sections of pipe. This is another example of where corrosion can occur. The surface conditions on the pipes are different. The older section of pipe acts as a cathode and will not corrode. The new section of pipe acts as an anode so it may corrode.

Figure 1-4 Corrosion of Different Surfaces. Figure 1-4 shows a different type of corrosion. The pipe and coupling are of the same material and the same age. However, the surface conditions are different. The pipe itself has bright shiny threads at the coupling. The pipe has been tightened into the coupling using a pipe wrench. The jaws of the pipe wrench have scratched the protective film on the pipe. Both the bright shiny threaded area and the scratched area on the pipe act as anodes. These areas will corrode. The rest of the pipe and the coupling act as a cathode and will not corrode. 1.7 CORROSION PROTECTION

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Unit No. 1 - Piping

Figure 1-5 Insulating coupling It is hard to stop corrosion completely but it can be slowed down. There are many ways to protect a system from corrosion. In piping systems it is common to insulate pipe sections from each other. At coupling joints the pipe sections may be insulated so that they do not touch each other. This insulation separates the piping into shorter individual sections which are easier to protect. Figure 1-5 shows a compression coupling being which joins two sections of pipe. Insulating material is placed between the pipe and the coupling. There is no direct contact between the metal coupling and the metal pipe.

Module No. 7 : Piping systems

Figure 1-6 Insulating Flange Figure 1-6 shows an insulating flange. The two faces of the flange are separated by an insulating gasket. The machine bolts used to install the flange have insulation around them. There is no metal contact between the two faces of the flange.

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Protective coatings may also be used to protect piping systems. The outside of the pipe may be painted with special protective paints. Special coatings are generally used on underground piping systems. Plastics and epoxies are some of the newer coatings used for corrosion protection. Figure 1-7 shows a coal tar coating system. This system has been used for many years.

Unit No. 1 - Piping

Figure 1-7 Coal Tar Coated Pipe. A primer is applied to the clean pipe. A layer of coal tar goes over this. Asbestos wrapping is applied over the coal tar layer. The asbestos wrapping is covered with Kraft wrapping. Coal tar is solid at room temperature but it can be heated and melted easily. This allows it to be poured over the pipe to form a protective coating. Sections of pipe are available with the coating already on the pipe. When the pipe is installed, the sections of pipe are joined together and only the joints have to be coated. 1.8 INTERNAL CORROSION Piping systems and static equipment may be affected by internal corrosion as well as external corrosion. Internal corrosion is much harder to see and detect than external corrosion. Internal corrosion may affect the system by eroding the surface or by causing a corrosion build-up. Erosion is the wearing away of the internal surface of the pipe. To eliminate or slow down internal corrosion on equipment special protective coatings can be used. Sometimes high silicon content cast iron is used. This is resistant to corrosion that may be caused by hydrochloric acid and chlorides. Stainless steels are used to protect against corrosion caused by nitric acid. Metals such as aluminium and copper form an oxide film on their surfaces. If the oxide film is not disturbed it will slow down corrosion. Natural and synthetic rubbers are often used to line sections of pipe to help prevent corrosion.

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Unit No. 1 - Piping 1 - Piping Unit No.

There are many different substances in the solutions carried In piping systems. Many of these substances may cause corrosion. Water in the plant may contain oxygen, chloride or sulphate. These substances may cause corrosion. Inhibitors are used to remove these corrosive substances. Inhibitors are chemicals which slow down a chemical reaction. There may be a lot of salt in the water system. Sodium chromate is used as an inhibitor to slow down corrosion caused by salt. If there is any hydrochloric acid in a steel pipe an inhibitor is needed. Corrosion from liquids such as fuels, lubricants and other petroleum products is usually caused by small amounts of water. Both organic and inorganic inhibitors are available to slow down this type of corrosion. The correct amount of inhibitor as well as the correct method of application must be used. Sometimes the vessel is made of extra thick metal to allow for corrosion. Some chemicals may react with the surface of the pipe and cause a build up of material. This deposit of material may become large enough to block the piping system. Adding an inhibitor to the product in the piping system can loosen this material and carry it away with the product in the piping system. However, this loose scale may block the piping system. A piping system must be cleaned before any corrosion inhibitor is added to the piping system. Shiny internal metal surfaces are more likely to be affected by corrosion than surfaces which are covered with an oxide coating. A plant piping system should not have sharp turns in it. Sharp turns can cause fluid turbulence. This fluid turbulence wears away any internal protective coating. The bare metal will then be exposed to both erosion and corrosion. Normally all metals and alloy can corrode. The amount and type of corrosion varies from metal to metal and system to system. 1.9 PIPELINE SAFETY When a piping system is designed or operated the following safety factors must be taken into consideration: What temperature is the pipe designed to operate at. What pressure is the pipe designed to operate at.

Module No. 7 : Piping systems Module No. 7 : Piping systems

What other things may limit the pipe capacity i.e. pipe material, atmospheric conditions, the material surrounding the pipe or what it is joined to. Pipe Uses Steel pipe is used for plumbing, heating, gas and air lines. Seamless carbon steel pipe is used in high temperature applications. Welded wrought iron pipe is used for condensate return lines in steam systems. Cast iron pipe is used for gas systems. Copper pipe is used where processing solutions may react with ferrous pipe. Plastic pipe can be used to carry corrosive materials. It cannot be used at high pressures and temperatures. Thermoplastic piping has a temperature limit of 66 C. Thermosetting piping has a temperature limit of 121 C.

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All piping has a special characteristics. Manufacturers information sheets and piping tables give information on temperature, pressure and flow limits for different sizes, material and wall thickness. Never try to use a pipe for a purpose for which it is not designed. Specifications for the piping system and the auxiliary equipment connected to the piping system should be carefully checked. All safety precautions must be followed.

Unit No. 1 - Piping

1.10 TUBING Tubing is pipe which has thin walls. It is made of metal or plastic. The type of tubing used will depend on the application it is being used for. There are advantages and disadvantages in using tubing instead of piping. Tubing is very flexible. This means it can bend easily. This allows the tubing to be connected to a device that vibrates without being damaged. Tubing has the following advantages over normal pipework: Can be used in small areas / a large number of lines will fit in a small space. e.g., at the back of an instrument panel. Flexible, it can be bent around corners. Absorbs shock or vibration. Requires less fittings and less supports due to its light weight. Easy and quick to install. Quick repair so that a system can be back in service quickly. Very little flow restriction or turbulence.

Tubing has the following disadvantages over normal pipework: Only small inside diameter, so only small volumes can be handled. Thin wall (Must be bendable). Unions weaken the tubing when they are tightened down or crimped. Tubing will crimp or break easily if hit or stepped on.

Cautions for Tubing Use: Bend correctly. Do not install where it will be hit or stepped on. Use the correct material for the job i.e. Always use same fitting material as tubing material. Use stainless steel in corrosive atmospheres. Use plastic for temporary installations only. Page 10/24

Module No. 7 : Piping systems

When you join tubing make sure the ends are fully in the fitting before tightening down.

1. 11 USES OF TUBING

Unit No. 1 - Piping

Tubing is thin walled and is used in various areas in a plant. However, it is mainly used for the following: Instrument air lines. Temporary lines. Hydraulic lines.

Copper tubing is used for plumbing, heating, cooling, gas, and steam lines. It can be buried underground as well as in the open air. Thicker walled copper tubing may be used in high temperature applications. Aluminium has the advantage that it becomes stronger at very low temperatures. For this reason it is used in cryogenic (low temperature) lines. Stainless steel tubing is very strong. It can stand very high pressures. Stainless steel is used in high pressure hydraulic systems. Stainless steel tubing is also used in cooling units, evaporators and fluid lines. Stainless steel tubing is always used on offshore installations as it is resistant to corrosion from the salt in the atmosphere. Low pressure pneumatic lines are made of copper or plastic tubing. Tubing can be bent quite easily. There are less connections are on a tubing system than on a piping system. Tubing usually has a small diameter so it can fit in spaces where it would be hard to install piping. 1.12 CONNECTING TUBING Compression Fittings

Module No. 7 : Piping systems

Figure 1-8 Compression Fitting

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Unit No. 1 - Piping

Figure 1-9 Compression Fitting

Tubing may be connected with compression fittings. Compression fittings are available in different sizes and styles. The tubing fits inside the compression fitting. By tightening the fitting nut a leak proof joint is formed. (See figures 1-8 and 1-9). The tubing slips tightly into the fitting on one end. There is a ferrule or bushing that fits around the tubing. The compression fitting is threaded at both ends. -The body of the fitting is held stationary while the nut is tightened. Tightening the nut causes the ferrule to compress. This makes a leak proof joint between the tubing and the fitting. There are also compression fittings for plastic and nylon tubing. Flared Fittings

Module No. 7 : Piping systems

Figure 1-10 Flared Tube and Fitting

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Unit No. 1 - Piping

Figure 1-11 Flared Tube and Fitting

A flared fitting means that the end of the tube is flared (made wider) (See Figures 1-10 and 1-11 ). First the flare nut is fitted over the tube. Special flare tools are used to widen the end of the tube. The tube and nut are tightened on the flare fitting body. The sleeve between the flare nut and the tubing gives a leak proof fit. Bending Tubing Hand benders and hydraulic benders are used to make bends in tubing. Hand benders are usually used for small size tubing. Hydraulic benders are usually used to make bends in the heavier and larger sizes of tubing. When making bends in tubing it is important that the tube is free of any kinks or pinches. An incorrect bend will limit the flow in the tubing. It may also weaken the tubing wall enough to cause serious problems. The fact that tubing can bend means you need fewer connectors. Fewer connectors means fewer chances of leaks. 1.13 PIPING INSULATION Need for Insulation Insulating material is used to form a barrier or wall against the flow of energy. Thermal insulation is used to stop heat or cold getting in or out of something. Thermal insulation is used on piping systems, steam lines, furnace walls, turbines, heat exchangers, ovens, boilers, freezers and buildings. Different types of insulating material are used everywhere in modern plants. Insulating materials help to make work areas safe and comfortable. They prevent the loss of heat energy. They also protect equipment against damage. Thermal Insulating materials

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Most metals are good conductors of heat. Heat transfers to metal. Metal will also radiate or transfer its heat to the atmosphere very easily. To contain heat or to stop heat from escaping thermal insulation must be used. Thermal insulation is also used to prevent heat from entering a building during hot seasons of the year or to prevent heat leaving a building during the cold season.

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Unit No. 1 Unit No. 1 - Piping - Piping

Thermal insulation has a lot of uses because it can be used for temperatures ranging from below zero to as high as 1 450C. The purpose of the insulation is to stop heat transfer. This saves money. Thermal insulation is also used to make the workplace safer and more comfortable. Most of the materials used as thermal insulation have a low density. This means that they have very little weight but they use a lot of space. These materials are loose and contain air spaces. The air spaces help the insulating properties of the material. There are many types of thermal insulation. One of these is "loose fill". Loose fill insulation is usually poured or packed into place. Some of the loose fill insulation materials used are:

Asbestos Powder Cork Granules Powdered Gypsum Mineral Wool Pellets Magnesia Powder and Light Weight Slags.

Some types of insulation are flexible. Flexible insulation can be fitted to curved surfaces. It comes in the form of blankets, sheets, and felts. it is installed by wrapping, nailing or by using glue. Flexible insulation is made from materials such as asbestos felt, cotton, fibreglass, mineral wool, foam rubber and wood fibres. Some types of insulation are rigid. They are available in blocks, boards, bricks, sheets and slabs. These rigid forms are often a mixture of different materials. They may contain internal bonders, air spaces and surface treatment. Rigid insulation is made from materials such as Asbestos Cork Fire Clay Mineral Wool Foam Rubber Paper and Wood.

Insulation for piping is usually the same shape as the piping (pre formed). It comes in rigid half cylinders to fit specific sizes of piping and tubing. This rigid insulation is usually fitted to the piping with wire or metal band. A section of pipe insulation is shown in Figure 1-12.

Module No. 7 : Piping systems systems Module No. 7 : Piping

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Unit No. 1 - Piping

Figure 1-12 Piping Insulation Insulating cements are supplied as dry powder. Water is added which turns the cement powder into a paste. A trowel is then used to apply the cement. Insulating cement is used to insulate devices that have irregular shapes such as valves, pipe fittings and turbines. Insulating Materials Asbestos is one of the materials used in insulation. Asbestos can be used at temperatures up to 650C. Asbestos will not burn. It is available in powder, felt, batt and rigid form. It is a good all purpose insulation. You must be very careful when handling and installing asbestos. Asbestos fibres very dangerous and can cause serious illness. Insulating material should be applied by skilled workmen who are experienced in the handling and installation of the different forms of insulation. Insulation manufacturers provide detailed instructions on how to use the material. These instructions must be followed closely. Mineral wool will not burn. It can be used at temperatures of over 100 C. Mineral wool, like asbestos, is available in loose fill, batts, blankets, sheets and in rigid form. It is also available as a cement. it is used to insulate ovens, boilers, air ducts, freezers and hot water tanks. It is made in Fujeirah and is replacing asbestos.

Module No. 7 : Piping systems

Fibreglass, like mineral wool, will not burn. It can be used at temperatures of over 1000 C. Fibreglass Is available in both rigid and flexible forms. Fibreglass is used to insulate piping and other industrial equipment. There is an insulating material which is 85 % magnesia. It can be moulded into any shape It can only be used at temperatures below 350 C. This insulating material is used on steam lines, around valves, on furnace walls, around turbines and on heat exchangers. Page 16/24

There are also other materials that are used for insulation such as cork, foam rubber and foam glass. The type of material used as insulation depends on the situation. The insulating qualities of any installation depends on how carefully the insulating material is handled and installed. In service areas the insulation may be in a place where it is easily damaged. It is important to maintain the insulation regularly in these areas. If insulation material is damaged it will not insulate properly

Unit No. 1 - Piping

Cryogenic Applications In recent years new insulating materials have been developed for cryogenic applications (very cold conditions). These materials must be able to withstand temperatures of minus 150C. The most common insulating materials used for cryogenic applications include: Expanded foam. Gas filled powders with fibrous materials. Evacuated powders with fibrous materials. Multi-layer foil.

Insulating material which is used depends on: Cost of the materials Cost and ease of application. Insulating quality of the material. Weight of the material. Mechanical strength of the material.

Common expanded foam insulations include: Plastics Resins Rubber Silica. Glass.

Module No. 7 : Piping systems

The foam is usually pumped under pressure into the space to be insulated. As the foam sets (dries) small spaces develop. These are filled with a gas which often comes from the chemical action of the foam. Helium or hydrogen are not very good insulating gases. Carbon dioxide is better. One disadvantage of foams is that the expansion and contraction of the foam is quite different than that of metal. At cryogenic temperatures this difference is even greater. Cracks can develop in the insulation. Heat can move through these cracks. Page 17/24

Foam is often used with other insulating materials. It is pumped into the open spaces left when Other types of insulation are applied. Fibrous insulating materials have many open spaces. The movement of the gas in these spaces can be slowed if the spaces are filled with powder. Gas that does not move has better insulating abilities than that of moving gas. Fibrous material with powder filler is usually a better insulation than foam.

Unit No. 1 - Piping

Examples of fibrous insulation materials are Glass Fibre. Mineral Fibre. Perlite.

The powder is often finely ground cork. Fibrous materials with powder insulate better if the gas is removed from the spaces. The extra cost of removing the gas must be calculated when you work out the cost of this type of insulation. The problem with powdered insulations is that the powder usually settles to the bottom. This can cause loss of heat. Multilayer insulations are the most efficient insulating materials for cryogenic use. They are made of several layers of aluminium foil or aluminised mylar. There is a filler material between the layers. The filler material is usually made of glass fibre. After the insulation is installed the air is removed from between the layers to create a vacuum. Multilayer insulation is lightweight. However, it is quite expensive and difficult to install on irregular shapes. 1.14 PIPE SUPPORTS Piping must be supported to keep it from sagging or moving. If pipework sags it puts stress on the connection fittings. This can cause leaks. The pipe support must allow the pipe to expand and contract as the temperature changes. There are many different types of pipe supports. Each one has its own application. Pipe supports must be able to do the following: Support the weight of the pipework, valves, flanges, insulation and fluids inside the pipe. Hold the pipework in a secure position. Allow the pipework to expand and contract due to high and low temperatures. Withstand vibration and fluid pulsation. Raise or lower the pipework as required by the process.

Module No. 7 : Piping systems

1. 15 PIPERACKS

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Piperacks are made of steel I beam or angle iron. They can support a large number of pipes side by side. The rack will be shaped in a Tee T or a F1 upside down U shape depending on the support required. The pipe rests on the surface of the rack and the weight of the pipe stops it from moving up and down. Pipe clamps are sometimes used to hold each pipe still in the pipe rack. The pipe rack can be mounted on the ground or overhead.

Unit No. 1 - Piping

The pipes rest on shoes, saddle plates or pipe clamps. These pipe rests are designed to: Secure the pipe position. Allow for thermal expansion. Reduce pipe wear due to vibration.

The pipes may rest on a support or hang from it. 1.16 PIPE HANGERS Some pipe hangers support pipes from steel beams or building support structures. They come in a number of different types designed to handle specific pipework. There are many different types of pipe hangers. The pipe supports on which the pipe rests are adjustable strap hanger, adjustable roller hanger, roller stand and adjustable roller stand (See Figure 1-13).

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Unit No. 1 - Piping

Figure 1-13 Various Pipe Supports

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Figure 1-14 Variable Spring Hanger If the pipe vibrates a lot variable spring loaded sup-ports are used (See Figure 1-14). Pipe supports are attached to any strong steel or concrete structure. The pipe support must be chosen carefully. The weight of the pipe, valves, fittings, insulation materials and the contents of the pipe must all be considered in the design of the pipe support system. Some of the tasks you have to perform as an operator are: Check welds on all support areas. Check the shoes for wear. Check the pipe for wear at the saddle or shoe. Check to make sure that the pipework is straight.(With no sags or bends). Check for excessive pipe vibration. Check hangers and clamps. Check for any leaks at the supports. Check that the supports are straight.

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