Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
Page 1
CHAPTER 4 Piping, Gaskets, Tubing, Hoses, and Fittings
Table of Contents
Contents
Page
Chapter Overview
2
Class Preparation Checklist
2
Chapter Objectives
2
Agenda
4
Lesson Plan
5
4.1 Gaskets and Flanges, Tubing, Hoses, Blinds,
Supports, and Expansion Items—Piping
6
4.2 Materials of Construction
9
4.3 Pipe and Flange Selection and Sizing Criteria
9
4.4 Connecting Methods
11
4.5 Potential Hazards
13
4.6 Process Technician’s Role in Operation and
Maintenance
13
Summary and Wrap-Up
15
Suggested Student Activities
15
End of Chapter Review Questions
15
Clicker Questions
27
Appendix
30
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
Page 2
CHAPTER 4 Piping, Gaskets, Tubing, Hoses, and Fittings
Chapter Overview
Piping, gaskets, tubing, hoses, and fittings are the most prevalent pieces of equipment
in the process industries. Some estimates state that piping accounts for 30 percent to
40 percent of the initial investment when building a new facility.
In most plants, you will see large segments of pipe going from one location to another.
These pipes carry chemicals and other materials into and out of various processes and
equipment.
When building a process facility, it is important to select proper construction materials
and connectors. Process technicians need to be aware that some materials and
connectors are inappropriate for certain processes, pressures, or temperatures.
Improper material selection and improper operation can lead to leaks, wasted product,
or conditions that are harmful to people and/or the environment.
Class Preparation Checklist
1.
Familiarize yourself with the chapter content.
2.
Bring cutaways or other hands-on teaching aids if available.
3.
Copy and distribute any fill-in-the-blank handouts for today’s content.
4.
Safety Minute prepared or assigned.
5.
Review the PowerPoint slides associated with this chapter (if used) and
make sure that your computer is correctly set up to navigate the slide deck
smoothly.
6.
Request the appropriate A/V equipment (if needed) and make sure that
your computer is correctly synched with the projector to avoid any delays in
the classroom.
Chapter Objectives
4.1 Describe the purpose, types, and uses of piping, gaskets, tubing, hoses, blinds, and
accessories (NAPTA Piping).
4.2 Discuss the uses, advantages, and constraints of various construction materials
(NAPTA Piping).
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
4.5 Discuss the potential hazards involved with piping, gaskets, tubing, hoses, and
fittings.
4.6 Identify the process technician’s responsibility with regard to potential hazards,
operation, and maintenance of piping, gaskets, tubing, and hoses (NAPTA Piping)
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
Page 4
Class Agenda
Activity
Minutes
PPTs
1. Welcome to Class
1
1
2. Introduction and Agenda
1
2
3. Introduction and Agenda (cont.)
1
3
4. Safety Minute
2
4
5. Objectives
1
5
6. Objectives (cont.)
1
6
7. Terms
6
7
8. Piping, Gaskets and Flanges, Tubing,
Hoses, Blinds, Supports, and Expansion
Items—Piping
2
8
9. Gaskets and Flanges
2
9
10. Tubing and Hoses
2
10
11. Blinds and Supports
2
11
12. Expansion Items
1
12
13. Materials of Construction
2
13
14. Pipe and Flange Selection and Sizing
Criteria
2
14
15. Carbon Steel Piping Properties
3
15
16. Flange (Class and
Pressure/Temperature Ratings)
3
16
17. Connecting Methods—Piping
2
17
18. Connecting Methods—Tubing and
Hoses
1
18
19. Fitting Types
2
19
20. Potential Hazards
2
20
21. Process Technician’s Role in Operation
and Maintenance
2
21
22. Process Technician’s Role in Operation
and Maintenance (cont.)
1
22
23. Steam Traps
1
23
24. Mechanical Steam Traps
1
24
25. Pipe Insulation
1
25
26. Piping Symbols
1
26
27. Summary and Wrap-Up
4
27
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
Page 5
Chapter 4 Lesson Plan
Welcome Everyone to Class
Time: 1 minute
Resources: Slide 1
Introduction and Agenda
Time: 1 minute
Resources: Slide 2
Sample Instructor Script:
Piping, gaskets, tubing, hoses, and fittings are the most prevalent pieces of equipment
in the process industries. Some estimates state that piping accounts for 30 percent to
40 percent of the initial investment when building a new facility.
In most plants, you will see large segments of pipe going from one location to another.
These pipes carry chemicals and other materials into and out of various processes and
equipment.
Introduction and Agenda (cont.)
Time: 1 minute
Resources: Slide 3
Student Safety Minute
Time: 2 minutes
Resources: Slide 4
(Note to Instructor: Follow this procedure for the Safety Minute.)
• Announce who has responsibility for today’s Safety Minute.
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
Page 6
Process technicians will encounter many different types of piping, gaskets, tubing,
hoses, blinds, and accessories throughout the course of their work. Technicians are
expected to be able to identify the purpose and uses of each type. Process technicians
should understand the uses, advantages, and constraints of various construction
materials. They should also be able to explain selection, sizing criteria, and flange
ratings.
Objectives (cont.)
Time: 1 minute
Resources: Slide 6
Sample Instructor Script:
Terms
Time: 6 minutes
Resources: Slide 7
Sample Instructor Script:
Turn to the terms page in today’s chapter in the textbook. I’ll call on some of you to take
turns reading the term and definition aloud and then using that term in a sentence.
4.1 Gaskets and Flanges, Tubing, Hoses, Blinds, Supports, and Expansion
Items—Piping
Time: 2 minutes
Resources: Slide 8
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
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and across long distances. An example of this type of piping is the 800-mile-long Trans
Alaska Pipeline.
4.1.1 Gaskets and Flanges
Time: 2 minutes
Resources: Slide 9
4.1.2 Tubing and Hoses
Time: 2 minutes
Resources: Slide 10
Sample Instructor Script:
Tubing is manufactured using an extrusion process to form it in the shape of small–
diameter piping, and it can be flexible or rigid. Tubing is used to transport small amounts
of process fluids and usually has a diameter of less than 1 inch (2.5 cm).
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
Hoses are flexible tubes that carry fluids. Hoses are used in a variety of applications,
4.1.3 Blinds and Supports
Time: 2 minutes
Resources: Slide 11
Sample Instructor Script:
Blinds (or blanks) are solid plates or covers that are installed between pipe or
blinds are thick because they are designed to handle system pressure. The exposed
side of the spectacle blind indicates to a process technician that the flange contains a
blind and that the flow path is either open or blocked. If the side with the hole in it is
visible from the outside, then the technician knows the pipe is blocked. If the solid side
is visible, the technician knows the pipe is unblocked and ready for service.
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
Page 9
4.1.4 Expansion Items
Time: 1 minute
Resources: Slide 12
4.2 Materials of Construction
Time: 2 minutes
Resources: Slide 13
Sample Instructor Script:
Industrial piping, tubing, hoses, and fittings can be made of many different materials,
such as carbon steel, alloy steel, stainless steel, exotic metals, glass, plastic, or clay.
However, carbon steel is the most common piping material because it is appropriate for
a wide range of temperatures and is relatively economical.
4.3 Pipe and Flange Selection and Sizing Criteria
Time: 2 minutes
Resources: Slide 14
Sample Instructor Script:
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
Page 10
Pressure, temperature, corrosiveness, and flow of the process fluid determine the
proper piping material and size. The amount of material that will flow through a piping
system determines the line size. The corrosiveness of the fluid determines the proper
material. The temperature and pressure determine the pipe schedule and flange class.
Design engineers calculate the anticipated flow rates and determine the required
material, piping size, and class when a unit is designed. Operating a pipe outside the
design flows can cause pipe failure.
4.3.1 Carbon Steel Piping Properties
Time: 3 minutes
Resources: Slide 15
Sample Instructor Script:
Piping comes in many different dimensions and ratings. To standardize these
dimensions and ratings, the American National Standards Institute (ANSI) published a
set of guidelines that industries follow. ANSI was sponsored by the American Society for
Testing Materials (ASTM) and the American Society of Mechanical Engineers (ASME).
The dimensions and characteristics specified in the ANSI guide are referred to as a
pipe’s schedule.
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
4.3.2 Flange (Class and Pressure/Temperature Ratings)
Time: 3 minutes
Resources: Slide 16
Sample Instructor Script:
In high–pressure systems, piping, fittings, valves, and flanges must be appropriate for
the pressure ratings of the piping system. Pipe flanges are rated by class. The classes
of common flanges range from 150 to 2500. As the class is increased, the flange
thickness increases and the allowable working pressure is increased. For pipe sizes up
to 3 inches and class150, a flange has four bolts. The number of flange bolts increases
in increments as the pipe size increases.
(Instructor: Go back to Slide 15.)
The 6–inch piping can handle 3753 psi at 200 degrees Fahrenheit.
(Instructor: Go to Slide 16.)
The class 1500 flange could handle 3375 psi at 200 degrees Fahrenheit. The system
must be operated below the lower of these two numbers. Therefore, the MAWP would
be 3375 psig.
4.4 Connecting Methods—Piping
Time: 2 minutes
Resources: Slide 17
Sample Instructor Script:
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
Page 12
Hazardous process piping is generally welded, flanged, or threaded if under 2 inches in
diameter.
4.4.1 Connecting Methods—Tubing and Hoses
Time: 1 minute
Resources: Slide 18
Sample Instructor Script:
4.4.2 Fitting Types
Time: 2 minutes
Resources: Slide 19
Sample Instructor Script:
Fittings are piping system components used to connect together two or more pieces of
pipe. There are many different types of fittings in the process industries. This slide
shows examples of some of the most common fittings:
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
Page 14
4.6.2 Steam Traps
Time: 1 minute
4.6.3 Mechanical Steam Traps
Time: 1 minute
Resources: Slide 24
4.6.4 Pipe Insulation
Time: 1 minute
Resources: Slide 25
4.6.5 Piping Symbols
Time: 1 minute
Resources: Slide 26
Sample Instructor Script:
Piping and instrumentation diagrams (P&IDs) show the equipment, piping, and
instrumentation contained in a process in a facility. Contained on a P&ID are many
different symbols that process technicians must be able to identify and interpret. This
slide (Figure 4.20 in the textbook) shows some of the more commonly used symbols for
piping.
It is important to note that, although there are standards, some symbols can vary slightly
from plant to plant.
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
Page 15
Summary and Wrap–Up
Time: 4 minutes
Resources: Slide 27
Sample Instructor Script:
Let’s summarize today’s lesson and consider what we will be doing in the next class.
(Note to Instructor: To wrap up the lesson, complete the following activities.)
• Summarize today’s lesson.
• Answer questions.
• Announce the next reading assignment and homework.
• Remind the next person who will be doing a Safety Minute.
Suggested Student Activities
(Note to Instructor: Time permitting, do the activities listed below or possibly assign
them as homework. Be sure to remind students what to read for the next class.)
End of Chapter Review Questions
(Note to Instructor: If you have time, you can use these questions to test your
students’ knowledge of the content presented in this chapter.)
1. What are solid plates or covers that are installed between pipe or equipment
flanges to prevent the flow of fluids and to isolate equipment or piping
sections when repairs are being performed?
A. Hoses
B. Gaskets
C. Blinds
D. Expansion loop
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
2. Which of the following is a material that is used to make tubing?
A. Alloys
B. Plastics
C. Copper
D. All of the above
3. What is the typical construction for a steam hose?
A. Plastic
B. Rubber
C. Fiber
D. Braided metal fibers
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings
Process Technology Equipment
Chapter 4 Piping, Gaskets, Tubing, Hoses, and
Fittings