Introduction
When utilizing compressed air systems for your business, you must always make sure that there are no air leaks and that pressure drop is kept to a minimum. This is why piping systems are so important.
Mechanical seals need them to deliver a flushing fluid across the seal faces. They also provide flow pathways for various seal configurations as well as the placement of components such as coolers, reservoirs, and pressure switches.
What Is a Piping System
A piping system is a full interconnection of pipes that includes in-line components such as pipe fittings and flanges. It is also defined as a collection of numerous components assembled in a correct manner of joints to carry fluid from its source to its destination.
A pipe system is primarily intended to meet the functional needs of piping a fluid from one location to another.
Other parameters that influence it to include the kind of fluid being carried permitted pressure drop or energy loss, required velocity, space constraints, process requirements such as a free drain, stress analysis, fluid temperature, etc.
A Brief History of Piping Systems
The first mention of pipe systems dates back to 2,700 BC. Ancient civilizations installed piping systems to transport water from springs to metropolitan areas. At the time, the pipe systems were built using non-metallic raw materials that were bonded together with asphalt between two non-metallic components.
The Egyptians created the first copper pipe systems around 2500 BC by utilizing copper alloying processes. The copper pipe system was used to regulate the flow of water from the Nile River. This approach keeps the river from flooding their crops when they are too high and from drying out their fields when they are too low.
The Components of a Piping System
A piping system is composed of three components: pipes, pipe fittings, and valves.
Pipes
These are long, hollow cylinders that are used to transport or transfer fluids. The most frequent fluids transported are water, oil, steam, air, milk, or finished goods, such as paints and juices. Other less common liquids may include pulp, acids, alkalis, or chemicals.
In addition, pipes can be used for plumbing, water irrigation, tap water distribution, and petroleum processing. These components are also vital in compressed air systems.
Pipe Fittings
These are used to link pipe lengths in order to build a lengthy piping system. They are also being utilized to adapt to varied pipe diameters or forms and regulate or measure fluid flow. The purposes of pipe fittings vary according to their kind, such as:
1. Elbows – Make angle turns in piping.
2. Nipples – Threaded on both ends with the threaded closed nipple to make close connections.
3. Couplings – Connect two identically sized pipes in a straight line.
4. Unions – Allow the easy dismantling of pipe.
5. Tees and Crosses – Connect branch lines at a 90-degree angle.
6. Y-bends – Connect branch lines at a 45-degree angle.
7. Return Bends – Reverse the direction of a pipe rub.
8. Plugs and Caps – Close off any exposed pipe ends or fittings.
9. Bushings – Connect pipes of several diameters. The male end is put into a coupler, and the female end is screwed into the smaller pipe. They can also attach a small tube to allow for easy drainage of water.
10. Reducers – Used to reduce the size of a pipe. They contain two female connectors into which the various sized pipes may be inserted.
Valves
In pipe systems, valves are used to limit, halt, or regulate the flow of fluid. Other functions of valves include:
1. Controlling the cooling rates of water through cooling lines to adjust the temperature
2. Controlling the passage of concentrated acids or bases through a pipeline
3. Redirecting the flow from one line to another to balance the system
4. Keeping reverse flow at bay
5. Stopping the flow automatically in the case of a system breakdown
Piping Supports
A piping system is not complete without the piping supports. These components help prevent the pipe weight from being carried by the equipment to which it is attached.
There are various kinds of piping supports that you can use for your piping system. That is why you must pick a support that can help prevent the pipe’s excessive sagging and allow free movement due to expansion or contraction.
In addition, the design for the supporting arrangement must carry the weight of the pipe, valves, fittings, insulation, and the fluid weight contained within the tube.
Piping Drainage
If you’re constantly using your piping system for steaming purposes, it’s necessary to regularly drain any form of condensate from the lines. Failure to do this will cause the condensated particles to be carried along with the steam and produce a water hammer or possibly rupture your pipes.
Aside from that, your piping system shouldn’t carry unnecessary moisture and steam to the turbines. To remove them from your drainage, there are various devices that you can use.
These include the following:
• Steam Separators
Also known as steam purifiers, these are devices that you can install in the steam line to remove moisture droplets and other impurities from the steam.
The separator must cause the steam to change its direction of flow suddenly, or else it will impart a whirling motion to the moisture. These scenarios can cause the water and other particles to be thrown out of the smoke stream.
• Steam Traps
This device is a must for steam piping, separators, and all steam-operated equipment. It discharges condensation water from the steam lines, separators, and other equipment without letting the steam escape.
The steam traps are also intended to remove any present air in the pipes. This is why they are permanently installed in places where unnecessary condensates must be drained. After all, the moisture rapidly accumulates over time. The remaining condensate must also be recovered for heating or boiling water.
• Piping Insulation
Most piping systems are used in environments with a higher temperature than that of the surrounding air. To effectively reduce the amount of heat lost to the surrounding air, the piping is covered with insulation. This component retains the heat in the hotlines and helps prevent the temperature from becoming uncomfortably high during the plant building process.
Materials Used for Piping Systems
A pipe system can be constructed from a variety of raw materials. However, keep in mind that the materials used for pipe systems should be carefully selected to fit the functional requirements of the piping system. The goal is to ensure that the material utilized is completely safe despite high pressure, temperature, corrosion, and erosion.
Aluminum
One of the best materials for piping systems is aluminum. This metal has become a solid alternative to other piping materials, especially for compressed air systems. Aside from being easier to install and modify than steel or copper pipe systems, they are much lighter and less prone to leakage.
In addition, they have corrosion-resistant properties, which include optimal airflow, reduced energy costs, and better air quality.
Plastic
Plastic has been widely utilized in the pipe system because it is simple to cut and mold into any shape or size required. Polyvinyl chloride (PVC) is a well-known kind of plastic utilized in the pipe system. A PVC pipe system is used for major water lines and water transfers.
However, plastic pipes are not suitable for compressed air systems. This material can’t usually handle hot water applications as it warps at temperatures above 140°F. When pressurized air is forced into a PVC pipe, the tube can expand and burst under high pressure. This can lead to potentially harming anyone in proximity.
Black Steel
Because of their high strength and low maintenance, black steel has been incorporated into various pipes to transport gas and water. This material helps lines protect electrical wiring and deliver high-pressure steam and air. This is why black steel pipes are more useful in the oil and petroleum industries, especially in remote areas.
Galvanized Steel
These pipes are made of steel that has been dipped in a protective zinc coating to prevent corrosion and rust. They were used as alternatives to lead pipes for water supply lines before the 1960s. However, galvanized steel pipes can quickly corrode and rust, especially when exposed to water.
Stainless Steel
Stainless steel is considerably more robust and can accommodate higher pressures with ease, making it an excellent material for piping systems. It also has a high resistance to corrosion and UV radiation. However, it is a heavy material, making it harder to install the piping system.
The Methods of Connecting a Pipe
There are three methods you can use to connect lengths of pressure piping. These are:
Screwed Connections
This piping system is done by cutting the threads on each end of the pipe and screwing fittings to join the lengths. The following threads are the unions, couplings, and elbows.
If you’re utilizing a pipe system with sizes of less than 101.6 mm or 4 inches, then you can use this method for low and moderate pressures. It also has the advantage of quick assembly and disassembly for the connected pipes.
However, keep in mind that this method is subject to leakage. This is because of the reduced threaded connections and pipe strength, especially when you cut the thread in the pipe wall.
Flanged Connections
If your piping system primarily utilizes flanges, then this method will work best for you. It uses flanges, usually bolted together at the pipe ends, to connect them with a gasket between two faces.
This method has been proven to be advantageous over welded connections in terms of permitting disassembly between flanges. In addition, they are more convenient in assembling and disassembling pipes than screwed connections.
However, if you want to prevent leakage under the flanged connections method, you have to use flat and smooth flanges. They have to face each other so they can grind against one another. Although this proposition is possible, it is time-consuming and expensive.
To reduce the amount of time used under this method, you can use gaskets between flange faces. They are typically made of a comparatively soft material, filling small depressions and preventing possible leakage when tightening the flanged connection.
Welded Connections
Under the welded connections method, you have to solder the pipe lengths directly to one another and any valves if they’re required. This method provides several advantages over screwed connections or flanged connections, such as:
1. You can eradicate the possibility of leakage by eliminating the screwed or flanged joints.
2. This method helps reduce the weight of the piping system by removing the connecting flanges and fittings.
3. It has a low cost for materials and maintenance.
4. Because there are no bulky flanges, the piping system looks neater.
5. You can efficiently insulate due to the lower number of fittings.
6. Welded joints provide more flexibility to the piping system because you can join the pipes at any angle.
When using the welded connections method for your piping system, you must consider hiring a skilled welder. This is to ensure that the soldering will fit, especially when you have to make a connection.
Where to Purchase High-Quality Piping Systems in the Philippines?
Wherever you are in the Philippines, Compresstech Resources, Inc. has got you covered. We provide flexible, premium-quality, and reliable piping systems that you can purchase at the best prices. Our products are made from high-quality aluminum to ensure the absence of air leaks and help minimize the pressure drop. They also come with a portable installation kit, eliminating the need for pipe threading equipment to simplify the process.
We offer three different products under the ‘Piping System’ category, including:
Complete Piping Systems
If you have no idea about different types of air pipes and accessories, you can opt for Compresstech’s complete piping system. This state-of-the-art product can efficiently be designed and installed for compressed air transmission.
It also has a superior design that you can upgrade quickly. Aside from that, our complete piping system is leak-free and corrosion-resistant, which helps save energy and produce high air quality.
Air Pipes
Our air pipes are lightweight and corrosion-free. They are made from 100% recyclable anodized aluminum for superior reliability and longevity. These pipes also utilize clamps and surface sealing rings to ensure tight, leak-free connections. In addition, you can install and upgrade them quickly and easily for an efficient pipe system.
We offer air pipes in various sizes, from 25 mm to 150 mm.
Accessories
In need of extra accessories for your piping system? We’ve got you covered! Our unique and complete set of piping systems is composed of:
1. Pipe connectors
2. 45 and 95 elbow pipes
3. Straight tee and reducing tee
4. Valves
5. Flanges
6. Hoses
Conclusion
A piping system is a piece of essential equipment for compressed air operations. They are quite expensive because they serve as the arteries of industrial processes. In some cases, they make up one-third of the total plant cost of a business.
If you’re still undecided about getting a piping system for your business in the Philippines, turn to Compresstech Resources, Inc. We always make sure to provide you with reliable piping systems that meet your business needs.
Get in touch with us today for more details about our products. We will be more than happy to address any of your questions or concerns. Our team looks forward to hearing from you.