Document jy7VQ3j36yvMJaGEXjOKeLR9

WA-TEX003924 TEXACO INC. PUGET SOUND PLANT PAGE i ' TRAINING OUTLINE DEPARTMENT: PIPE CLASSIFICATION: PIPEFITTER (TRAINEE) DATE: JULY 1, 1971 Subject A. BASIC TRAINING ' Page No. *1. Departmental Organization 1 *2. Relationship of Department to Refinery Operations 2 *3. Department Standards and Working Rules 3 *4. Department Fire Protection 5 *5. Department and Plant Safety practices 8 *6. Departmental and Plant Housekeeping 12 *7. Departmental Lubrication 14 *8. Care., Purpose and Use of Hand and Portable Power Tools 16 *9. Procedures for Obtaining and Transporting Tools, Materials and. Equipment 19 *10. Location and Use of Utilities 20 *11. Departmental Standards of Craftsmanship 21 *12. Procedures for Obtaining Work Permits 22 *13. Identification, Purpose, Characteristics and Use of Materials 23 *14. Read, Interpret and Work from Blueprints, Sketches, and Bills of Material and Requires a Knowledge of Shop Mathematics 39 *15. Measuring and Layout `Methods and Tools 83 *16. Care and Purpose of Shop Equipment 89 *17. Taking Field Measurements and Job Planning 90 X : WA-TEX 003925 WA-TEX003925 TEXACO INC. PUGET''SOUND PLANT PAGE ii TRAINING OUTLINE DEPARTMENT: /PIPEW-: t4 CLASSIFICATION!--PIPEFITTER (TRAINEE) DATE: JULY 1, 197_Q Subject B. Cft? THE JOB TRAINING Page No. *1, *2. *3. 4. *5. *6. .. Assemble and Transfer Equipment and Tools Move Materials Load and Unload Materials Dope and Wrap Pipe String Out Pipe Dismantle Pipe and Fittings 99 100 101 102 103 105 *7 Salvage Piping *8. Use Hand Dies lCfc 109 *9. Operate Power Tools 10. Operate Pumps 111 112 a. Sump Pumps 112 *b. Test Pumps 11. Operate Compressor^. 12. Operate Hoists 112 113 114 *a. Air Hoist 114 *b. Electric Hoist 114 *e. Air Tugger 114 *13. Cut Gaskets ' 116 *14. Use Hand Tools 118 *15. *16. Sharpen Tools . Clean Up Shop and Work Areas 120 122 *17. *18. *19:. - Tie Knots and Hitches- Rigging and Hoisting of Material, Tools and Equipment Check Tools 123 127 134 1 WA-TEX 003926 WA-TEX003926 Subject *20. *21. *22. *23. 24. *a. **b. *25. *2S'i. *27. *28. 29. *a. *b. *c. 30. *a. *b. *c. *31. *32. 33. *a. *b. 34. *a. *b. B. ON THE JOB TRAINING Install and Remove Blinds and Orifice Plates Unhead and Head-up Vessels and Similar Equipment Move and Assemble One and Two Stage Scaffolds Install Lubricators Layout and Prefabricate Pipework Welded Screwed Operate Pipe Machine Bend Pipe Fabricate Tubing Install Bell and Spigot Pipework Install Pipe and Fittings Welded Screwed ' Plastic Remove and Install Valves Gate* Globe* Cock and Check Regulators Relief Valves Make Hydrostatic Test-- Renew Tubes Burners - Gas and Oil Remove and Install Clean and Repair Coils Remove and Install Repair WA-TEX 003927 PAGE iii Page No. 135 136 138 145 146 146 146 147 148 165 167 171 171 17.1 171 174 174 174 174 175 176 177 177 177 180 180 180 WA-TEX003927 B. ON THE JOBTRAINING PAGE Iv Subject ' Page No. 35. Steam and Air Traps l8l *a. Remove and Install 181 *b. Repair and Inspect l8l *36. installation and Repair of Plumbing 219 *.37. Install Tubing 220 38. Steam Radiators 221 a. Remove ' 221 b,. Install 221 cv. .. Repair ' 221 *39. Install Pipe Hangers and Supports 222 40. Paclf Valves 230 *4l. Install and Remove Ohmart Level Controller 231 ' 42. Repair Hydrants 233 *a. Service Water ` - 233 *b. Fire Water . 233 *43. Install Expansion Joints 237 *44. Flange and Unflange Equipment 238 *45. Install Eductors 239 *46. Install Temporary Field Pumps 24.2 *47. Install Steam Tracing on Pipe and Fittings 243 *48. Make Pressure Taps 244 49. Dismantle* Repair and Reassemble Oxygen Lines and Equipment 259 *50. Install Pipe Clamps 261 51 Conduct On-The-Job Training 52 Conduct (Basic) Classroom Training WA.-TEX 003928 WA-TEX003928 TEXACO INC. PUGET SOUND PLANT PAGE 1 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION: PIPEFITTER (TRAINEE) DATE: July 1, 1970 ITEM NO. A^l SUBJECT: DEPARTMENT ORGANIZATION The Pipe Department is one of several departments of Puget Sound Plant whicn come^ under the Jurisdiction of the Assistant Plant Manager. The Supervisor-Maintenance is in charge of the planning, scheduling and execut' on of work *' nvolving all the maintenance depart ments of the Plant including the Pipe Department. , The. foreman of the Pipe Department is in direct charge of the personnel or the department and is responsible for the selection and assignment of craftsmen and trainees in accordance with the require ments of the daily work schedules. He is also responsible for the follow up of work performance to assure proper application of craft skills and quality workmanship. The Pipe Foreman directly supervises the work of Pipefitters assigned to the respective units, coordinates the work and cooperates with the various operating departments in accomplishing scheduled work. - PIPE DEPARTMENT ORGANIZATION WA-TEX 003929 WA-TEX003929 TEXACO INC. PUGET SOUND PLANT PAGE 2 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION: PIPEFITTER(TRAINEE) DATE: July.1, 1970 ITEM NO. A-*2 SUBJECT: RELATIONSHIP OF DEPARTMENT TO REFINERY OPERATIONS The purpose of a refinery is to process crude oil ..and convert it into highly refined and saleable petroleum products, as economically and safely as possible, while maintaining high standards of quality which assure continued confidence of the buying public. Each operating unit and department is designed, constructed and operated with the objective of providing a continuing supply of quality-controlled petroleum products for a highly competitive market. Maintaining each unit in a safe operable condition requires the knowledge and skills of many people and crafts. New techniques, materials, tools and methods are constantly being developed which require increasing knowledge, skill and training in order to take advantage of these developments and remain competitive. The Pipe Department has an important role in maintaining continuity of refinery operations. The Pipefitter fabricates, installs, repairs, replaces, tests and maintains various types of pipe work, fittings, valves and operating equipment. The continued safe operation of a unit or related equipment may be dependent on how well the Pipefitter has performed such work as repacking a valve. Installing the correct type and schedule numbered pipe or fitting, tightening up on a vessel head or pipe flange, cleaned and tested shell and tube equipment, and many other similar jobs requiring skilled craftsmanship and high standards of workmanship. Since the Pipefitter's work may involve other crafts, or effect several operating departments, it is essential that he closely coordinate his work and cooperate with others in order to do a safe, workmanlike job. It can thus be seen that the Pipe Department plays an important part in relation to both the mainte nance and operation of refinery equipment. As equipment or pro cedures are changed the Pipefitter may find it necessary to adapt himself to the use of new methods, new tools and undergo re-training. However, the Pipe Department still bears a continuing reaponsiblity and relationship to operations of the refinery which contribute substantially to the maintenance of the safety, economy and conti nuity of the refinery productive capacity. WA-TEX 003930 WA-TEX003930 TEXACO INC. PUGET SOUND PLANT PAGE 3 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION: PIPEFITTER (TRAINEE) DATE: July 1, 1970 ITEM NO. A-3 SUBJECT: DEPARTMENTAL STANDARDS AND WORKING RULES 1. When you cannot report for work as scheduled, and on time, give your Craft Supervisor or the Night Foreman on duty as much advance notice as possible. If you are unable to call, have .someone call for you. 2. Requests for time off should be handled with your Craft Super visor as far in advance as possible. 3. When you have been absent for any reason such as sickness, accident, vacation, etc., call your Craft Supervisor as far in advance.as possible before returning to work so he can arrange schedules and advise you when to report for duty. 4. In case of change of address, notify your Craft Supervisor of new address and telephone number. 5. When you have finished a job, go at once to your next assign ment, if known; otherwise, contact your supervisor. Do not loiter or loaf between jobs. 6. It is a Pipefitter's responsibility to see that his job pro gresses In a safe working manner, keep his helpers lined up and working, and to know where his helpers are at all times. 7. It- is a Pipefitter's duty to make sure all necessary materials, equipment and tools are transported to his assigned job. 8. Instruct his helpers of proper tool handling and work procedures on the job. 9. Request work permits when required to do a job such as blinding lines or pumps, opening vessels or towers, entering and burning lights in vessels or towers, etc. (Read permits and follow special instruction written on permit.) 10. In an oil refinery, we must eliminate all possible causes of fire. Smoking is permitted, therefore, only in certain clearly marked areas and at specified, times. People who cannot observe this very important safety rule just don't belong in an oil refinery. For the safety of everyone, this rule is rigidly enforced. "11 11. Pipefitters will be furnished tools necessary to perform their specific duties. It is the responsibility of each Fitter to make sure that the tools he uses, or returns for the use of others, are in safe working condition. Replacement of broken or damaged tools will be handled by the Main Tool Room. [ WA-TEX 003931 WA-TEX003931 ITEM NO. A-3 TRAINING DETAILS PAGE 4 12. The Plant telephone system is primarily for the transaction of Company business. Personal calls ordinarily should not be made during working hours. You are expected to use good judgment in this respect. Please use the phones for personal business only when absolutely necessary. 13. Do hot leave the Job unless reported to your Maintenance Supervisor. 14. It is a Pipefitter's responsibility to train and instruct a Craft Helper in the methods and procedures of his trade whenever so assigned by his supervisor. WA-TEX 003932 WA-TEX003932 TEXACO INC. PUGET SOUND PLANT PAGE 5 TRAINING DETAILS DEPARTMENT: PIPE 4 CLASSIFICATION: PIPEFITTER (TRAINEE) DATE: July 1, 1970 ITEM NO. A-4 SUBJECT: DEPARTMENT FIRE PROTECTION .. Fire protection and fire fighting are the concern of each and every individual at Puget Sound piant. All employes, exclusive of women, are subject to fire fighting duty as required, whether or not directly attached to the Fire and Emergency Organization. Accordingly, supervisors assigned a copy of this manual are res ponsible for keeping all personnel under their supervision informed in regard to their individual roles. X. HON TO REPORT A FIRE OR EMERGENCY To report a fire or other emergency there are simple rules which should be followed: 1. REMAIN CALM - DO NOT PANIC You have certain vital functions to perform - functions which must be carried out promptly and effectively - functions which call for clear thinking and sound judgment. 2, SIZE UP THE SITUATION QUICKLY Is the fire small enough to handle alone- or will .help be needed? Spot the nearest fire extinguishing equipment weigh the possibilities of personal Injury 3. TAKE ACTION (a) Extinguish Fire if you can handle it alone - SAFELY! or (b) Give Alarm If the fire is too large to handle without help even if necessary to leave location to do so. TAKE NO .CHANCES OF LETTING FIRE GAIN SERIOUS HEADWAY BEFORE GIVING ALARM, 4. GIVING THE ALARM Call the Boiler House Immediately by telephone (22) giving: 1. Your name 2. Location of fire and department: have this information repeated back. 3. Nature of fire - seriousness. ; WA-TEX 003933 WA-TEX003933 ITEM NO. A-4 TRAINING DETAILS PAGE 6 f * Mobile radio equipment may be used if telephone is not convenient and would cause delay in sounding alarm. In this case, call the Gate or the Garage who in turn will relay the call to the Boiler House. However, it ii preferable to call the Boiler House direct. REMAIN CALM - HAVE PERSON RECEIVING CALL REPEAT INFORMATION BACK - BE SURE HE CLEARLY KNOWS LOCATION. II. FIRE AND EMERGENCY SIGNALS REGULAR EIRE ALARM: One wildcat cycle followed by number of short blasts to indicate zone number. Repeat wildcat cycle and zone signal one time, as follows: ZONE NO. ZONE SIGNAL 1 : 1 Wildcat 2 : 1 Wildcat 3:1 Wildcat 4 : 1 Wildcat 5 : 1 Wildcat (pause 10 sec.) (pause 10 sec.) (pause 10 sec.) (pause 10 sec.) (pause 10 sec.) 1 short blast (pause 10 sec. ) Repeat wildcat and zone 2 short blasts (pause 10 sec.) Repeat wildcat and zone 3 short blasts (pause 10 sec.) Repeat wildcat and zone 4 short blasts (pause 10 sec.) Repeat wildcat and zone 5 short blasts (pause 10 sec.) Repeat wildcat and zone Responsibility: When Regular Fire Alarm sounds, all personnel assigned to the Fire and Emergency Organization who are on duty are required to report to their respective assignments as out lined herein. The only exceptions would be in the case of scheduled fire drills when individual members may be excused by authority of the Fire Chief (Plant Manager), or Assistant Fire Chief (Assistant'Plant Manager) only. Persons temporarily on "limited duty" due to physical condition will be considered as temporarily relieved from fire fighting duties. Off duty employes ar.e not required to report unless called out, except that Supervisors on Call Out Lists should not necessarily wait to be called, ' The term "wildcat" or "wildcat cycle" refers to the variable pitch feature of the wildcat fire whistle, sounding the whistle through its range from high pitch down to low pitch and back to high pitch again pitch is used for zone signals. tl JJ * Fire Drill: Same as Regular Fire Alarm, including repeat. Recall: One long blast of the high pitch. "Recall" to be sounded only when .authorized by person acting as Fire Chief, Assistant Fire Chief, Fire Marshal or Acting Fire Marshal. Person calling the "recall" to the Boiler House should identify this authority. Wft-TEX 003934 WA-TEX003934 ITEM NO. A-4 TRAINING DETAILS PAGE 7 GENERAL ALARM: 10 continuous wildcat cycles (approximately two minutes.) "General Alarm" to "be sounded only when authorized by person acting as Fire Chief, Assistant Fire Chief, Fire Marshal, or Acting Fire Marshal. Person calling a 'General Alarm" to the Boiler House should identify thi3 authority. ` Responsibility: When General Alarm is .sounded, all available employes except women are rnquS to mnort as outlined jn UJ. KJli XVII - General Alarn - of the Plant Fire Manual. Off duty employes should report on earing the alarm or on being called. UNIT EMERGENCY ALARM; Series of short blasts (approximately 10), of air whistle on unit concerned. Fire whistle will be tested each Friday noon immediately following the regular plant noon whistle. Test will consist of sounding one wildcat cycle. If wildcat fire whistle is inoperative, the plant shift whistle will be used. Signals will be the same as above, substi tuting one long blast for each wildcat cycle. Hourly employes reporting in response to General Alarm or Call Out should punch in as usual at the Main Gate. ' WA-TEX Q03935 WA-TEX003935 TEXACO INC. PUGET SOUND PLANT PAGE 8 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION: PIPEFITTER (TRAINEE) DATE: July 1, 1970 ITEM NO. A^5 SUBJECT: DEPARTMENT AND PLANT SAFETY PRACTICES PURPOSE: The purpose of this section is to assemble in one place the more important and pertinent safety information applicable to the work of the Pipe Department. In general, all of the Regulations, Procedures, Practices and information contained herein should be studied carefully by every craftsman and trainee and practiced constantly. REGULATIONS: The following regulations MUST be observed:(l) (l) No flange or head can be unbolted on any vessel or tank, or any line opened until a SAFETY WORK PERMIT, Form R-241-A (yellow form) has been issued by the operating department involved. The PERMIT must be posted conspicuously at the work site or point of entrance. ' (.2) ,No tank, vessel, tower, drum or other enclosed space is to be entered until a SAFETY WORK PERMIT has been issued authorizing entry. (3) No burning, welding, grinding, chipping, sandblasting, pressure tapping, breaking concrete, use of Internal combustion engines or other work can be performed which could be a source of ig nition for any flammable materials, unless and until a HOT WORK PERMIT, Form R-24l, (pink form) has been issued in proper form by the operating department involved and properly countersigned by an authorized operating supervisor. (4) Standing instructions for issuing both Hot Work and Safety Work Permits must be reviewed by each Pipefitter and trainee. (5) CAUTION - Always read the PERMIT - be sure you understand the precautions which must be observed - note the time period it covers - be sure it describes or identifies the line, vessel or equipment to be worked on - note the requirements fur use of personal protective equipment - be sure the condition of the line, vessel or surro"nding area is specified - and obey all the precautions written on the permit. WHEN IN DOUBT, CONSULT YOUR FOREMAN. . (6) Do not open or close valves on lines, vessels and operating equipment (except valves at utility stations - air, steam and water). Only Operators on the particular unit or area are permitted to operate valves. (7) Hard hats must be worn on the job. Goggles must be used when ever a hazard to the eyes may be encountered. For example: chipping, breaking concrete, hammering on overhead lines and objects, breaking into lines, working where dust and rust is WA-TEX 003936 WA-TEX003936 ITEM NO. A-5 TRAINING DETAILS PAGE 9 blowing around, grinding, buffing, etc. Protective clothing (impervious suits) and other protective equipment must be worn when specified on HOT or SAFETY WORK PERMITS, when working on lines or equipment in acid or caustic service, or when instructed to do so by the Foreman in charge of the work; (8) Pressure Tapping or Hot Tapping must never be performed until a HOT WORK PERMIT, Form R-241 (pink form) has been issued and then countersigned by the Assistant Plant Manager or the Plant Manager, and a fire watch is maintained. The Pipe and Operating Foremen shall provide close supervision during the entire tapping operation. (9) Gloves should not be worn while using abrasive grinding wheels. (10) When work is performed on pipe lines connected to equipment or lines in service and there is any danger of oil or other products escaping from a open end, or open-end valve, the valve flange or open end of the line should be blanked (blinded) off or plugged. (11) When work is to be done on_a line equipped with a cathodic pro tection system, the Ins,trTElec Foreman must be .consulted before the line is broken (disconnecced) and SAFETY WORK PERMIT, Form R-241-A, must be issued. (12) High pressure air shall not be used for testing pipework except as approved by the Engineering Department. In no case shall air be used to test lines last containing a volatile product, acid or caustic. Water or high flash oil is recommended for testing pipework in preference to air. (13) Vrhen using buckets to raise or lower tools, equipment and material to top of towers or vessels, remove bail and replace with a heavy gauge wire or small cable. (14) If working in a trench with straight up and down walls over 4 ft. deep, shoring should l.e Installed to prevent cave-ins of dirt. (15) Bpfore pe^ating on air tugger, cable and spool should be ins pected for tangles in cable on spool and broken strands in cable. PROCEDURES: The procedures outlined herein should be followed when 1 ever performing the work described. (1) Unheading, Breaking Into Lines, Blinding and Disconnecting . Practices - Obtain Safety Work Permit. In addition, the following precautions should be observed: (a) Use a drift pin, spud wrench or other suitable tool in lining up bolt holes in flanges. KEEP FINGERS OUT OF BOLT HOLES. (b) Do not stand in line with faces of flanges when a wedge is being driven between them as a precaution against injury in event the wedge should jump out. WA-IEX 003937 WA-TEX003937 ITEM NO. A-5 TRAINING DETAILS PAGE 10 (c) When unbolting flanges be sure to loosen bottom bolts first on side opposite where you are standing so as to divert any possible pressure remaining in line away from the feet and body. (d) When necessary to break into or unflange lines, pumps or vessels handling TEL (Tetraethyl Fluid) the current rules and regulations of the supplier (Dupont) shall be followed, therefore, consult your foreman and secure properly prepared SAFETY WORK PERMIT. (2) Wording on Scaffolds Before using a scaffold the person using should check the following to assure safety: (a) Supports should be solidly set on level surface or properly blocked, (b) Cross braces should be firmly attached. (c) Guard rails should be provided. (d) Decking boards should be free of splits and checks. (Boards should be at least 2" X 10" lumber at least as good as #1 Common.) (e) Decking boards shall have cleats at both ends to prevent boards slipping off bearing ledger. (f) Decking boards should overhang the bearing ledger at each end at least 8" but not more than 12". Where overhang exceeds 12" the decking board should be wired down at both ends to prevent tilting. (g) Decking boards must be free of oil and grease and kept free at all times. (h) Ladders should be installed in best position for climbing and exit. (i) Before beginning job worked from scaffold, check all exits possible, in case a quick descent has to be made. PRACTICES: The following practices are considered orecautionary1 in nature a- ' -t is recommended they be observed. (1) Avoid walking on pipe lines whenever possible. Major jobs of work should not be done while standing on lines or fittings. (2) Avoid walking on asbestos or transite roofs, on defective roofs, and on insulated lines. (3) Keep clear of suspended loads wherever and whenever hoisting is being done. WA-TEX 003938 WA-TEX003938 ITEM NO. A~5 TRAINING DETAILS PAGE 11 (4) When lifting, make full use of the leg muscles, keep the hack as nearly upright as possible and avoid twisting while lifting. Get help with heavy loadsi (5) When working with or around welding operations, secure and use safety glasses (goggles) with dark lenses. These may be obtained from the Tool Room. Never look directly at electric or acetylene welding rays. Reflection of electric arc off light colored (aluminum) surfaces can cause flash burns. (6) All excavations of any kind In any area where employes are likely to walk must be -ither" refilled, covered, fenced or roped off and warning flasheis used at night, (7) Leather gloves should be worn while fabricating pipe and fittings with welder. ` (8) When using a come-a-long for lifting, arrange rigging so come-along is in a safe reach for operating. If rigging Is too far above head, use a chain fall instead of a come-a-long. WA-TEX 003939 WA-TEX003939 TEXACO INC. PUGET SOUND PLANT PAGE 12 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION: PIPEFITTER (TRAINEE) DATE: July 1, 1970 .ITEM NO. SUBJECT: DEPARTMENTAL AND PLANT HOUSEKEEPING DEFINITION: Theterm "housekeeping" is generally used throughout ' the petroleum industry and refers to the continuous maintenance of clean, neat and orderly conditions within a refinery. Lack of good housekeeping practices contributes to safety, fire and health hazards detrimental to all employes. . RESPONSIBILITY: It is the responsibility of each supervisor and employe in the Pipe Department to maintain the department and assigned work areas in conformance with Refinery Housekeeping Practices. PIPE DEPARTMENT PRACTICES: In addition to the general practices ' ~~ applicable to every employe in the refinerv, there is a number of "Housekeeping Practices" which are emphasised here and which must be observed by everyone in the Pipe Department. (1) All roadways, passageways, aisles, stairways, platforms, etc., shall be kept free of unnecessary tools, materials and debris. Clean up after every job. (2) Oil or chemically damaged scaffold decking boards should be promptly removed from service and tagged for destruction in order to prevent re-use. (3) Any oil or chemical spilled on stairways, platforms, scaffold decking, walkways and similar areas where persons must work or walk should be cleaned up immediately or sand applied to prevent slips and falls. (4) Waste material should not Le allowed to accumulate but should be cleaned up and ar*niie,,7ents mad*- ! it hauled away. Sal- ` vageablfe. materials'shoe'd be neatly piled until they can be hduled to the Plant salvage area. (5) Never block access to fire fighting equipment with equipment or materials. (6) If it is necessary to leave a job before clean up can be completed, advise the Pipe Foreman so arrangements can be made to reschedule clean up. It is the responsibility of every Pipefitter, after completing a job, to leave the work site in a clean, orderly and safe condition unless specifically directed otherwise. W&-TEX 003940 WA-TEX003940 ITEM NO. A-6 TRAINING DETAILS PAGE 13 (7) Area around pipe maeiiine should be kept free of pieces of pipe, blocks, chips or shavings. Oil drippings should be kept cleaned up. Either Super-Dri or sand should be used to prevent slips and falls until clean-up can be effected. (8) All tools and equipment should be cleaned and returned to their proper storage area. Broken tools should be tagged and sent to Main Tool Room for repair. ! WA--TEX 003941 WA-TEX003941 TEXACO INC. PAGE l4 PUGET SOUND PLANT /'"N i , TRAINING DETAILS DEPARTMENT: PIPE ' DATE: July 1, 1970 CLASSIFICATION: PIPEFITTER (TRAINEE) ITEM NO. A SUBJECT: DEPARTMENTAL LUBRICATION LOCATION AND STORAGE: (l) Oils are delivered from the Storehouse in 5 and 55 gallon drums and dispensed through a spigot. Grease is delivered from the Storehouse in 5 pound and 35 pound metal containers. Climax or stick grease is stocked in the Storehouse and may be found in Lube rooms on rv->o-->ifcing units. Pipe Thread Dope, Graphite and thread cutting oil will be found at the Portable Tool Room or at the Storehouse. Teflon tape is provided by Craft Supervisors. GRADES AND USES: (1) When operating pneumatic (air) tools, such as Impact Motors, Knocker Motors, Portable Power Saw, Box Pressure Pumps, etc., use Regal C in the oiler. (2) Graphite is used on bolts, flange faces where composition gaskets are used, valve stems, and pipe threads. ' CAUTION: DO NOT USE THREAD DOPE ON DRINKING WATER OR INSTRUMENT AIR PIPING. (3) Marfax 1 or 2 is used on the drilling bit of the pressure tap machine. " (4) Climax (any grade) is used to hold exchanger head gaskets in position while installing heads. (5) Use a thick mixture of Universal Gear Lubricant HD 90 and Flake Graphite on heater bends, biscuits or where you may have extreme heat. CAUTION: NEVER USE PIPE OR THREAD DOPE ON HEATER BENDS OR BISCUITS, OR WHERE YOU HAVE EXTREME HEAT. (6) Cutting oil is used with the portable power hack saw, when-cutting threads with stock and die, with the portable pipe machine, and pipe machines in the Pipe Shop. METHODS OF APPLICATION: (l) Tail hose with built-in oiler ,are provided when operating pneumatic tools. If ione are available, install an oiler in the air supply which are available at the Portable and Main Tool Rooms. CAUTION: CHECK THESE OILERS REGULARLY TO SEE THAT THEY ARE FULL AND OPERATING PROPERLY. WA-TEX 003942 WA-TEX003942 ITEM AT TRAINING DETAILS PAGE 15 ' (2) Lubricators are installed on all air-operated pressure box pumps. Check lubricator before and during operation. (3) Threads and gasket face should be wire brushed to remove all dirt and grit before applying thread dope. (4) Marfax 1 or 2 should be applied to drill bit on pressure tap machine to serve as a lubricant during drilling operations. (5) Before applying climax stick grease to exchanger heads, the gasket seat should be wire brushed and wiped clean with a rag. Any small particles of rust or scale left under a gasket may cause leaks. (6) A mixture of graphite and Gear Lubricant should be applied with brush to threads of bolts used in all types of services. When heat comes in contact with this mixture, it burns the oil out leaving the graphite. When heat comes in contact with pipe or thread dope, it burns the liquid out leaving a hard "inish, making it very difficult to remove nuts. (7) When cutting threads with a stock and die, use an oil can to . apply cutting oil at regular intervals. This lubricates cutting edge of die helping to cut smooth threads. (8) Portable and shop pipe machines have built-in cutting oil reservoirs and pumps to lubricate dies while cutting. (9) One wrap of teflon tape is used on threads of drinking water lines rather than thread dope. If dope is used, it may get into lines a cause a bad taste-in the water. Use one wrap of teflon tape on piping of instrument air. The use of thread dope may cause clogging and damage to instruments. WA-TEX 003943 WA-TEX003943 TEXACO INC. PUGET SOUND PLANT PAGE 16 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION: PIPEFITTER (TRAINEE) DATE: July 1, 1970 ITEM NO. A-8 SUBJECT: CARE, PURPOSE AND USE OF HAND AND PORTABLE POWER TOOLS CARE OF HAND TOOLS: (1) Each Pipefitter is assigned a tool box of hand tools, these tools should be kept clean and orderly at all times. If at any time a tool becomes broken or damaged, it should be re turned to the Main Tool Room. A broken tool slip has to be signed by the Pipefitter before a tool is replaced. (2) Tools checked out of the Tool Rooms should be cleaned and returned upon completion of job. If tool is broken or damaged notify toolkeeper so tool may be repaired or a replacement tool can be ordered. PURPOSE AND USE OF HAND TOOLS: (1) Knowledge of the proper tools to use and how to use them is necessary to good handling of pipe fittings. Wrenches are used on practically every pipe job, and if used improperly can cause serious damage to materials as well as tools and personnel. Be sure to select the right type and right size tool for each piping or maintenance job. (2) Steam, air, water and pressure hose are also considered as tools for pipefitters. Hose should be coiled up when not in use and kept in their designated locations. In some cases, hose may be permanently left attached at some locations (steam and water). Hose for air and water are tested to withstand maximum plant air pressure, and may be used interchangeably. Hose for air and water are equipped with Chicago couplings and should never be used for steam or pressure testing service. Steam hose is a specially constructed, wire-wound hose designed to withstand both heat and pressure. Pressure hose is designed to withstand high pressures, and used with pressure pumps when testing lines or vessels for leaks. " CARE OF PORTABLE POWER TOOLS,: (l) Portable power tools are available for many different types of jobs. These tools must be lubricated at all times when in operation. Never drop or lay these tools in oil or where water can get on them. Impact guns are designed for only so much load, so use the proper size for the size of nut to be broken loose. Use an impact in short bursts from 10 to 15 seconds. Portable pipe machines should be kept covered at all times when not in use. 1 WA-TEX 003944 WA-TEX003944 ITEM NO. A^8 TRAINING DETAILS . PAGE 1J (2) All pneumatic portable power tools are equipped with a fine wire mesh filter screen, to filter out small particles of dirt and rust to keep them from entering the mechanism. Before operating, blow out hose with air to clean it. PURPOSE AND USE OF PORTABLE POWER TOOLS: (l) Portable power tools can save a Pipefitter a lot of hard manual labor if used properly. They are designed to only carry so much of a load, so select the proper size tool for the Job. CAUTION: NEVER TRY TO REPAIR A POWER TOOL IN THE FIELD. IF THEY ARE WORKING IMPROPERLY, SEND TO MIN TOOL ROOM FOR REPAIR AND INFORM TOOLKEEPER. . SAFETY: (1) Do not use defective tools. (2) "S" wrenches or light wrenches of any 1,"5nd shall not be struck with a hammer or maul. Only ''striking" tools may be hammered. (3) The use of two open end wrenches to secure extra leverage by one into the jaws of the other is a dangerous practice and is prohibited.. The extra leverage may cause the wrench to break or spread and results in an injury. Where more leverage is needed, get the proper type and size of wrench. (4) When using a wrench, be sure it fits properly and in applying force, push or pull evenly and steadily, otherwise, a sudden jerk or slip may cause inj.ury. (5) Before using any pneumatic (air) tool, inspect the hose couplings and hose connections to see that.they are safely attached and in good condition. Chicago couplings should be wired. (6) Chain hoists and chain blocks should never be used to hoist any load greater than its safe working capacity. Inspect carefully before each use to assure it is in good condition. . (7) Carry and handle tools in such a manner that they are not liable' to cause injury to yourself or others. Be especially careful that sharp-edged tools are not carried in the pocket or in a manner where the arms or other parts of the body may strike the tool. ' (8) Tools should not be carried in the hand or loosely in the clothing, while climbing a laduei* ^j. 0 limbing onto a scaffold. Heavy tools must be hoisted or lowered by a line, (9) The proper tools in good repair shall be used only for the purposes intended. . WA--TEX 003945 WA-TEX003945 ITEM NO. A-8 TRAINING- DETAILS PAGE 18 (10) Small tools, when not in use on elevated locations, shall be kept in tool box, and large tools shall be placed in position where there is no danger of their being kicked off or causing a tripping hazard. Upon completion of a job, tools shall be removed from elevated locations. NEVER THROW TOOLS OR MATERIALS PROM ELEVATED LOCATIONS. (11) Grinding wheels shall not be operated at speeds greater than their designed rating - check to make sure th.it proper wheel is attached to tool. Examine wheel for cracks - discard wheel if cracked. (12) Air or electric driven wire brushes shall be examined before each use to be sure they are in safe operating condition. Wear goggles when using to protect eyes against small flying particles of wire. Pace shields and rubber clothing may also be needed. (13) Before using any pneumatic (air) tool that requires lubrication, check to make sure oiler is operating properly and filled. If no oiler is furnished with tool, install an oiler in air supply to the tool. Oilers should be checked and refilled often during working operations. WA-TEX 003946 WA-TEX003946 TEXACO INC. PAGE 19 PUGET SOUND PLANT /'"'S TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION! PIPEFITTER (TRAINEE DATE: July .1, 1970 ITEM NO. A^9 SUBJECT; PROCEDURES FOR OBTAINING AND TRANSPORTING TOOLS. MATERIALS AND EQUIPMENT TOOLS AND EQUIPMENT: (1) Tools will be in Pipe Shop Tool Storage Room. If additional tools are needed you get them from the Main Tool Room in the Machine Shop. You must sign a charge out slip, do the job and return the tool to the Tool Room. (2) Equipment may he located in the following areas: Warehouses 1-2 or 4 , East of Warehouses in storage area South of Warehouses in storage area West of Machine Shop STOREHOUSE: (l) Each Pipefitter is authorized to order and receive material from . the Storehouse. Before calling for or receiving material, compile a list giving the name, size, weight, type of material, and give estimate number. Bill of Material number or type of equipment and unit to be used in. METHODS OF TRANSPORTING: ' (l) Call Trucking Department giving type of material or equipment to be hauled, where equipment or material is located and where it is to be hauled. Also give type of trucking equipment needed. '-`X | WA-TBX 003947 WA-TEX003947 TEXACO INC. PUGET SOUND PLANT PAGE 20 TRAINING DETAILS DEPARTMENT: PIPE classipicationT~"PIPEFITTER (TRAINEE) DATE: July 1, 197Q ITEM NO. A-10 SUBJECT: LOCATION AND USE OF UTILITIES USE: (1) A utility is a form of .energy used to get work done. At Puget Sound Plant, utilities include steam, electric power, service water and compressed air. These utilities amount to approximately 40$ of the total cost to operate the Plant. (2) A Pipefitter uses these utilities almost every working day. Compressed air is used for pneumatic tools, box pumps and cleaning tubular equipment. Steam is used to gas free lines, vessels, clean oil spills, unplug lines and in some cases to pressure for system tests on units. Service water is used for pressuring lines, vessels, system tests, drilling and clean ing tubular equipment. A Pipefitter uses electric power for light to work inside towers, vessels and for operating some types of portable power equipment. CAUTION: ALWAYS USE A 32 VOLT LIGHT WITH VAPOR PROOF COVER WHEN WORKING IN TOWERS OR VESSELS. (3) It is each Pipefitter1s duty to see that utilities are not wasted. - LOCATION: ' (l) In every operating unit and designated spots throughout the refinery, utility stations are mounted on stanchions, In most cases, service water, air and steam are mounted together. Steam lines are insulated to prevent personnel from burning their hands. Water lines are usually 1-1/2" pipe and are marked with a sign ''Service Water Do Not Drink. ' Air and water lines will have a Chicago fitting attached. Electricity is mounted separately, 440 volt tie-ins are also provided for electric welding machines. Utilities are also mounted in all the working shops. The one used most by Pipefitters is on the North end of the welding shop, used for cleaning tubular equipment. : WA-TEX 003948 i WA-TEX003948 TEXACO INC, PUGET SOUND PLANT PAGE 21 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION: PIPEFITTER TRAINEE DATE: July 1, 1970 ITEM NO, A-ll SUBJECT* DEPARTMENTAL STANDARDS OF CRAFTSMANSHIP A pipefitter as directed* performs on his own responsibility all types of pipe and plumbing work necessary to install, repair and maintain pipe and plumbing installations and similar equipment in the shop or in the field. May direct the work of others assigned to the Job, Cooperates with others in the performance of duties assigned. Performs customary rigging incidental to the work of the department. Observe safety instructions applicable to work performed and for adherence to general safety Instructions applicable to all plant employes. Also, while actively directing others. Is responsi ble for their adherence to such safety instructions. May be assigned to plant fire fighting organization, attend fire drills and assist in or direct fighting of fire, as necessary. May be required to instruct or train employes or others in the work of his vraft. Should have ability to understand verbal and written orders and issue instructions accurately and clearly for their proper execution. Requires a general knowledge of company standards, requirements, specifications and common practices for pipefitting work in order to perform duties and jobs in a standard manner. This would include the proper use of valves, fittings, gaskets, bolts and pipe dope; main taining proper elevations, knowledge of when to use screwed or welded pipe, flanges or unions and a multitude of common practices that are standard to Texaco and Puget Sound Plant. This refers to knowledge gained only through experience and might enable a pipefitter to perform a job without benefit of prints. Requires a general knowledge of conditions under whieh equip ment operates and plant locations of such equipment. ! WA-TEX 003949 WA-TEX003949 TEXACO INC o PUGET SOUND PLANT PAGE 22 TRAINING DETAILS DEPARTMENTS PIPE CLASSIFICATION: PIPEFITTER TRAINEE DATE: July 1, 1970 ITEM NO. A-12 SUBJECT: PROCEDURES FOR OBTAINING WORK PERMITS a. PERMITS , (l) Before any type of equipment can be disassembled or blinded, a Safety or Hot Work Permit (whichever the job requires) must be obtained. b. SCHEDULED DOWN PERIODS (1) A permit list is turned in to operations each afternoon by a down period Supervisor for the work permits required the next day. (Note: This does not preclude the craftsman calling to his supervisor's attention that a permit may be required on a specific job.) ' (2) If a work assignment arises during the shift that requires a permit, and the permit has not been issued, the Pipefitter should contact the Supervisor in charge and advise him accordingly. (3) A permit is usually hung on equipment to be worked on during the unit down period and Operators will post the permits. All requirements noted- on the permits should be carefully followed. c. OPERATING UNITS (l) The Stillman should be contacted for permits to work on units in operation. Explain the work to be performed and - the equipment that is to be worked on. Conditions on permits must be followed. d. TANK FARMS (l) The Operating Supervisor in charge should be contacted and advised of work to be performed. If equipment or material Is required, a Hot Work Permit should be requested for Transportation to enter firewalls around tank in order to. make material delivery.. NOTE: All permits should be posted in open sight for inspection. WA-TEX 003950 WA-TEX003950 TEXACO INC. PUGEfr SOUND PLANT PAGE 23 TRAINING DETAILS DEPARTMENT". PIPE CLASSIFICATION! PIPEFITTER TRAINEE DATE." July 1, 1970 TTEM NO. A-13 -------- SUBJECTS IDENTIFICATION, PURPOSE. 5hSrKCTERISTICS AND USE OF MATERIALS a. VALVE IDENTIFICATION (1) Valves are listed by code numbers that identify the type, pressure rating, and variation in body, material and trim. A common type valve used in listed as V-100F1. (a) In this example, the "V,f represents valve and on blueprints will be prefixed by the nominal valve size. (2-V-100F1)o 2 would be a 2" valve. (b) The number 100 refers to the type of valve,. (c) The second letter, F, indicates the pressure rating. (d) Listed below is a table showing the type classification given valves which identifies the large number in the code; CODE CLASSIFICATION BY TYPE 100-299 - Gates 300-499 - Globe.s 500-599 - Angle 600-699 - Checks 700-849 - Cocks 850 - Miscellaneous Note; 250-299; 450-499; 550-599; 650-699; 800-849; 900-944 covers TTCO. Ball Joint Facing. (e) Listed below is a table showing the pressure rating of the valve, identifying the second, letter in the code; A - Iron and Brass below 125# B - 125# Iron and Brass C - 150#, 175#, 200#, 300# and 400# Iron, Brass and Semi-Steel D - 250# Iron, Brass and Semi-Steel E - 150# Steel F - 300# Steel G - 400# Steel H - 600# Steel J - 900# Steel K - 1500# Steel L - 2000# Steel M - 2500# Steel N - 300# Steel R - 300# to 1500# Ammonia Valves . : WA-TEX 003951 WA-TEX003951 ITEM NO. A-13 TRAINING DETAILS PAGE 24 (2) To identify V-100-F1 (a) The V always indicates a valve. 0>) The number 100 indicates a gate valve. (c) The letter F shows the pressure rating to be 300# Steel.'- Note: Sub-classifications under any one item number cover the variation in body material, trim facings, and other features. To identify this material in valves, reference must be made to the "Valve Specifications Manual" for details. PURPOSE (1) . Valves are most important to the piping system since their use singly or in combination provides the means for control ling flow of fluids in the system. This unit of instruction covers valves most commonly used in refinery piping install ations and the particular purposes for which they are best suited. (2) The sole purpose of valves, of whatever type they may be, is to control the flow within the lines. Some of these valves are designed to stop the flow, that is, they should be used fully open or nnmriotely closed. Others are designed to check or to regulate, and .some are designed to open auto matically when the pressures reach a certain predetermined 'value, thus relieving the pressure in the vessel or line be fore it becomes dangerously high, c. GLOBE VALVE (1) Globe valves have a single body seat ring which is screwed into a web or seat that is cast into the body. Fluids change direction when flowing through a globe valve. This seating construction increases resistance to, and permits close regulation of, fluid flow. Note: A simple rule to remember about globe valves flow goes in the bottom and out the top. (2) The main purpose of a globe valve is to regulate a desired flow of liquid. (3) Globe valves are used as a bypass valve on regulator systems. Example: If a regulator is not operating properly, the bypass can be used to manually control the flow while the regulator is being repaired. (4) Globe valves should be placed in the lines in such position that the pressure will be against the bottom of the disc when the valve is closed. This relieves the bonnet and the packing of the working pressure when the valve is in a closed position. WA-TEX 003952 WA-TEX003952 ITEM NO. A-13 TRAINING DETAILS PAGE 25 (5) CAUTION; It Is dangerous to repack a globe valve under pressure in hot or corrosive service for the following reasons: (a) Foreign matter may become wedged between the flat faces of the disc or body seat. In either case, there will be a pressure against the bonnet, tend" ing to blow the packing out of the stuffing box when the gland is removed. d. GATE VALVE (1) Fluids flow through gate valves in a straight line which offers minimum resistance to flow and reduction of pressure drop, A wedge-shaped disc operated by a hand wheel moves up and do.wn.at right angles to the flow and when In the down position fits snugly against two seat faces to shut off flow. (2) Gate valves are best suited for services that require infrequent valve operation and where the valve is kept either fully open or fully closed. Ordinarily they are not suitable for throttling service since close regulation of flow is difficult and velocity of flow against a partly opened disc may cause damage to seating surfaces and severe wire-drawing errosive effects in the disc. CAUTIONs For reasons of safety, these valves should never Be repacked under pressure, either wide open or completely closed. e. NEEDLE VALVE ' (1) Needle valves employ the same general construction as do globe valves with the exception of the discs and seats. Normally small, screwed needle valves are used. (2) The disc and seat of a needle valve have a long gradual taper which permits a very close control of the flow. They are recommended where close control is essential. f. CHECK VALVES (D Fluids can flow through check valves in one direction only, preventing back-flow when desired. There are only two basic types of check valves, the swing check and the lift or ball check. (2) The swing check type has flow characteristics similar to that of gate valves and is generally used in conjunction with gate valves for this reason (3) The same applies to the flow characteristics and operating principles of the lift or ball cheek valve as c.x>mpared to globe valves. In lift check valves, flow moves through the body in a changing course as in a globe valve.* * Wa-IBX 003953 WA-TEX003953 ITEM NO. A-13 TRAINING DETAILS HANDWHEEL PAGE 26 STEM GLAND FLANGE GLAND PACKING BONNET BUSH6NG BONNET ' PACKING NUT GLAND PACKING BONNET GASKET DISC ' . UNION BONNET . RING DISC SEAT RINGS DISC BODY *>" BODY SEAT BODY SEAT RING RINGS BODY GATE VALVE GLOBE VALVE PLUG- CHECK VALVE COCK VALVE TYPES /IF VALVES WA-TEX 003954 WA-TEX003954 ITEM NO. A-13 TRAINING DETAILS PAGE 27 * .i WA-TEX 003955 WA-TEX003955 ITEM NO. A-13 TRAINING DETAILS PAGE 28 (4) In both types, flow keeps the valve open and reversal of flow or gravity will close them automatically. g. PLUG VALVES (1) Lubricated cock type plug valves, using insoluble lubricants to insure ease of operation, tight sealing and resistance to wear and corrosion, are used fo~ many services throughout the plant. They are the most satisfactory valves available for handling of gritty fluids and many other destructive, errosive, and corrosive industrial and chemical solutions. (2) Since the valve is opened and closed by rotation only, the movable valve member and the seating surfaces are self- protect.ing and self-cleaning. h. HAMER VALVES (1) Hamer valves have an attached figure-8 blind, which acts as the flow stopping element of this valve. When reversing the blind, open valve wheel in a counter-clockwise motion, reverse blind and tighten valve wheel. (2) This type of valve Is used where a quick removal of or installing of a blind is necessary. CAUTION; BE SURE BLOCK VALVES ARE CLOSED ON BOTH SIDES OP A HAMER VALVE BEFORE REVERSING THE BLIND. i. RELIEF VALVES , (1) To avoid damaging positive displacement pumps and to prevent the over pressuring of lines, towers, vessels and other equipment, relief valves are provided. These return the flow to a reservoir, to the pump's suction or to the flare line. When the operating pressure equals the valve pressure setting, the relief valve opens and discharges enough flow to hold the pressure at the predetermined level. (2) Relief valves must be taken out of service at regular inter vals and sent to valve shop to be reset and repaired if necessary. (Removal determined by Inspection Department). (3) Another type of relief valve is a vacuum breaker. It is used on tanks or vessels where a vacuum could be pulled. In case a vacuum is pulled, these valves open to let In air from the outside. j. SLIDE VALVES (1) The mechanism of the slide valves at the FCCU is maintained by the machine department. (2) These valves are hydraulically operated but can be manually operated in case of emergency. j WA-TBX 003956 WA-TEX003956 ITEM NO. A-13 TRAINING DETAILS PAGE 2? ----, /..OCWAfG- SCEEitf CO.twoven /*/ Cfs&) t* BOA/^&T YA/r ABJeJS7A3C BODY VEA/r TO ELAJZ& L/ef system VT) E ve SEAT AA/D P/.UG y P/WJC/PLB.--OF TH - . ' WA-TEX 003957 WA-TEX003957 ITEM NO. A-*13 TRAINING DETAILS PAGE 30 (3) A Pipefitters job on these valves is to disassemble, reassemble piping and flanges. . (4) The line side of most of these valves is connected with van-stone flanges and requires a corrugated iron gasket. It is necessary at times to crawl up Into the larger lines to make sure the gasket is straight when reinstall ing these valves. k. HEX VALVES (l) Hex valves are used mostly on instrument piping. They are very compact, taking very little space to install. Hex valves can be purchased with Pulsation Dampeners built in for use with pressure gauges. -PACKING RING RETAINING RING VALVE BODY hx. VALVE 1. IDENTIFICATION OF PIPE AND TUBING (l) Piping -classification is determined by three factors: size, weight (or schedule) and material. (a) Size of piping has to do with the diameter. (fc) Weight is determined fcy wa31 thlckress. (c) Piping is made in a wide variety of materials for an equally wide variety of services. These material range from clay soil pipe through various metals and alloys to plastics and fiberglass. j WA-TEX 003958 ITEM NO. A-13 TRAINING DETAILS PAGE 31 (2) Pipe sizes -up to and including 12" are known by the inside diarater (i.D.) which is referred to as the "nominal pipe size." Above 12" the pipe size is deter mined by the outside diamter (O.D.). (3) The outside diameter of all classes of pipe, regardless . of wall thickness, always remains the same. The added wall thickness is always gained on the inside and therefore reduces the inside diameter of the pipe, (4) Reference tables vary in classifying pipe. Some refer to wall thickness as being standard, extra heavy, or double extra heavy; while others use schedule numbers such as Sch. #40, Sch. #80, or Sch. #160, Standard pipe up to 10" inclusive, and Sch. #40 pipe have the same dimensions. This is also true of extra heavy and Sch. #80 pipe up to 8" inclusive. (5) Double extra heavy pipe has no corresponding schedule number. In larger pipe sizes, the schedule number will vary from Sch. #10 to Sch. #160. By using schedule numbers, a more accurate classification can be given on wall thickness. (6) In specifying pipe size, it is correct to refer to size as being the nominal pipe size. Wall thickness is referred to as the schedule number, EXAMPLE: Three-inch pipe with a wall thickness of .216" would be classified as 3" Sch. #40 pipe, NOTE: Welded fittings are also classified by schedule number and should always correspond with schedule number of pipe being used. m. PURPOSE AND USE (l) Piping used in a refinery is purchased in several types of material and various combinations and weights. (a) Cast Iron - Soil pipe generally used for sewage and similar service. It is usually equipped with some variation of the bell and spigot end connection. (b) Carbon Steel - Used primarily for field and unit installations where a low corrosion effect is anticipated. (c) Alloy Steel (Chrome and Stainless Steel) - Used for piping installations with a high incidence of corrosion, high pressures and extreme heat. (d) Galvanized - Used for drinking water and instrument air installation. (e) Brass - Used for connections on wash basins and some types of instruments. . ! WA-TEX 003959 WA-TEX003959 ITEM NO. A-13 TRAINING DETAILS PAGE 32 (f) Plastic - Used In chlorine and demineralizer service and some water service. n. TUBING (1) Tubing is used frequently in pipe Installations where high temperature and pressure are present. (2) The classification of tubing differs from that of pipe sizes. Tubing size refers to the outside diameter and wall thickness. EXAMPLE: Tubing measuring 3-1/2" outside diameter and having a wall thickness of 1/2" would be classified as 3-l/2" X l/2" tubing. This wall thickness may also be referred to as "gauge." (3) There are some common sizes of tubing used that correspond with the outside diameter of standard pipe sizes and can be used with pipe fittings. (4) Listed in the following table is a comparison of tubing size and corresponding pipe size: Pipe Tubing Pipe Tubing Pipe Tubing Pipe Tubing SIZE 1-1/2" 1-7/8" 3" 3-1/2" 4" 4-1/2" 6" 6-5/8" OJX 1.900 1.875 3.500 3.500 4.500 4.500 6.625 6.625 o. FLANGES (l) Many different types of flanges are used in refinery piping and several kinds of materials are used in flanges. Flanges are installed in lines for future construction, blinding when necessary to steam and repair, installing"new block valves, running jumpovers from one line to anotner, and easy disassembling for maintenance purposes, etc. (a) Flat Face - Has a gasket seat the entire surface of the flange, used mostly on pumps. May be either iron or steel. (b) Raised Face - Has a raised gasket face approximately 1/16" above the surface of the flange. This is the type of flange most commonly used in the refinery. 1 WA-TEX 003960 WA-TEX003960 ITEM NO. A-13 TRAINING DETAILS PAGE 33 (c) Ammonia - Ammonia flanges are a type of tongue and groove flange requiring a gasket for seating. These flanges come in three different shapes, oval, square and round. They must he purchased in pairs, one flange having the tongue face, the other having the groove. These flanges have a wide application in high pressure ammonia refrigeration service. (d) Tongue and Groove - Similar to an ammonia flange. Gaskets must be used in the seating surface. Must be purchased in pairs, one flange having the tongue face and the other the groove face. (e) Ring Joint - These are weld flanges and come in many different weights and combinations of materials * Metal rings are used for gaskets and come in two shapes, an oval ring and an octagonal ring. These Flanges are used in conjunction with high temperature, high pressure and gases. Each flange has an R number stamped on it. This designates the size and type of ring gasket required. (f) Orifice - These flanges have holes drilled through from the outside to the Inside opening, and tapped for pipe thread. Lines are run from these taps to instruments. Orifice plates are installed between flange to create a high and low pressure side. (g) Reducing - These are flanges to reduce from a larger to a smaller size line. Used for reducing line size, end lines for clean out or pressure testing and tsking samples. (h) Screwed - Screwed flanges are drilled and tapped to pipe sizes. Used in low pressure service. (i) Weld Hub - Weld hubs are constructed with a short nozzle reduced to pipe sizes and weights. They butt against the end of pipe for welding. Flanges are available in many weights and types of material. (j) Slip-On - These flanges are constructed to slip over the end of pipe, then back-welded Inside and out. These flanges OJ.e also available in many weights and types of material. Note; It is advised that slip-on flanges be used when welding with pipe plugs. (k) Van-Stone - Van-Stone flanges are a type of slip-on flange, but have no gasket face. The end of a line has a gasket face installed and the van-stone flange serves as a tightening agent to bring two gasket faces together. I WA-TBX. 003961 WA-TEX003961 ITEM NO. A-13 TRAINING DETAILS PAGE 34 p. GASKET PURPOSE (l) The principal purpose of gaskets is to form a seal' to prevent leaks into or out of vessels* pipeline* vacuum or pressure pumps* compressors* etc. q. GASKET USE (1) Gaskets are used between'nori-v^f^Tns'parts such as the openings in vessels, betw~.-. 1 ranges on pipeline, or the head and block on an engine or pump. In general* gaskets are used between the fixed parts of any vessel or line that must hold either a pressure or a vacuum without leaking between the Joints. r. GASKET MATERIAL (1) Gaskets are made from a great many kinds of materials. They are made from metals such as spft steel* copper* lead, monel, stainless steel and aluminum. They are made of natural or synthetic rubber* plastics* such as neoprene* asbestos, cotton* flax., rayon* paper, leather, or a combination of these materials bonded together. (2) Gaskets are made in a great many sizes and thicknesses. They are made to fit the openings where they are to be used or they may be cut to fit from sheet material. All types of soft gasket material are manufactured in sheet form. (a) Composition - More commonly known as Garloek are . used on lines or vessels with low temperature and pressure, l/l6" thick material is normally used, but 1/8" thick material is provided when required. Pull face composition gaskets are also used when required. (b) Ironclad Asbestos - These gaskets are used on Joints and equipment with high temperature. This type of Ironclad gasket is asbestos filled. These gaskets are used on some types of exchangers. (Plat heads, channel heads* floating heads and cover heads.) (c) Oval Ring - These gaskets are made of metal and are used with ring flanges only. Each ring flange has an R number stamped on it designating the size and type required. They are oval in shape. (d) Octagonal Ring - These gaskets are made of metal and are used with ring flanges only. They are octagonal in shape. (e) Flexitailic - Has a solid metal ring on the outside with an inter-ring constructed of asbestos with metal rings separating the asbestos rings. These are used on lines or equipment with high temperature. - WA-TEX 003962 WA-TEX003962 ITEM NO. A-13 TRAINING DETAILS PAGE 35 s ` (f) Aluminum - These gaskets are made of soft aluminum arid used' on lines and equipment in refrigeration service. (g) Ball Joint - These gaskets are made of metal, and used with ball joint flanges. Similar in shape to an oval ring. Not commonly used in newer constructed operating units. (h) Corrugated Iron - Has a corrugated appearance on surface of gasket. Made of soft iron and used on lines and equipment with high temperature. (i) Copper - Used on some types of pumps and compression heads. (j) Soft Iron - Used on some types of exchanger heads with high temperature and pressure. Also used as bonnet gaskets on some types of valves. (k) Rubber - Used on sight glasses for sealing, and also in some types of ammonia flanges. (l) Teflon - Used as bonnet gaskets on valves in water condensate service. 8. PIPE FITTINGS,, PURPOSE (l) Pipe fittings are used to join lines from one given point to another in order to control flow of products. t. TYPES AND USE OF FITTINGS (1) Unions (a) Most commonly used union in a refinery is the forged steel ground joint type. (b) Socket weld unions are used when running steam tracing lines. (c) Galvanized unions are used on drinking water and instrument air lines. (d) Orifice unions are used to control or reduce flow. (2) Orifice Fittings ' (aj Orifice flanges are used in conjunction with instru ment to control flow of products. Orifice flanges come in many different weights, sizes* and types of material. Notej Orifice flanges should always be drilled and tapped to proper size before installing. ; W&-TEX 003963 - WA-TEX003963 ITEM No 4 A-13 TRAINING DETAILS PAGE 36 (b) The diameter of the center hole in orifice plates is determined by the Power Department. (3) Screwed Fittings (a) The Storehouse stocks screwed fittings up to and including 2". Most- weights* sizes and types of material are provided. Larger sizes must be purchased by special order. (4) Pipe Repair Clamps (a) Repair clamps are only used as a temporary means of repair for small leaks in lines. Rubber gaskets are provided with pipe clampsj use asbestos gaskets for temperatures over 215F (5) Compression Fittings for Small Tubing (a) Tubing fittings are provided in three types of material* steel, stainless steel and brass for copper tubing. Most fittings used at Puget Sound Plant are provided with ferrules or sleeves. (b) Most types of tubing fittings are provided in the Storehouse; such as elbows (tubing to tubing or tubing to pipe), adapters (tubing to pipe), unions (tubing to tubing)* tees* plugs and crosses. Note; When using valves with copper tubing, brass should be.used. (EXPLAIN WHY.) (6) Tube Turns or Bends (a) Coil boxes and some heaters are equipped with welded l80 tube turns, these should be equal weight or more as the tube or pipe weight and of the same type of material as the tube or pipe. (b) Removed l80 bends on heaters are stamped with a number corresponding with the tube number. These numbers should be installed looking up. (7) Flanged Sittings (a) Most of the flanged fittings (excluding valyes) used in this refinery are cast iron (elbows and tees.) (b) Cast iron fittings are easily broken when not tightened evenly. Always tighten evenly around flange. If one bolt Is pulled up too tight. It may cause a gap on the opposite side and subsequent leak or break in the flange. I WA-TEX 003964 WA-TEX003964 ITEM NO. A-13 TRAINING DETAILS PAGE 37 (8) Nipples (a) Nipples from an all thread up to 6" lone: in pipe sizes up to and including 2" are available in Jbhe Storehouse. (9) Dresser Couplings (a) These couplings make tight connections on steel, cast iron and other lines. Parts consist of two resilient gaskets, a steel middle ring and two steel follower rings which fit over plain-end pipe and are bolted to gether. Resulting Joints absorb expansion, contraction, vibration and deflection. (10) Victaulic Coupling (a) Serves the same purpose as a dresser coupling. The lines to be Joined have groove cuts in them near the ends to match the gripper parts of the victaulie coupler. (11) Collars (a) Pipe couplings are commonly known as collars and are used to Join two lengths of pipe together. Collars are constructed of steel and are provided in pipe sizes up to and including 2". (12) Machine Bolts and Stud Bolts . (a) Machine bolts are more economical to buy. These should be used when there is no high temperature or high pressure present. Machine bolts are threaded on one end only, the other end being upset into the form of a head. (b) Stud bolts are threaded the full length for nut assembly on each end. These should be used when high temperature or high pressure is present. Most Bills of Material will specify which type of bolt is to be used. U. THREAD AND SEAT DOPE . (1) Graphite and Oil (a) A thick mixture of graphite and oil should be used for a lubricant when installing heater bends or .biscuits. It is recommended that this mixture be used for bolts where extreme high temperature is present. i WA-EEX 003965 WA-TEX003965 a~*-. ITEM NO. A-13 TRAINING DETAILS (2) Thread-"Tex PAGE 38 (a) Thread-Tex should be used on bolts-and gasket seats with low temperature. Since Garlock gaskets are only . lubricated on one side; Thread-Tex should be be applied to assure easy removal of gaskets. (3) Copalfclte (a) Copaltite is used on gaskets on flange or exchanger - heads when leaks are very difficult to stop. (*) permatex (a) Permatex-#1 Is used for forming a hard gasket. 00 Permatex #2 is pliable and will not completely harden. Used for sealing engineer's tape on tray sections in vessels and towers. (5) Use of Proper Gaskets . The use of improper gaskets can be very costly if an operating uni1* has to come down for this reason. Remember that aluminum gaskets are used for refrigeration service, metal gaskets are used for high temperature and pressure. Garlock gaskets are used In low pressure and cool tempera* ture service. s, (6) Flange Insulation ' Insulated gasket, sleeves, and washer sets are used to prevent galvanic corrosion caused by static electricity. They are installed as shown below. ' 11 | r.t rIIf 4- M ;.T>wca1 i n in n ;.u 1 111 tA,ach ir'tG bolt Steel 1, To* u jrt /1 ti -y u/ O. s /i r In suJo f fr. 7 3le.e. c: ) Flan ;je S a c t. >*_ / Tn so fa f t f'-j S 7st. S a s k <-' ' f' 1-3 0 eye 7 N .7 t WA-TEX 003966 WA-TEX003966 TEXACO BIO. ` PUGET SOUND "PLANT PACE 39 TRAINING DETAILS DEPARTMENTS ALL CLASSIFIC ATIONT"ALL DATES July 1, 1970 ITEM NO- A-l4 SUBJECTS, READ, INTERPRET AND " WOPK" FROM BLUEPRINTS , ` '' SKETCHES ANP~BT.LLS OF' MATERIAL AND REQUIRES A KNOWLEDGE OF SHOP ' . - MATHEMATICS a. INTRODUCTION; The following material Has been developed to give the craftsman a working knowledge of- mechanical and construction drawings., elementary mathematics. Bills of Material and field sketching- _ The .craftsman' ir, modern industry, regardless of his trade, must have the ability to study a blueprint or- sketch and visualize the appearance of a finished Job or object as well as the details of its construction- The necessity of taking precise field measurements' and making accurate and legible field sketches is also an Important cart; of the craftsmanis work- Practically everything that'Is construe in a refinery today originates with a drawing or sketch along with a . Bill of Material. It Is essential, then, that each person thoroughly under stand every detail of a blueprint or sketch, and it's care and preparation, to easily read and Interpret them. b- FUNDAMENTALS OF READING AND INTERPRETING BLUEPRINTS nun ii - i ---*i --* ---- 1 .- -- -- - - - -- --------------- -------- ------ iiiioijm aSOketchEsT^ (l) Blueprints - what they-are; A blueprint is the reproduction to scale of a drawing which has bc-on prepared by the engineer or draftsman to provide the work-man with a description of the shape and ri-re of on object, and other details essential to its construe. on,, in mob a form as to be easily recognizable by anyone familiar with a blueprint- Blueprint Is actually a misnomer, as they may be black ard white, brown and white, or blue and white. At Puget Sound Plant, the prints used are technically not , blueprints. However, blueprint or print is r. commonly accepted term for both types nf reproduction:-. < - Blueprints are actually the language of modern construction. They provide an excellent means whereby the engineer can transmit his ideas, and explain to the craftsman the details of what he wants accomplished- The drawings made by an engineer in some other country, or In some other section of this country, or in some 5 nr1 ustry, | WA-TEX 003967 WA-TEX003967 ITEM NO. A-l4 TRAINING DETAILS PAGE 40 other than the petroleum industry., could be followed by any one of you who Is familiar with prints made by Texaco* Inc,, .'engineers. The only difference might be in the unit of measurement used* such as the metric instead of feet and Inches, and in the use of certain symbols. '* (2) Use in Industry by Craftsmen; A print given a craftsman should be an accurate working drawing of an object and should show all the information necessary for the craftsman to perform the Job in question* It is essential that the craftsman read every note and symbol on the blueprint. The blueprint Is an exact copy of a working drawing on file in the Engineering Department, and by following every note and detail exactly as shown on the print, he is pro tected In case of errors. However, If he checks each ' detail accurately he may find the error and call it to the. attention of his supervisor and prevent possible improper work. In the case he has followed the blueprint accurately and an error has been made, the craftsman cannot be held responsible for a drafting room error. (3) Drawing Paper and Sizes; To better understand prints and their origin, it Is well for the craftsman to know more about them. The engineer or draftsman, in undertaking the preparation of plans for the construction of some object, makes what is known as a working drawing on thin white paper, or a high grade of cloth which has.been starched and treated until it is transparent . Paper is used only on temporary drawings or where permanent records are unnecessary. For example, 3imple sketches of some minor change In piping. Cloth .is generally used where it is necessary to make permanent drawings to be retained for years. Prints and drawings are usually made in certain standard sizes,. At Texaco, these sizes are normally identified by a' `letter* preceeding the drawing number as well as by actual measurement. A *D* size drawing is 22" x 38", a *C drawing is I7n x 22", a *B! size is 11" x 17" and an *A* drawirg Is 8-1/2" x 'll". Sketches are drawn on 8-1/2" x 11" sheets. These sizes are not compulsory, however, the craftsman must work with whatever size drawing is best suited for a particular Job. . (4) Making the Blueprints In making a blueprint the working drawings^ whether made on paper or cloth, are then used In much the same manner as a negative is used to make a finished photograph. The blueprint paper regularly used is yellow-green on one side, white on the other. It must be kept in a dark room as bright light will cause it to change color. j Wa-TEX 003968 s WA-TEX003968 -ITEM fV*; T`^5^ & DERAILS The b'lueprint Is me as foiaoivss . . PAGE 4l ' (a) The-v,\>rkir-' '.rev.' ng i placed over blue print paper. ' ' ' ` . (b) A strong electric arc light or sunlight is focused through the tracing paper, ' (c) The inked or pencilled lines keep the light from parts of the blueprint paper* which - changes color everywhere except where there ' are markingsor lines on the original drawing, (d) The blueprint paper.is then immersed in water* which turns the paper blue except where there.are lines* etc. These lines turn white thus-completing the blueprint, A blueline is mads in a similar manner except that a different type of reproduction paper is used with an ammonia solution yielding blue lines* etc, on a white background, - As many copies as needed can be made from the original working drawing* which is then retained for future use as additional-prints may be required, . (5) Care of Prints by Craftsmen; Although the craftsman's chief interest fs in using "the blueprint to guide him as to materials and dimensions* rather than paper* paper- sizes* and how the prints are .made* knowledge of these things . help him to understand the JmpcsrLance of taking proper care of the blueprints in his possession, There are several things to remember . -. - (a) If the print Is rolled* r-e-roll It after use. Do not fold a rolled print, (b) If the print is folded* fold it Just as it was originally. Do not fold it opposite the original fold or crease, _ ' (c) Do n6t leave exposed to sunlight xvhen. not in use, or for any great length of time - sunlight will cause fading. (d) Do not get prints i?et. . (e) Do not mark up prints with pencil* ink . or crayon*'unless given permission to do so, - From the foregoing it can be seen that blueprints are relativelv exoensive to oroduc-e. therefore- the least that can be expected of each craftsman is that he take considerable care when using these prints. j WA-TEX 003969 WA-TEX003969 FIGURE I WA-TEX003970 ITEM NO. A-l4 TRAINING DETAILS PAGE 43 . (6) The Use of Titles and Margins on Drawings '' _ . . Identification of a. drawing maites it- .necessary- to provide some means of showing what it represents,, the' _ . Company name* initials or names of the persons making the drawing* checking and tracing the print., date of making., * issuing or revising* name of object*, materials required* a number for easy identification* etc, ' Normally* there are two types of titles used - BLOCK and STRIP, Block titles are used at Texaco and are located inside the right and the.bottom margin lines at the lower right-hand corner of the drawing. (See Figure l) Strip titles or strips are located at- the bottom of the . drawing and are most often, found on manufacturer's drawings. MARGIN LINES are placed around the border of the drawing and act as a frame for the object or objects drawn.*- and provide means for proper spacing, (7) Alterations or Revisions? Alterations or revisions of drawings must frequently be made due to ndny? error in the original drawing* changes In. design* dimensions., or for other reasons. When this is necessary, a reissue of the print is made with the change or changes noted, or, in some instances, the original drawing may be VOIDED and a new blueprint issued under a new date. (See Figure 2) (8) Use of Scales on Drawings-: In most Instances* -small objects are drawn full sice by an engineer or - draftsman. 'However, some objects are so large that it presents a problem to-the draftsman, who must reduce the size to where it can be conveniently drawn on available sizes of drawing paper. Where the object is extremely small* the size may be increased in drawing. The reduction or increase of the drawing size in accurate proportion to the actual -size is the device used by the draftsman to provide a readable print and is known as 5drawing to scale*, (fee Figure 3.) . The foot is the most common means used as a basis for establishing the .scale to be used in making a drawing. FULL SIZE is.Shown as 12" = 1* - 0" HALF SIZE is -shown as 6" =1* 0" QUARTER SIZE is shown as 3" = 1* - 0" DOUBLE SIZE is indicated as such 'Or may be shown as 2" = 1"* etc. - , WA-TEX 003971 WA-TEX003971 WA-TEX003972 WA-TEX 003973 WA-TEX003973 ITEM-NO. A-l4 TRACING DETAILS PAGE 46 Scales of smaller sises are most frequently used In Texaco drawings., as 1/2" = l5-0",, 1/4" = 1 ' -O'' or l/8" = le-0"o Some drawings are draw*'* to no particularscale to speed the draftsman's work &hd so state in the title block, CAUTION; THE BLUEPRINT SHOULD NEVER BE MEASURED TO OBTAIN A SIZE NOT SHOWN OR ONE THAT IS NOT IN APPARENT AGREEMENT WITH OTHER DETAILS. CONSULT WITH YOUR FOREMAN OR THE PERSON RESPONSIBLE FOR. THE JOB, The reasons for this caution ares. ' '(a) During the preparation of a print, shrinkage and distortion of the paper oncurs, which may cause Inaccuracies if measurements are taken directly from the finished blueprint, (b) Changes in dimensions are sometimes made on the blueprint without changing the lines of the drawing, (e) A correctly scaled drawing should .show all dimensions, lines, and any special notations necessary to adequately describe the object, and it should not be necessary for the .craft- man to scale the drawing, (Unsealed drawings ' or simple sketches may require some measure ments being taken in the field by the craftsman,) The ordinary rule, scaled in sixteenths, is all that will be required normally by a crafts man for taking measurements, and the rule can be used for making simple drawings or sketches. (9.) Identification and Meaning of Lines on a Drawing.; As is obvious. Tines playanTmpoFtarrtr'part 'in the interpretation of prints and therefore each craftsman should know something about how drawings are made. The craftsman must learn a new "language". He must first understand that a print is a set of instructions..in a hew language which he must learn to read. Since the alphabet of this language is in lines, then he must learn.to read lines, (See Figure 4) The types of lines commonly used can be shown as followss (a) HEAVY BOLD LINES - used to represent surfaces and edges which can be seen from the side that is being drawn - also known as visible lines, fxr.il lines, solid lines, object lines, visible boundary lines, etc. j WA-TEX 003974 WA-TEX003974 ITEM NO. A-l4 TRAINING DETAILS . PhGE 47 WA-TEX003975 ITEM NO. A-14 TRAINING DETAILS PAGE 4& r*\ (b) EXTREMELY HEAVY LINES - used to differen' ; tiate between existing facilities and new Installationso This is done by the drafts man so that the craftsman can readily pick out .he work to be done in an existing system. (c) DASHED LINES - or "dotted" lines as they are better known* are used to represent Invisible ` surfaces or edges which cannot be seen. (d) LIGHT SOLID LINES - known as "guide" lines or extension lines* are used to extend the object lines to points away from the object . to give the draftsman more room to put in dimension lines. (e) LIGHT SOLID LINES - with a break In the middle for the insertion of dimension figures and arrows at each end, are known as "dimension" lines and used to indicate distance between two points. (f) LONG AND SHORT. LINES - alternately spaced* are known as "center" lines and used to locate or denote the center of an object. ' (g) BREAK LINES - are used to indicate that part of an - object has been left out - usually because of space limitations of the paper on which the object is drawn. (h) HEAVY LINES WITH TWO DOTS AND A LONG DASH - are known as "cutting plane lines" or "section lines'* and are used to Indicate where a certain section of the object is to be taken and drawn in greater detail elsewhere on the blueprint. Usually capital letters of the alphabet are used to identify the particular sections to be drawn in detail elsewhere on the blueprint and for cross . reference. (10) Significant Markings on Drawings; In discussing . the fundamentals of drawings* the many illustra tions and markings* or symbols* used on drawings by the . draftsman cannot be ignored. In order to read and Interpret - a print correctly, the workman must know the symbols most commonly used. Limitation of space prevents the draftsman from inciting out on the drawing all Information necessary to show the kinds ^ of material* thread, finish* measurements* and other detail. 5 Therefore* symbols have been developed for this purpose. I WA-TEX 003976 WA-TEX003976 WA-TEX003977 ITEM NO. A-I4 TRAINING DETAILS PAGE 50 ' .(a)- Sectional Drawings; Sometimes the construction .of an object is so complicated or the size, shape, etc., are such .that the regular size drawing will not adequately'show the detail or . give a complete understanding of the particular object. When this happens, a sectional ' drawing is made. " Sectional drawingsgenerally show a part' l .. or- section of the object In such a way as to reveal the shape or construction In more understandable detail.- Figure 5 illustrates a standard flanged tee such as most refinery workers are familiar with. * The top view shows the tee as normally viewed from the side. -.The exact part which Is to be sectioned is indicated by the 'CUTTING PLANE LINE A-A. ' The"lower view shows a cross-section view which Is Indicated by slanted lines ' at 45 degrees. This part of the surface Is "cross-hatched". (b) Cross-Hatching Combinations; In many sectional views, it is pecessary in order to clearly picture an object to slant the cross-hatching In opposite directions. This may be done regardless of whether the material, depicted is the same or a different material. Where there is a-single piece or object depicted, the cross-hatching is always in the same direction. (See.Figure 6) Some objects, such as bolts, nuts, screws, keys, rivets, oil cups, pipes, pulleys, etc., are seldom cross-hatched when shown in conjunction with a sectional view drawing. (c) Conventional Breaks s Quite frequently, the heed' 'arise s'/ duetto the length of the object being drawn or paper size, to depict the object in less than its normal length. When this is necessary, the draftsman uses a device known as "conventional breaks" which permits shortening the length of the object on the drawing, yet avoids a reduction In scale while aiding in illustrating the object so broken. (See Figure 7) j WA-TEX 003978 if WA-TEX003978 ITEM NO. A-14 TRAINING DETAILS SECTIONED VALVE PAGE 51 1-Handvrheel 2-Yoke Nut 3-Bearing Rings 4-Packing Gland 5-Bonnet 6-Ring Gasket 7-Seat Rings . Wa-TEX 003979 8-Body 9-Jarab Nut '' 10-Alemite Fittings - 11-Bolt-Studs & Nuts ' 12-Packing 13-Stem .. 14-Solid Wedge tJTnTTRR fi WA-TEX003979 ITEM NO. A-14 TRAINING DETAILS PAGE 52 WA-TEX003980 training details PAGE 53 CAUTION;- REMEMBER, THE DIMENSIONS SHOW ON THE PARTS OP AN OBJECT WHICH HAS BEEN "BROKEN" ARE THE ACTUAL LENGTHS - ALWAYS.* (d) Other Symbols and Magicians As has been stressed several times, jie draftsman must use many symbols or abbreviations to express in the least possible space his ideas and the requirements of a particular Job which he must illustrate. - Therefore, certain standard conventional symbols, markings, and abbreviations, other than those previously discussed, have been developed.to further simplify illustration and conserve space,. In order to clearly interpret a print, these commonly used standardized markings and abbreviations should be studied by the workman. (See pages through 5Jj _ Mentioned previously were universal symbols and markings. Later In this material, symbols pertinent to your specific craft will be illustrated. In addition to symbols, "notes" concerning some facts may be shown on the drawing. Usually in using notes the draftsman prints the word "NOTE" somewhere near the bottom of the drawing, with the necessary infor mation. To fully interpret a blueprint, the workman Is cautioned to; / (1) ALWAYS STUDY THE DRAWING. (2) TRY TO FORM A MENTAL PICTURE OP THE - OBJECT. (3) READ EVERY WRITTEN NOTATION ON THE DRAWING.. (Sometimes the bit of Information which is presumably missing will be found as a note in. some conspicuous place.) I WA-TEX 003981 WA-TEX003981 ITEM NO. A-14 TRAINING DETAILS ABBREVIATIONS AND MARKINGS PAGE 54 American Petroleum Institute American' Pipe Threads American Society for TestingMaterials American StandardsAssociation Angle . Ball Joint Bend Line Bevel End Bolt Circle Diameter ' Bottom' . Brass Bronze Building Line Cast Iron Center -Line Center to Center . Centrigrade (degree) Chamfer Channel Circular Column Concentric Copper Counterbore Counter sink Coupling Cylinder . ' API , APT * ASTM ASA BJ __ BL BE BCD bott br brz BL Cl e-c C chfr elr col Cone Cop C'bore Csk cplg eyl ! WA-TEX 003982 WA-TEX003982 ITEM NO. A-l4 TRAINING DETAILS Degree Diagonal Diameter Discharge . Drawing Eccentric Elbow Elevation Extra Heavy Paced and Drilled Fabricate Fahrenheit (degree) Feet Field Weld Figure 8 Blind Flate Face Flange Forged Steel Gallons Gallons per minute Gauge High Pressure I-beam Inches Inside Diameter Insulate Liquid Level ' ' PAGE 55 deg dlag D disch dwg ecc ell elev EH or XH F& D fab F ft FW 8 FF Fig FS gal gpm ga,, HP I in. I.D. insul. LL i WA-TEX 003983 WA-TEX003983 ITEM NO,.., ArJ.4 --- TRAXTOG'bETAILg Linear Long Radius Low Pressure . " Mark' ' " Maximum Number ' Outside Diameter Piece (s) Plain end Plate ' * -Pounds per square inch Pressure Raised Pace Flange Reducer Required Revolutions per minute . Round or Round bar Schedule Screwed Short Radius Slip-on Flange Specifications Square or Square Bar Square Feet Square Inches Stainless Steel Standard . PAGE 56 ^ . L-p max # or 0,,D,, Pc^ Pes 1L psi press RF Flg redo req*d RDM 0 soh serd SR SO Fig. spec. jij I f* f~T . std | W&-TEX 003984 WA-TEX003984 ITEM MO. A-14 TRAINING DETAILS Steel , .' Suction Swaged Nipple - Tack "Weld . Tangent line Temperature Thread one end Threads Volume Weld Cap or Welded Connection Wide Flange Beam Weld Neck Flange _ Working Point Equipment Designations Furnaces or Heaters Exchangers or Coolers Towers, Drums and Vessels . . Pumps Compressors Turhines Tanks ' PAGE 57 stl suet sw nip' TW TL temp TOE thds vol WC Vf WN Fig. WP FEVPCTTk- ; WA-TEX 003985 WA-TEX003985 ITEM NO, A~lft TRAINING DETAILS PAGE 58 (ll) Types of Drawings: The petroleum worker will come In contact with many varieties of drawings, all of which he should be capable of reading and Interpreting, The most' frequently encountered drawings ares (a) Flow Diagrams; The primary purpose of flow diagrams is to convey pertinent information . regarding material quantities and their destination with the process. They are also ' intended to act as guides for construction men and plant engineers in order that the problems which arise In the erection and operation of ' the plant may be intelligently solved, (See Figure 8) . (b) Plot Plans; This type of drawing gives an accurate picture of the plot or layout of a unit or system. It shows locations of equipment and buildings within the unit. Plot plans are used to denote the location of new installations relative to existing equipment or structures, (See Figure 9) (c) Assembly Drawings ; Assembly drawings show an oBjecuwitH~Its par13 assembled and ready to operate. They are carefully drawn with sufficient views to show the location of each part that goes into the makeup of the machine. Each part is identified by a number giving reference- to another drawing, sketch or note so that the workman can see where the parts go and place them in the proper position. The only dimensions given are those which are necessary to put the object together. Frequently, no assembly dimensions are necessary, - (See Figure 10) Cd) Schematics; A schematic is a line drawings using conventional symbols, that shows only the connections between parts. It has no scale and Is not related to'the actual ' positioning, in an assembly, of each part. Schematics are used'primarily in electrical and Instrument work, (See Figure 'll) . (e) Conventional Working Drawings; The interpre' tation of prints depends primarily on the ability of the Individual to translate a view or a series of views. The following arc types of projection drawings; 1, Perspective Drawings; A picture of an oF^ec t "s^iFTi?oulanorma lly appear to anyone looking at it is known as a perspective drawing, - i WA-TEX 003986 WA-TEX003986 WA-TEX003987 (1fj \1 . WA-TBX 00. 3988 ' pTfLTTPT? o WA-TEX003988 WA-TEX003989 ITEM NO, A~l4 TRAINING DETAILS CONTROL CIRCUIT SCHEMATIC PAGE 62 WA-TEJt 003990 FIGURE 11 WA-TEX003990 -fSBto--- ITEM NO. ft-14 TRAINING DETAILS PAGE 63 A picture, or perspective drawing, will give a clear mental picture of an object, but it will not give exact detailed infor mation which would enable a workman to make that object. It will be noted from the perspective drawing in Figure 12 A that the three dimensions "B" are not equal, although they should be. Neither are the two dimensions "A" equal.- Therefore, a good Image of the object Is seen but It would be difficult to reconstruct the object as sufficient information is not available. 2. Oblique Drawings Oblique drawings are construe ted~^5HxThree axes, representing three mutually perpendicular - edges, upon ' which measurements can be made. Two of the axes are always at right angles to . each other and both lie in the picture or frontal plane. (See Figure 12B) The third axis makes an angle with the picture plane. Oblique drawings, like perspective drawings, are seldom used In the petroleum Industry. 3. Three View Drawing? A common type of working drawing Is the two or three view drawing. In this type of drawing, the views are . either plan or .elevation. A plan view represents what an object would look' like when looking directly down on top of it. An elevation view Is what Is seen when the object is shown'face on, either from- the front or side. (See Figure 12 C) Quite often, one or two' views is sufficient to show the necessary detail of an object. The arrangement of views Is critical to the interpretation of a.three view drawing. The plan view is always shown directly over the front elevation on a drawing. A side elevation Is shown to the left or right 'of the front elevation,'whichever Is applicable. _ 4. ..Isometric Drawings The most important type of drawing in the petroleum industry today Is the isometric drawing. Three view drawings are sometimes rather complicated, thus this more pictorial type of drawing is used (Sec Figure 12 D),, The isometric drawing originates with three axes, repre senting three mutually perpendicular edges. ,I WA-TEX 003991 WA-TEX003991 WA-TEX003992 ITEM NO. A-14 TRAINING DETAILS PAGE 65 much the same as an oblique drawing. These three axes form equal angles of 120 and are called isometric axes. The axes may be arranged in different ways provided their relative positions are not changed. Any line of an object that parallels an isometric axis Is an isometrie line. Any other line on the drawing is a non-isometric line. Such lines will not show In their true length, as with non-Isometric angles. Isometric drawings are seldom drawn to scale since the primary purpose of these drawings is to show the craftsman what the object looks like. . ' ~ (12) Dimensions; The size cf an object, whether.length, - width, height, thickness, depth, diameter, radius, etc., is indicated on a print by various means.- These measures of the object may be shown in whole numbers, mixed numbers, fractions, and decimals, usually In terms of feet and inches. Metric measurements are very infre quently used. These measurements are called dimensions. Angles of degree are also considered as a part of the dimensions. . o--L2Q-- F*svi^s 13 WA-TEX 003993 WA-TEX003993 r"\ .. . ^-\ . ITEM NO. A-l4 ' ' '` ' PAGE 66 The''dimensions of the object are usually shown in relation to the dimension lines. They may appear near the'center of the dimension lines or elsewhere between the dimension ' 1 lines, depending on the space available. The-ends, or terminals, of the dimension lines are shown by arrowpoints. Dimension values are either given as common fractions,1/^5 3/8", ete, or as decimal fractions, 0.25, 0,375? etc. The - .common fraction is generally used in dimensioning drawings in the petroleum industry. One of the views of an object will usually describe the shape of some detailed feature better than will the other view or views. Therefore, dimensions are usually shown in that view which is characteristic = of what the object looks like, (See Figure 13), " (b) Bill of Material; Every craftsman, in ' order to fully understand a print or drawing, should be familiar with the use of Bills of Material,' The Bill of Material may be and usually is issued on sheets separate from the print, or may appear on the print itself. The Bill of Material is helpful to the craftsman in many ways. Its purpose is to give,`as nearly as possible, necessary details about all the materials to be used on the Job. The arrangement, method of preparation, language and symbols used all are intended to reduce confusion among those who must read, interpret and discuss the Bill of Material even If the discussion takes place at opposite ends of a telephone connection. (See Figure 14), The Bill of Material shows? (a) The title, who prepared the Bill of Material, the B of M number and the charge number. (The B of M number is especially -important to the craftsman because in general, each piece of material is identifiable by this number). . -(b) Scope of Work, which includes a.brief description of the Job, list of drawings or sketches neces sary for planning the Job, and the timing of completion in most cases. (c) The initials of those receiving copies of the Bof M (Always in the upper left-hand corner of the first page). ` ( W&-TEX 003994 ! WA-TEX003994 ITEM NO. A-14 TRAINING DETAILS Va.aJz.C5J " .' . PkxJrJ', B1LL OF MATERIAL . "---------- -- ' REFINING DEPARTMENT PAGE 67 ' torn R.4J5-CC -J.dfs Vvj X. 11..-. / $.su CP cp.v.. ... - . B. M. NO. EST. TITLEPAAOl?.UCP.P/p//^p.J(AjAC6rSypPf/Ayj.P___________ ___ _________ /' `' " - f-^T. NO. j5,0,_ _____ '* MADE m AJaCS-J . . DATE..<$r-^?3"-<5> <3. ' : ` * .. JATJON^^^^^.^?/ .' ___ CHECKED BY.- . <*/ 2..*7 / D > ' SHEET NO../&/r/. - . J+'CSA. i /J/5 if/ * * .. inoii.z QUANTITY and unit ` DESCRIPTION 4Wft . DWG. NO. MARK furnished by \ 9 !- T? 4 <r ^' *7 1 8j ` dec? '-- *--- - -< ` ... . yVo-gd -m..t .j fZ) PjP0 'SUppQ/?^ D H//4* UrA-dPA* CU/a? JF&7Z - PcaaPp P-/'// & OA/er Pcjaa/P P-/7S. PtJAs'SP 4c?cP'7~/C?a/ Pv^'D-At-4o /P APc.4/40 CPCJ pap pi \/az >r ' -. _ - 0 r> ii / i ' --\f .- *. * . . / ' -- ' * - ' - :,i P^7U) ycrP'p/P /. "Ps~(0 u/jpaf.d ` A :l ' ya?zzsPi a P. Pd> .V'rJ 1 ji <5 JZ. <3> rj^ rr'/r>A. A:j * * ` * r 1 IPsa/afp s/ijcPyp >:? ` *1 / * 3L3di,J Srz?AP/-/r .. 4 /6 d &> 4 x /-a "a3 v -^/pz/ry/A/PsLAr Jp7./P / ! 7 f<Jy / "dr^c/c~rtspx?z C/SPASA/&cy/Y'Hy/h7^ . ! .. &-343 . "243 . ^r3<3 . 2 1 // <jV 'dez/azrsns? -'&&& Js/ 3I 1 <<rz2vt>& "rl" '' ' *1 1 ' _ 7i - J -. T- ` - ' i ^1 /1 sJ . /( > 1 ` f /| -. I '' ' -" : .` * ` _ . -. " " ; " ' tfA-TEX 003995 1 1 j ? nT/irmt? i )l WA-TEX003995 ITEM NO. A-l4 . TRAINING DETAILS PAGE 68 (d) Where the materials are to be used* (e) Who furnishes the material, or the order number upon which^material was ordered for delivery to the- Storehouse or Job. > (f) The number of pieces and a brief description . of each kind of material to be used on the Job and, in many cases, the dimensions. (g) Whether materials are to be fabricated in the shop or to be purchased pre-fabrlcated. c. MATHEMATICS REVIEW FOR THE CRAFTSMANS In all crafts ~^ome^^pe~6I;'^iatE^F~uied,'^AietEer^t is the addition or subtraction of dimensions or the calculation of an angle. Thus, it is necessary that each craftsman be familiar with and have a working knowledge of simple mathematics. (l) Fractions? A fraction is a numeral with two basic partsj the numerator and the denominator. In the fraction 3/4, the 3 is the numerator, the 4 is the denominator. Additional terms relating to fractions ares (a) Equivalent fractions - fractions which represent the same number as S/4^1/2, 8/8=1, or 6/8=3/4=12/16. (b) Like'fractions - fractions with'similar denominators, such as 3/4 and l/4. (c) Unlike fractions - fractions with dissimilar denominators, like 2/3 and 3/8. (d) Common denominator - a denominator which Gan be common to all fractions to be added or subtracted. (e)_ Lowest term - the simplest form of a fraction. Addition of like fractions is simple. The numerators arc Just added . together and placed over the common . denominator, then the result is reduced to its lowest terms. EXAMPLES In Figure A the overall dimension Is required. To obtain this dimension, the two fractions must be added.. 3/4"+3/4!,=6/4" ,, Since 4/4=1, then 6/4" = 1-2/4" 2/4=l/2, thus 6/4"=1/2" Lj, J The overall dimension Is 1-1/2" =3--------- --------- fe- ' WA-TEX 003996 WA-TEX003996 ITEM NO. A-l4 TRAINING DETAILS PAIS 69 Addition of unlike fractions is wore difficulty for a common denominator must be found For example, to add 2/3 and 3/4 the common denominator is found by multiplying^he denominators together Thus, 2/3 + 3/4=? can be solved by finding,the number of 1/12' s in 2/3 and in 3/h aM adding . them together; There are 8/l2 in 2/3, or 2/3=8/12 and 3/4=9/12. So, 9/12 4- 8/12=17/12=1=5/12 Very often it is not necessary to multiply the- denominators' together to find the common dcnomlna= tor. If two or more fractions are to be added together, such as 3/4*t-l/8-fl/2=?, a common denominator may already exist as the denominator of one of the fractions. In the example, 8 is a common denomina tor all the fractions to be added as It is divisible evenly by all of the denominators. Thus, 3/4=6/8, 1/8=1/a, and 2/2=4/8. Now that a common denominator has been found, the fractions can be added. Then the stxm of the fractions is 6/8-M/8P 4/8=11/8. Reduced to lowest terms the solution becomes 1=3/8. Subtraction of fractions is done in much the same manner, as a common denominator must be found before subtracting. EXAMPLE? In Figure B, a missing dimension is' needed. To find the dimension, one fraction must be subtracted from the other. *77 //8R,M! "9/l6l,=? Since 16 is divisible evenly by both denominators, it is the common denominator. (2) Another type of numeral denoting a part of a numbt-r that is less than one is called a decimal. Examples of decimals ares " 2 .. =* two tenths .13 = thirteen hundredths ' .469 = four hundred sixty~nine thousandths A fraction may be converted to a decimal by dividing the numerator .by the denominator, as l/2=5. Then .5 lo the same as l/2. . Decimals are added and subtracted the same as vrhole numbers. The only precaution to be taken is to keep the decimal point's aligned. WA-TEX 003997 WA-TEX003997 ITEM NO. A-l4 TRAINING DETAILS PAGE 70 /"'N (3) Solving Eight Triangles with Square Roots The following formulas are given to find the length of any side of a right triangle when the other two sides are known. A righttriangle, by definition* is any triangSe that contains a 90 angle. (See Figure C) B= v2 + C2 - A \/B2 - C2 C= Vb2 - A2 ^Ttsoeti C . 'C The symbol \/ indicates that the square root of the quantity within the symbol must be found. The small 2 at the upper right of the letters in the formulas means that the lengths represented by the letters must be multiplied by themselves. This process of multiplying a number by itself is called "squaring1 the number. EXAMPLE?' Find the length B! when A15n and C=2d', ' B= s/& + C? ' * .^15305)^^2^20) = s/223~nm =y^5 . B= 25s' . Squares and.square roots of whole numbers from 1 to 100 are found in a table on pages 167-169 of The Pipefitter"s and Pipe Welder's Handbook, by T. W,, Frankland. All piping offsets, are based on right triangles. With only two dimensions* the third may be found, (See Figure D). (4) Calculating an Angles In computing piping offsets, the pipefitter wifi"use'"'the six trigonometric functions of the angle of fitting. This calculation also makes use of the right triangle, (See Figure E) ! Wft-TEX 003998 i WA-TEX003998 ITEM NO. A-.14 TRAINING DETAILS PAGE 71 These functions ares Sine = set/travel* ^ Cosine = run/travel Tangent - set/run Cotangent =' run/set Cosecant = travel/set . Secant = travel/run The angles equivalent to the sines-, cosines* etc** are found In the Trigonomety Tables on Pages 171-175 of The Pipefitter's and Pipe Welder's Handbooks) by T* W* Prankland* EXAMPLE? Find the angle of fitting if the travel of an- .. offset'Is 8" and the set Is 4" (Refer to Figure E) ' Sine = set/travel Sine = 4/8 = 1/2 - *5 Refering to the trigonometry Tables* the angle whose sine Is *5 Is 30 ,, Therefore* . the angle of fitting is 30 * *This equation means that the sine of the angle of fitting equals the set divided by the travel* j WA-TEX 003999 WA-TEX003999 ITEM NO. A-14 TRAINING DETAILS PAGE 72 ft ( do Additional Print Information fog the Pipefitters * The pipefitter will come^IH^oiniac'S^witnvarious types of pipe drawings* Pipe is used in many places and for many purposes in construction work. It Is used primarily for the transportation of liquids and gases in the petroleum industry. ' (l) Two View Piping Drawings? One or two views is all that is necessary to show most piping drawings,, however, three views are sometimes used. This type of piping drawing is used very seldom used because it can be complicated.!. (See ,% Figure 15) (S) Isometric Piping Drawings; So that a piping drawling may be be fctert^ced~and understood, the isometric type of projection Is preferred. In a refinery, the greater part of piping work is the addition to or changing of lines already in service. In this case. Isometric drawings are made of the existing piping systems with additions'or changes shown in very heavy lines and noted on the drawing. As mentioned before, this type drawing is seldom drawn to scale, their purpose being to enable the pipefitter to form a mental picture of the completed system. CSee Figure 16) NOTE? Figure 15 and Figure 16 are of the same assembly. , (3) One Line and Two Line Drawings? Piping drawings using "the two~iIne system"re sembTethe actual pipe Job moro closely than the one line drawings. (See Figure 17A). One line drawings are the easiest and fastest to prepare, and for these reasons are used most often by Texaco, Inc. (See Figure 17B) , ' (4) Symbols and Conventions % Anyone who has Installed pipefifttings and valvesTknows that they are complicated pieces of mechanism. It will be readily seen that it is a waste of time for a draftsman to make complicated a working drawing of every gate valve to be installed in the field. The draftsman kndWs that a gate valve is and so does a fitter, so . a note on a print Is all that is necessary to convoy the Information. This applies to other types of valves and pipe fittings used In the field. In order to simplify the kraftsman* s work, symbols for fitting and valves have been agreed upon and accepted by engineers and draftsmen. , WA-TEX 004000 WA-TEX004000 ITEM MO. A~I4 BY...,,.S&?>. DATE..IQ.tAS' CHKD. BY.................. DATE........................ TRAINING DETAILS Xw.o\.)d W.....VS....X.SOX-0.&X5?.'e, SUBJECT. __...____ .........3?.\.V.i.t>>.G.......................... PAGE 73 SHEET NO........;_____OF. JOB NO....'.............................. H0-M 0H- ~t) ^--------------- t0 PLAN 04----- - bs 9 -+-- V-----------1 .*----- - K rv ELEVATION FIGURE 1 ISOMETRIC FIGURE If; WA-TEX004001  ITEM NO. A-l4 TRAINING DETAILS- ' by. S.RS.............. date,,U.t.1.4)-.^S suBJF-cT...._Dausc:.L.i.w.e,...yft....SiMO.>-e.Lij-j.e jpAGE JA sheet no__________of, CHKD. BY....................DATE........................................................................................................................................................................ JOB NO.... DOUBLE LINE Pi PING DRAWING FIGURE 17 WA-TEX004002 ITEM WO. A~l4 TRAINING DETAILS PAGE 75 The symbols of common pipe fittings are Shown In Figure 18. Bach symbol la drawn as simply as possible and to resemble ' the fitting being described. Symbols are given for screwed, flanged and welded fittings. . (5) Piping Details; Used primarily in the pipe and-weld ' ^aopsVlplPlSg"detail drawings show how sections`of piping should be fabricated. Often the detail drawings or spools are issued along with an assembly drawing (See Figure 19"24). The notations on the assembly drawing refer to the Individual spool drawings. - (6) Dimensionings The dimensions on a piping drawing are principally location dimensions most of which are made to center lines, both in double and single line represents~ tions. Flanged connections are dimensioned to the face of the Flange. Common dimensioning is then from center to center, ' face to face, center to face, end to end, center to end or face to end iSee Figures 19"24 for examples of types of dimensioning.) | WA-TEX 004003 WA-TEX004003 ITEM NO. A-l4 TRAINING DETAILS '____ STANDARD PIPING SYMBOLS 76 ....:---------- UNION ' ' ELBOW ` STREET ELBOW TES ' CONCENTRIC - `. . REDUCING ELBOW ECCENTRIC REDUCER -' LATERAL RISE OR DROP IN LINE CONN. TO MAIN - PROM- TOP tt ft t - PROM SIDE II It tt - PROM.BOTTOM ANCHOR EXPANSION JOINT PLUG COCK VALVE ' ' . - GATE VALVE GLOBE VALVE' - CHECK VALVE ` ANGLE VALVE ' DIAPHRAGM OR CONTROL VALVE MOTOR OPERATED VALVE QUICK OPENING VALVE RELIEP VALVE MULTI-PORT VALVE . -IXf-- --HO?!--r "HOr- ~--llXJi-- --oJXjs--- ---{txlf--- --cfX}8-- ---- ---- v^}{ . --Cb --'- ---- 1 ---- T' ---- fr~ ---- FIGURE 15> i WA-TEX 004004 WA-TEX004004 ITEM NO. A-14 TRAINING DETAILS PAGE 77 cHARcelst "[ CfVjvO" " (3. FOIL) V-40 G p{vq^>wco i/v-by title .............. .. w ***w*<-<. *, *xVy..o..<..t...... ....\.r*v*-yLOe'T_iiiJ* * [&& RS> t oio-!^-5i-0Arr: a-iS-47 .iELlEP VALVE SWTiTA'S MO* AS- 1016' APPO CP K /&MS < DATE , ISSUED 6'2-'~&7 A5SEMBLV SKETCH' FIGURE 19 WA-TEX004005 WA-TEX004006 WA-TEX004007 i\ i/ l Y ,/i \ l/ i V./ V / \ i f ; V r i \ i / . \U ; \.V . \i/1 \ !/; /; \ t / : \ i/ REQD.JL-- MARK 'n>rTj,'<r^iL_.i^irv-rr --------- lVC,, - __ ____ *_ PEC jyjrlla ^rarrrrs^x -tfV'k(D jtem|fRoCrQO NO io.vf 4 Ql /5 Z ' 0- size G" BSOOCRRHe -' -` - VYT | GRADS cfi&3 \BCf: STD TYPE ' DESCRIPTION ` - FUR. sy RP 'WN FLiM'J&E--- S> M . . U2.9\O0 WELD ELL. "v . 3 IV! *}Z&~ ft .* ' -. - Ps P . , I- - - . ` ................................................... .. H- ? i i . ,i i i. i 1 i- i . ' '. ^ ' WA-TEX 004008 I ! . - ` l FIGURE 22 ' i { .* . / / / ren WA-TEX004008 WA-TEX004009 / \ l >%<*! /IV ib. 1 (a! v.M / iM / a 'i/ u i/ ^ i/ . M / iX i/ K l/ lx 'i/ iM / M / K i/ iV i/ M / ix i _REQDjl_ ^ARK^JOJ^zBsPEC STRS5 r'elIEVE >4QlT_J1 ^ITeM\jFROcRQ'D NO tr>\` p size G" p 1 1 v' SOCRH POP!; IC V.LOA/TRS..P. 6 BADE- . . 150*1 - - STD JI TYPE |RP0 -. DESCRIPTION FUXW&~ WELD (= LL jj P*U}By HHsf - 0- ! . 6" sro \L^5 WELD ELL. " * p i C" 40 . ISMLS PiPE(6/e-P)e}^'- 1 G'r 46 . } G" *10 .. 1:IC" 1*101 .. . . .* $ML p)PEtB\e-p))\\ SMIS P\?b(S/E-p/s) *4 E0S-</.' i * SMLS -Ipjpe LBis-Ste) | HTT?1 MtiG\ <32 H S 1 n` - ....... Jj------ : WH"tAnrfmlAr rwtO-*Awrt*lwA ....^. _ |l---- * -i 1 !J .. 1f FIGURE 24 I11 WA-TEX004010  TEXACO INC, PUGET 'sQUND FLAM1 PAGE 83 TRAINING DETAILS DEPARTMENT: < PIPE . .. . DATE: .JULY 1, 1970 CLASSIFICATIONs" PIPEFITTER (TRAINEE) ^ ITEM NO* A-15 .. -------- SUBJECT:. MEASURING AND LAYOUT METHODS AND TOOLS ' a* ' MEASURING: _ (1). Principles of piping measurement, like piping ' " - prints> may at first glance seem somewhat complicated when a number of lines are involved. However, when the job is taken a section at- a time, it will be found that developing measurements are relatively simple. ' (2) The greater majority of piping jobs In a refinery will normally be replacement or addition to existing lines* b REFERENCE POINTS:-- (1) In order to make accurate piping measurements. It is necessary to know and accurately locate the points from which measurements are taken. These are known as reference points. (2) Reference points may be center lines, flange faces, vessel walls or stanchions* c. LAYOUT METHODS AND TOOLS'? ... Cl). Top and side center lines may be easily located with a carpenter's square and level as shown in the following Figure 1. The Inside angle of the square .Is placed against .the pipe and --the top leg levelled. One point on the center is located under the scale at a distance from the Inside angle of the square, . equal to l/2 the outside diameter (OD) of vhe pipe* j WA-TEX 004011 WA-TEX004011 ITEM NO. A-15 TRAINING DETAILS PAGE 84 ' Repeating'the" process at another section of'the pipe will locate a" second pointy and a line connecting "the 'two points will be the "top"center line* Applying the same method to - the vortical'leg of the square will locate the quarter point center lines. *. Bottom center lines may be easily located by dropping a plumb line from the top center points* and making the points of intersection on the bottom of the pipe* shown in following Figure 2t (2) The measurement"between two lines with different ` elevations can be found with a straight edge and level as shown in following-drawing. (Figure 3) Place a straight'edge' on the top of the high olevatloh and across the top of the low elevation. Level the top -of straight edge. . Take a measurement at point "A*** from top of low elevation to bottom of straight edge. . " Point "A" is the same measurement as point "B". Giving you the center to center elevation difference between the two lines. * WA-TEX 004D12 i WA-TEX004012 ITEM NO. A-15 TRAINING DETAILS PAGE 85 (3) In determining the Angle of intersection, where the angle of intersection is unknown, it must of course'be determined"before proceeding with the measure ment and layout of the job. The angle of intersection may be determined by stretching chalk lines In the position so that the center lines of the proposed piping job will be located. Use a protractor to measure the angle of Intersection directly. See following drawing (Figure 4) %I Settings for Various Angles Degrees ' 5 10 15 20 22-1/2 . 25 30 35 . 4o 45 50 55 60 65 TO 75 . 80 .90 Set On 24 " , 23-15/16 23-7/8 23-23/32 23-23/32 23-5/8 23-1/2 23-3/8 23-3/16 22-31/32 22-3/4 22-1/2 22-1/4 21-15/16 21-ll/l6 21-Y8 21-1/32 20-9/32 I WA-TEX 004013 i WA-TEX004013 ITEM NO. A-15 TRAINING DETAILS PAGE 86 .For'a 45 degree angle, bend the'rule at the first and second Joints, setting the end oh 22 and 31/32 Inches as Indicated in Table above. The desired angle wi$.X be formed as shown in following drawing.'(Figure 5) (5) When necessary to layout to cut odd-angle elbows, reference should be made to the tables shown in the rtPipeFitters and Pipe Welder's Handbook" on pages 31, 32, 33 and 34. - (6) Patented bending machines are available and are-used to a great advantage, especially for bending small pipe sizes. - . These bending machines are mechanically operated by leverage. . . Accurate bends can be obtained with the machine and either hot or cold bending methods may be.used. The machine has a separate form for each radius bend. , \The pipe is forced around this form by a bending shoe, which fibs the outside radius of the bend. This helps to prevent the pipe from flattening. '' The bending process is one involving skills that musf'be learned in actual practice on the Job. For example, when a bend is cooling, it has a tendency to straighten, and therefore must be bent to an arc slightly greater than, that of the template. . It is recommended when bending small pipe that a wire template be made of the degree of bend to be made to use for reference. , WA-TEX 004014 WA-TEX004014 ITEM NO. A-15 TRAINING DETAILS PAGE 87 As seen in Figure 1, the measurements of A & B must be the same in order for the flange and 90 ell to align properly with the pipe and each other. FIGURE 2 In Figure 2, the flange must be two holed or leveled, as shown above, with 90 ell being plumbed. This way the 90 ell will be aligned properly with flange. j WA-TEX 004015 WA-TEX004015 . ITEM. NO,. A**15 ' ' TRAINING DETAILS PAGE 88. , FIGURE 1 As seen in Figure 1, you can level 90 ell and plumb flange to.align properly with the pipe and each other. FIGURE 2 In Figure 2, the flange must be two holed or leveled with 90 ell being leveled to properly align flange with 90 ell. ! VJA-TEX 004016 t i. WA-TEX004016 TEXACO INC, PUGET SOUND PLANT PAGE 89 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION: PIPEFITTER (TRAINEE). DATE: JULY 1, 1970 ITEM NO. A-l6 SUBJECT: CARE AND PURPOSE OF SHOP EQUIPMENT A. PURPOSE (1) The hacksaw is to be used to cut 1/4" to 6" pipe, flat bar, roll and angle stock. The hacksaw can be set to cut 90> 45, and 22| angles,. Be sure to use oiler. (2) The pipe machine is used to thread to 2" pipe. The pipe dies have to be set to the size pipe you have to thread. A sample thread should be run to be sure dies are set right. Be sure to use oiler. (3) The power grinder is to be used to sharpen tools, bevel pipe, flat bar, etq. and clean up material. Wear goggles at all times. Use iront, not side, of grinder, (4) The iron worker is used to punch holes, cut flat bar, angle and round stock. Read instructions on machine for maximum capacity. B. CARE (1) The hacksaw is to have.a sharp blade in it in order to get a straight and .clean cut. Check to be sure oil level in tank is okay, if not, use soluble oil C and mix 30-1 and put into tank. Keep area clean. (2) The pipe machine is to have dies cleaned before each use. Check dies to be sure none are broken or chipped. Be sure oil level is okay, if not, use cutting oil Sultex-340. Area is to be kept clean at all times. (3) The power grinder is to be kept round by a wheel dresser kept at the machine. Check for cracks or chips. Keep area clean. (4) The iron worker should be cheeked for broken or chipped punches and dies. Keep machine greased and area cleaned. WA-TBX 004017 WA-TEX004017 PUGET "S'51,: .'V '.NT TRAILING BETA:, NS DEPARTMENT: PIPE . DATE: JUT lf l?-0 CLASSIFICATION: PIPEFITTER { TRAINEE .............. " ITEM NO. A'-17 SUBJECT: TAKING FIELD MEASUREHENIS ?3Sr 7qb~ planMno * a. FIELD MEASUREMENTS {D This unit: of Instruction will be devoted to the illustration of various reference points from which measurements are taken. . (2) As seen In Figure X, the measurement "M" is taken from center to center., ar.d will give the proper information in calculating cuts for .any connections between the two lines. The same measurement- can be obtained at *'0" without locating center lines. (3) In Figure 2, a connection is to be made between the two lines illustrated. The measurement nM" is a Face to Center measurement. 11C" is a center to center measurement^ but allowances would have to be made for the weld neck flange and welded ell already in place. j WA-TEX 004018 WA-TEX004018 ITEM NO. A-17 TRAINING DETAILS PAGE 91 (4) Figure 3, illustrates a measurement taken between two flange faces3 which could be a Face to Pace measurement. (.5) In Figure 4, the welded ell dimension "F" is deducted from the measurement "M" to determine the length of the cut "C". The dimension "F" is known as the J,take off". The "K1* measurement Is a center to end measurement. r\ | WA-TEX 004019 1 WA-TEX004019 ITEM NO. A-17 'TRAINING DETAILS PAGE 92 (6) Many variations of reference points will be found in taking field measurements. These 4 Illustrations show the basic measurements used: Figure 1 - Center to Center (& to ) Figure 2 - Center to Face (E to P) Figure 3 - Face to Face (F to F) Figure 4 - Center to End (E to E) ^ ' . b. FITTING ALLOWANCES ' . ' (1) In calculating cuts for piping installations, it ' is of course necessary to deduct from field measurements the space that will be taken up by the fittings to be installed. ' (2) Manufacturers of pipefittings have standardized dimensions on all types, classes and weights of welded fittings. For example, all welded ells of the same classification and size are made to uniform dimensions. See chart "Dimensions of Valves and Fittings." (a) Using the fitting dimensions table, determine the fittings needed, and the cuts of pipe needed to install the job shown in'Figure 5* Installing 6'300# Steel Gatevalve. Center to Center measurement "M" between the existing lines is 78 inches. (b) It would be difficult to remember all dimensions of all sizes and types of fittings, so hand books and manuals are provided with tables of dimensions, i.e. (Pipe Fitters Manual-Tube-Turn, Welding Fittings and Flanges). (The Pipe Fitter's and Pipe Welder's Handbook). WA-TEY 004020 WA-TEX004020 ITEM NO , A-17 training DETAILS page 93 Copyriph" '.>50 WA-TEX004021 ITEM NO. A-17 TRAINING DETAILS PAGE 94 S' WA-TEX 004022 f WA-TEX004022 ITEM NO* A-17 TRAINING. DETAILS. PAGE 95 c. JOB PLANNING? (1) Before measuring or laying out a pipe job* you ' should pick a route for theTIhew line* Be sure you have a clear path from starting point tp finish point. Avoid running lines that will cause stumbling hazards such as* too low across aisleurays* across ladders and cat walks. Also leave head room for over-head valves and lines. . (2) It Is important that field measurements be recorded In a manner that may be easily under stood in figuring cuts to assemble the job. A simple field sketch will serve the purpose* making sure that all dimensions are recorded* size and schedule of pipe* size and weight of valves and fittings. " .(3) Compile a list of equipment and material needed for the job before ordering. (4) Lines-or vessels must be-gas freed before making a new tie-in on existing equipment. Obtain a . safety work permit from operations to blind and steam. (5) When welding is to be done* all sewers and drains must be covered in the immediate -area to prevent escaping gas fumes from flashing during welding operation. (6) After steaming is completed a Hot Work permit must be obtained from operations. A gas test must be taken, and Gas Tester must O.K. and sign the permit before the equipment can be cut into with a cutting torch or pipe cutters. ' CAUTION; READ PERMIT AND MAKE,SURE ALL SAFETY PRECAUTIONS OR SPECIAL EQUIPMENT REQUIRED AS LISTED ON THE PERMIT ARE .FOLLOWED. - (7) In some cases when a line cannot be gas freed* a Hot Work Permit can be issued to cold cut. In order to weld on this line* a welding plug or pipe plug must be .inserted into the line. Run a hose from the pipe plug connection a safe distance away from the area of welding. Gas test then must be taken around the pipe plug to be sure no gas fumes are escaping. CAUTIONS IT IS ADVISABLE THAT SLIP-ON-WELD FLANGES ONLY USED ON THIS .TYPE OF JOB. ONE TO THE INSIDE WELD BEAD ON HIGH HUB WELD FLANGES PIPE PLUGS ARE VERY DIFFICULT TO EXTRACT FROM LINES. d. JOB PLANNING-WORKING FROM BILLS OF MATERIAL AND PRINTS s (l) Read the Bill of Material to be sure the proper fittings and pipe have been ordered to complete ! WA-TEX 004023 ' l WA-TEX004023 ITEM NO. A-IT % TRAINING DETAILS . PAGE 96 or start a Job. Some Items will have a storehouse order number, check to see If material has been received or when It Is expected to be received. y (2) In most cases, a print is provided with the Bill of Material.. Read every detail on this print, trace the lines out from starting point to finish point to insure a clear layout path. . (3) After completing Job, return all tools, equipment and excess material to Its proper storage area. Clean up the Job and leave it in a safe working condition e. S..C..R..E..W.. ED"r 'Pn IPE AND FITTINGSs' * (l) In Figure 6, showing a screwed fitting, "F" represents the fitting dimension and "M" the measurement. (2) To determine take-off "T", subtract "L" (thread make-up) from "Fn. - The cut length 11C" Is determined by subtracting "TM from "M". (3) This principle applies to installation of all screwed fittings. j WA-TEX 004024 i WA-TEX004024 ITEM NO. A-17 PAGE 97 (4) Face to center measurements on screwed fittings as a rule are standard In, dimension by weight and size. However; In some cases, fittings may vary alightly in dimension. The followings tables are recommended: TAKE-OFF TABLE SCREWED FITTINGS 12 5-*POUND CAST IRON TAKE-OFF TABLE SCREWED FITTINGS 250-POUND CAST IRON SIZE 90 TEE 45 SIZE 90 TEE 45 1/4" 3/8" .3/8" 1/2" 7/8" 3/8" 1-1/8" 7/l6" i/4" 3/8" 7/8" 1" 1-3/4" 2" ! 110 ro 1/2" . 5/8" 1-1/4" 3/8" 1/2" 1-1/2" 1/2" 3/4" 3/4" 1-1/2" 1/2" 7/8" 1-5/8" 9/16" 1 7/8" 1-5/8" 1/2" 1" 15/16" 1-3/4" 5/8" 1-1/4" 1-1/16" 2-1/8" 5/8" 1-1/4" 1-1/4" 2-5/8" 7/8" 1-1/2" 1-1/4" 2-1/2" 3/4" 1-1/2" 1-7/16" 2-3/4" 1" 2 1-1/2" 3" 15/16" 2" 1-3A" 3-1/2" 1-1/4" 2-1/2" 1-3/4" 3-1/2." 1" 2-1/2" 2" 4" 1-54.6" 3" 2-1/8" 4-1/4" 1-1/8" 3" 2-3/8" 4-7/8" 1-1/2" 4" 2-5/8" 5-1/4" 1-1/2" 4" 3" ' 6" 1-11/16" 5" 3-3/4" 7-5/8" 2-1/4" 6" 4-5/16" 9-7/8" 2-3/4" J8" 5-1/8" 10-1/4' 2-3A" 8" 5-9/16" 11-2/8" 3-3/16" j WA-TEX 004025 WA-TEX004025 ITEM NO. A-IT TRAINING DETAILS TAKE-OFF TABLE FORGED STEEL SCREWEDFITTINGS " ^^OOO-POUND W.O.G. PAGE g8 oin % 00 SIZE 90 TEE UNION COUPLING 1/8" 1/2" 1" 1/4" 1/2" 3/8" iA" 5/8" 1-1/4" 3/8" 3/4" " i/2" ' 3/4" 1-5/8" 1/2" . 15/l6" 3/4" 1/2" 3/4" 1-5/16" 1/2" 15/16" 7/8" 15/16" 1-7/8" 9/16" 1-1/8" 1" 1" 1-3/16" 2-1/8" 5/8"... 1-1/16" 1" ' l-^L/4" 1-5/16" 2-5/8" 3/4" 1-5/16" 1-1/2" 1-1/2" 1-11/16" 3-1/2" 1" 1-5/8" 1-1/2" 2" 1-3/4" 3-1/2" 1" 1-7/8" 1-7/8" 2-1/2" 2-7/16" 3"______ 1-1/8" 2-1/8" 1-3/4" 3" 2-3/4" 6-1/2" 1-1/2" 2-5/16" 2-1/4" 4" 3-3/8" 6-3/4" 2" 2-1/2" : WA-TEX 004026 iI WA-TEX004026 TEXACO INC. PUGET SOUND PLANT PAGE 99 TRAINING DETAILS DEPARTMENTS PIPE CLASSIFICATIONS JPIPEFITTERS (TRAINES) DATE: JULY 1, 1970 ITEM NO. B-i SUBJECT; ASSEMBLE AND TRANSFER TO^S^AN^EQUXP^ffiNT " A. TOOLS (1) When assigned a job, make a list of all the tools needed to complete the job. (other* than tools provided in Pipe fitter's tool box.) The portable tool room is usually spotted at the unit that is down for I & T Most smaller tools can be obtained from the portable tool rcom. Larger tools and portable power tools may be obtained from the Main Tool Room. Call in a list of tools required to the Main Tool Room, giving the location or station where tools are to be delivered. ' (2) Tools supplied from the tool rooms are checked out to the Pipefitter on the jdb and should be cleaned and returned to their proper place upon completion of the job. (3) Broken or damaged tools should be reported to the toolkeeper so they may be repaired or replaced. B. EQUIPMENT (1) Several equipment storage areas are located throughout the plant for equipment such as field pumps, tuggers, pipe machines, pipe benches, and test pumps. (2) The dispatcher should be notified by the person needing the equipment where the equipment is located and where it is to be delivered. ! WA-TEX 004027 WA-TEX004027 TEXACO INC. pugetTSUIEidTSant PAGE 100 TfiAfNINft D'-TA I> DEPARTMENT; PIPE . CLASSIPICATIOS; PIPEFITTER (T---AINFI-.; LATE: JULY 1, 1970 ITEM NO. B-2 SUBJECT: MOVE MATERIALS A. PALLETS (1) Flat pallets are provided for moving material packed in barrels, sacks and crates with & forklift. (2) Straddle carrier pallets are provided for moving materials such as pipe, exchanger iieads, motors, and pumps. (3) . Metal straddle carrier box pallets are provided for hauling valves, PRV1s, large quantities of fittings and tools. This same type of pallet is provided on shutdowns for salvaging fittings and bolts, * B. BOLSTERS (l) Bolsters are provided for moving pipe and plank with the straddle carrier. 0. BUNDLE RACK'S (l). Bundle racks are constructed to cradle a tube bur/*, ' prevent rolling while moving with the straddle carrier. E>. SKIPS (l) Skips are provided for moving material such as dirt, sand, broken concrete, and coke with the lugger truck. In some cases the lugger truck is also used for moving valves and pumps. E. SMALL MATERIAL (1) A route truck delivers material ordered from the Storehouse or tool rooms to job sites or stations near job sites. It also delivers tagged material from stations back to proper storage. ' F. DISPATCHER (l) When moving material on pallets, bolsters, bundle racks and skips, the dispatcher should be notified of the location of the equipment to be moved and the location for delivery. All material should be marked with a yellow tag showing the delivery location. WA-TEX 004028 WA-TEX004028 TEXACO INC. PUGET- SOUNITTLa NT TRAINING DETA ILS PAGE 101 DEPARTMENT; PIPE CLA3SIPICATION: PI PEF.ITTEH C TEA IMRE) PATH'.t JULY 1, 1970 . ITEM NO. B^3 SUBJECT? LOAD A NT) UNLOAD MATERIAL?? A. LOAD (1) When loading materials on trucks, place In a position where materials can be tied down. In case of smaller items, place so they cannot roll or bounce off the truck. (2) Never drop or throw tools or materials onto truck beds, this may damage items being loaded. (3) Place blocks or wedges under pipe to avoid rolling while hauling. Always center and block pipe when loading onto bolsters or pallets. (4) Ask for help When heavy items are being loaded. Always lift with back in an upright straight position. B, UNLOAD (1) Unload material as near to job site as possible. (2) Avoid dropping small pipe, tools, fittings, etc. from truck beds. Rolling small pipe from trucks may bend the pipe or bounce and cause injury to personnel. The process of loading and unloading materials, equipment, and tools is the perfect setting for an injury or accident. Be alerteror rolling pipe, burrs on metaT," 'ahd~"aFove all, rmproper lITtlngf ! W&-TEX 004029 WA-TEX004029 TEXACO INC. puGET-gocHij- mtrar PAGE 102 TRAINING DETAILS ......................... DEPARTMENT? PIPE CLASSIFICATION; PIPEFITTER (TRAINEE) DATE; JULY 1, 1970 1 ITEM NO. B~4 SUBJECT? DOPE AND WRAP PIPE The surface of all piping must, be clean before applying dope. Then apply an adhesive primer, commonly known as dope, to the pipe surface with a brush, spray, or swab. A swab may be made from rags attached to the end of a sticks The primer must be dry before wrapping. The wrapping, commonly known as doping tape, is applied in a spiral motion in ..order to insure overlapping. For Instance, if you are using 2W tape you will overlap .1", if you use 4'* tape you will overlap 2", etc. Select your wrapping as follows; Pipe Size 1/2" - 2" 4" and 6" 8" and larger Size Tape 2" 4" 6" WA--TEX 004030 WA-TEX004030 TEXACO INC. PUGET SOUND PLANT PAGE,103 TRAINING DETAILS DEPARTMENT; PIPE ,, CLASSIFICATION: PIPEFITTER (TRAINEE) DATE: JULY 1, 1970 ITEM NO. B^5 , SUBJECT: STRING OUT PIPE A, STRING OUT PIPS (1) Two-wheel pipe carts are provided for stringing pipe in places where cranes cannot reach. CAUTION: Avoid stringing pipe where it could cause a stumbling hazard, and make sure it's placed so it cannot roll. (2) Cranes should be used where space permits them to operate. (3) Tuggers may also be used for pulling pipe into position or along pipe ways. When pulling pipe with a tugger, follow closely to avoid hangups. CAUTION: Always tie down loose pipe l^ft laying in overhead pipe ways. Remove all excess pipe when the job is completed. (4) Before connecting joints together, check to see that there are no foreign objects inside the pipe (often when moving or pulling pipe, gravel or dirt may be picked up in the ends of the pipe.) . (5) Avoid dropping pipe, this may bend the pipe or cause damage to the ends. (6) When transporting threaded pipe, cover threads with a collar or pipe cap. If none is available, tie rags around threads to protect them from being damaged. (7) When pipe is being strung out to be installed in a trench, lay blocking across trench, string out pipe along side the trench on the blocking. After piping has been jointed, roll the pipe over the center of the trench. Set *tripods astraddle the line. Using a cable sling and eome-a-longs or chain falls, lift the line, remove the blocks and lower line into trench. In order to remove slings from the line, blocks should be set in the bottom of the trench to lower line into, (*tripods are constructed with three legs -hinged together at the top. The bottom of the legs spread, creating a tripod. A U-bolt is installed between top section of legs for rigging a come-a-long or chain fall.) (These are stored in one of the designated storage areas.) WA-TEX 004031 WA-TEX004031 ITEM NO. B-5 TRAINING DETAILS PAGE 104 NOTE: It is recommended that long runs of large pipe not be set on welding jacks for fabrication. Jacks may slip causing pipe to roll oIf and.cause injury to personnel. (8) When lifting single joints of heavy pipe, it is recommended a cable sling be used, making sure equal weight is balanced on both ends. (9) When sliding pipe along pipe ways, trenchs, or on the ground, never put hands or fingers inside the pine, _If the end of the pipe strikes an object it could cut off fingers. Be alert for and prevent pipe from rolling onto feet and insteps. j WA-TEX 004032 WA-TEX004032 TEXACO IMP. piioBiHroi^TOa^ " ' PAGE 105 'paEBUBicr tobhes - BEPARTMEMTs . PIPE GIASSiy^ttggr^IgBPIWBB. (TRAINEE) BATE? JULY 1, 1970 ' ITEM MO:* B6 ! , SUBJECT2 DISMANTLE PIPE AMD FITTINGS All pipe usfed in the refinery is either screwed or welded and fittings are either.screwed9 welded or flanged* When dismantling. screwed fittings* be sure you are using the Fight si?e wrench and that .your pipe wrench has good Jaws-. Do not use a wrench as a hammer. ' n` ' . Serened fittings include unions* valves* flanges^ ells* tees* and nipples. , Bp sure that all fittings are in good condition a$d properly doped if they are. to be reinstalled. - ` WA-TEX 004033 WA-TEX004033 TEXACO INC, PUGET SOUND PLANT PAGE 106 TRAINING DETAILS DEPARTMENT: PIPE , CLASSIFICATION! PIPEFITTER (TRAINEE) DATE: JULY I, 1970 ITEM NO. B-T SUBJECT? SALVAGE PIPING To prevent accumulation of second hand and salvaged materials, the following procedures shall be followed. All segregation of salvage and junk materials shall be done at the job site if possible. A, PIPE All reusable carbon steel pipe in- sizes 2", 3"# 4", 6" and 8" in lengths of 10 feet or more shall be salvaged and tagged for delivery to the Storehouse where it will be credited to stock. Useable carbon steel pipe 10" and larger should be stored in the Salvage Yard if 10' or more in length. All other carbon steel pipe shall be tagged for junk. (Mark with yellow paint with the word JUNK.) Disposition of Alloy pipe should be discussed with the Foreman-Pipe Department. Alloy pipe which is saved should be color coded, B. VALVES Ail diaphragm operated steel control valves should be salvaged, tagged and transported fco the Instrument Shop for overhaul, identification, and storage in a designated area of the Store house Annex. The Instrument Foreman is responsible for main taining an up-to-date list with complete identification of all available used control valves. All cast iron control valves shall be tagged for junk. All 1-1/2" and 2" screwed carbon and stainless steel and brass globe and gate valves and all flanged steel globe, gate and check valves should be salvaged, tagged, and sent to the Valve Shop for reconditioning. Repaired valves are sent to the Storehouse and credited to stock. All cast iron and all other brass globe, gate and check valves should be tagged for junk. All steel pressure relief valves shall be salvaged, tagged and sent to .the Valve Shop for reconditioning as time permits. All cast iron PRVs shall be tagged for junk. All repaired PRVs are put in Storehouse Stock-and stored in a suitable place. C. FITTINGS AND FLANGES In addition to all Ring Joint flanges and 900# ball joint slip flanges, the following carbon steel weld fittings and flanges shall be designated for salvage. a) Std,, and XH 90 ells b) Std. Tees c) XH Tees 4", 6" and 8" -3", 4% 6" and 8" =3", 4", 6" and 8" j WA-TEX 004034 WA-TEX004034 ITEM NO. b-7 TRAINING- DETAILS PAGE 107 Series 150 and 500 slip-on flanges -3% 4", 6" and 8" Series 150 and 300 weld neck flanges -3", 4", 6" and 8" All cast iron blind flanges 125# and 250# only -All sizes through 8" All steel blind flanges -All sizes through 8" All other carbon steel fittings shall be tagged for Junk. D. CARBON STEEL FLANGES AND FITTINGS 600# AND HIGHER PRESSURE RATING ' Save and salvage only materials for which specific requirements are known. When questionable cases arise, review with the Foreman for decision as to disposal. When salvaging fittings and weld neck flanges a minimum of 3" of pipe shall be left beyond the weld, and when salvaging slip-on flanges, at least 8" of pipe shall be left with the flanges so that proper reconditioning may be done on the fittings and flanges. RF flanges shall be salvaged only by the weld shop. Any RF flanges requiring facing by the Machine Shop shall be junked. All other salvaged fittings and flanges should be stored at the Salvage Yard for sale or reconditioning as determined by Plant Management. Reconditioned flanges and fittings shall be delivered to the Storehouse where they will be credited to stock. . . E. ALLOY FLANGES AND FITTINGS - ALL PRESSURE RATINGS Save and salvage all such material which is commonly used in the Plant. Reconditioned material shall be sent to the Store house. Msf-of'ials Questionable for salvage a hall be discussed with the Supervisor of Maintenance for decision. All Alloy materials to be identified by Inspection Dept,., marked and tagged. F. GAUGE GLASSES All reflex type gauge glasses shall be salvaged and tagged for delivery to the Valve Shop where they will be reconditioned as time permits. After repairs have been made, they shall be sent to the Storehouse. All transparent type gauge glasses shall be tagged for junk. ' G. INSTRUMENTS All instruments such as transmitters, flow recorders, tempera ture recorders, pressure gauges, leveltrols, etc., sutitable for reuse, shall be salvaged and tagged for delivery to the Instrument Shop for reconditioning. All instruments ^nsidered unsatisfac tory for further use by the Jnstr.-Electr. Foreman or his Assistant shall be tagged for junk. !{ WA-TEX 004035 WA-TEX004035 ITEM NO. B-7 TRAINING DETAILS PAGE 108 The salvage or junking of items or equipment not covered by the above instructions shall be referred to the Supervisor of Maintenance.i i W&-TEX 004036 t WA-TEX004036 TEXACO INC. PUGET SOUNITpLANT PAGE 109 TRAINING DETAILS DEPARTMENT: PIPE , CLASSIFICATIOin PIPEFITTER (TRAINEE) ITEM NO. B-8 SUBJECT: DATE: JULY I, I97Q USE HAND DIES a .1' STOCK AND DIES . cd; Hand5pipe threading dies and stocks (handle) are . ' available in the .Main Tool Room in sizes from l/B" .through and including 2". .. ' (2) Pipe to be threaded should be cut square. Pipe ' threaded without a square end causes poor penetration- [.into screwed fittings. ' (3) The stock has a built-in lever for reverse and forward. -.(4); Threads are cut in a 'clockwise motion. , b. CUTTING THREADS (l) . Place dies on end of pipe to be threaded. Apply ` . ' pressure with heal of hand on the end of dies while moving the stock in a clockwise motion. This helps dies to ..begin cutting the thread. (2) Apply cutting oil often to dies while cutting. This , . serves as a lubricant and helps to cut a smooth uniform thread. "Cut threads to desired length,' reverse lever and ..turn stock in a counter-clockwise motion to remove dies from pipe. "Threads are tapered to assure a tight fit into a fitting. (Avoid over threading,- this can cause threads to penetrate., too far into a fitting and not complete a leak proof seal.) ' NOTE:.It is recommended that a fitting be screwed on :the first thread cut to be sure the dies are in adjustment. " CAUTION: Brass pipe is very soft, the end being ' ' threaded may easily be egg shaped. It is recommended that a spud wrench he inserted through the dies into the end of the pipe. WA-EEX 004037 WA-TEX004037 ITEM HO. B-8 TRAINING DETAILS PAGE 110 -1 c FIELD PIES . -. . '/l'"', Field dies are available In the Main Tool Room In four sizes: 3", 4", 6" and. 8". These dies may be manually , ' operated with a ratchet handle or power operated with an . air motor. Pipe to be threaded should be cut square. Take f- offs for threaded fittings should be figured before threading '. pipe.;' `All rust scale and dirt should be cleaned from the . pipe at least 8" from the end. Each set of dies has a 'threaded nipple built into it to run the dies in and out, : One .'end of this nipple has 3- set screws, or bolts to grip \. onto the pipe to hold the dies in position while threading. The cutting dies are 'attached to the other end of this ' nipple. Dies should be unscrewed off the nipple far enough ; to cut the thread.' Measuring the exposed threads determines '.the length of travel of.the dies. d . CUTTING THREADS (l) Figure the length of thread to be cut. ,,{2} ' Back',the dies-off the nipple far enough to allow dies ' ' enough travel to cut the proper length of thread. {3)' Place the dies on the pipe, set screw end first, with ` the dies against the end of the pipe. Tighten the set screws, making sure of equal 'distance between the pipe and nipple holding the set screws. NOTE: It is very important that dies be square on , v , pipe before threading. If set screws are ' tightened without equal spacing between the : pipe and nipple, it will cause the dies to ' cut deep threads on one side of the pipe and shallow threads on the opposite side. This ' weakens the strength of the metal and may . cause the threads to leak. (4) Cut threads by turning dies In a clockwise motion. . Always cut the first two or three threads with a ratchet handle, before attaching air motor. Always use thread cutting oil when cutting threads. Thread oil is available at the Portable and Main Tool Rooms,, WA-TBX 004038 WA-TEX004038 TEXACO INC, PUGET 'SOUND PLANT page :m TRAINING DETAILS DEPARTMENTS PIPE CLASSIFICATIONS PIPEFITTER (TRAINEE) DATE: JULY 1, 1970 ITEM NO, .. SUBJECTS OPERATE POWER TOOLS A. " ^%1%R TOOLS . (1) Be sure that you have the right tool for the job, That includes the right drill, tap, saw blade,.etc. Also be sure to have the right tool capacity for the job. When you-have these right you will work more efficiently and do a safer job. ' (2) All power tools shall be returned to the proper tool room after the job is completed and the tool has been properly cleaned. B. PNEUMATIC TOOLS (1) Before hooking up any pneumatic toqlj, the air hose to be used should be blown out to remove all dirt, rust and water. (2) An Oiler should be installed in the line to insure proper lubrication. Pig tail hoses are provided at the Portable and Main Tool Rooms with attached lubricators for most pneumatic tools. Larger lubricators are available on the Khoeker wagon when using Knocker motors. These lubricators should be cheeked and refilled several times each shift while being used. Note; When using a power hack saw, use cutting oil on the saw blade. (3) Pneumatic sump pumps should be suspended a few inches from the bottom of ditches and holes when jumping out liquid. This keeps dirt from being sucked into motor. C. ELECTRIC TOOLS (1) The Electrically Controlled Tube Rollers has a ground wire attached to it and must be connected to the equipment being worked on. (2) Electric drill motors have a three wire system built in, one being the ground wire. (3) Electric reeepticles are located throughout operating units to hook up power tools. Extension cords are provided and may be found on electric storage pallets. t S WA--TEX 004039 WA-TEX004039 ' rae0 ppq@nsBij^g^ijr' PAGE 112 THA1IOTGT' VBUSnsr BEPARTMEHfs PIPE CLASSIFICATIQgl^IFmTM** (TR&IMEE ) MTS? JULY la 19TO ITEM MO. B=10 SUBJECT? OPERATE PUMPS PUMPS A Sump Pumps . Cl) .Are used to pump w&t@r<, oil, etc. (2) have gas and air operated sump pumps. |3) Be sure to have sufficient auction and discharge hose. -SB. Test Pump Test pumps are a dangerous piece of equipment and should be operated with care. Be sure a relief valve set at testing pressure is installed on test pump. Before starting pump, |&en bypass valve and know testing pressure. Be sure all air -# out of system. Pipefitter running test must stay with test i&iteSLo Close bypass valve slowly and raise to testing pressure. Ifell $Hiap and test pumps should be drained and cleaned after Jpfi ! is .^flet@d. Return pump to storage area. ' - '***&&& '1 1l WA-TBX 004040 WA-TEX004040 TEXACO INC, PAGE 113 TRAINING DETAILS DEPARTMENTS PIPE , CLASSIFICATIONS 'PIPEFITTER (TRAINEE) DATES JULY 1, 1970 ITEM NO. b-11 SUBJECTS OPERATE COMPRESSOR COMPRESSOR '< '1 Start gas operated motor and let It run until it is warmed up. Then engage compressor clutch and let It build up pressure. Connect your equipment and it is ready for use. Be sure tractor is. out of gear before engaging compressor. ; WA-TEX 004041 WA-TEX004041 PAgE 114 ITEM 80o b-12 TBAISTHGT "BKHHES "(TRAIHEE) DATE? JULY 1, 1970 SUBJECTS OPERATE HOISTS A. AIR HOIST Ll-l I-- !- HIM III ll ' : Connect air hose and be sure hose is lor^g enoupn for travel and safety wire is put in hose connection. B ure- load, is properly . rigged before lifting. " Bo ELECTRIC HOIST Cheek capacity of hoist and insure that load is properly rigged before lifting0 ' Co AIR TUTOR 4 Tie tugger down- with a cable to t$gpp@3f anchor Just out from unit slab. Run cable through pulley ari@0&se of tower to top ef- tower through pulley and down to Job site. Be sure capacity of cable will lift your load.. All portable hoists and tuggers should be returned to storage area a: r being properly cleaned. WA-TEX 004042 WA-TEX004042 ITEM NO. B-12 TRAINING DETAILS PAGE 115 UTILITY AIR HOISTS ^ 5000 lbs. (2268 kg.) sizes K6UA and K6UAL Both of these heavy-duty Hoists offer big capacity, yet retain the adaptability, portability and flexibility of smaller Ingersoll-Rand Utility Hoists. Both have a rated capacity of 5(300 lbs. (2268 kg.) with a rope speed of 95 feet (28.9 meters) per minute. Both are virtually identical in construction and features except that Size K6UAL incorporates a rope drum that is twice as long as the drum on the Size K6UA and consequently can wind twice as much wire rope. Among their many important features are: Powerful, six-cylinder, piston-type reversible motorpermits full control of the load by the throttle at all times. n* Heavy-duty, tworsegment, self-energizing, high-ca pacity brake. v Three-stage gear reduction, with power transmitted to the rope drum through balanced planetary gear ing. si Rubber-faced throttle valve--assures a positive seal at all times, never needs lapping, and greatly re duces maintenance. if Sealed gear `case--gear case is sealed around rope drum to keep dirt out of the rope drum ring gear. _* Rope drum---rotates on large roller bearings mount ed on a drum shaft that is rigidly supported at each end. Size K6UA Hoist SPECIFICATIONS--performance figures are at 80 pst (5.6 kg/cm') air pressure j........ ........... SIZE ' _ _ K6UA ........ K6UAL ! Capacity 5000lbs. f. 2268kg. : 5000lbs. : 2258kg. I ; Rope speed per min. at rated load : 95' 28.9 meters i 5Ize and maximum length of wire rope 34" x 600' I 54" x 183 meters _ _ - 34" x 420*_ i 34" x 128 meters Weight without wire rope 1 13)5 lbs. } 596kg., 1 Both sizes have a 114" hose connection pipe tap; 1 54" (38 mm) hose Is recommended. 95' I 28.9 meters -; 54" x 1200': 54" x 355 meters - 34" x 840' ' 34" x 256 meters i 1550 lbs. ' 703 kg.. ' Size K6UA Holst used to lift moforials to various working levels on a targe construction proieet. WA-TEX004043 TEXACO INC. PUGET SOUND PLANT PAGE 116 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION: PIPEFITTER (TRAINEE) ITEM NO. B-13 SUBJECT: DATE: JULY I, 1970 ' CUT GASKETS a. GASKET CUTTER A manually operated gasket cutter is mounted on a work ` : ' bench at the east end of the pipe shop. Sheet gaskets . ' material in thicknesses of l/l6" and 1/8" Is provided at ` / this location. The storehouse stocks gasket material if none Is available In the pipe shop. A measuring slide bar . is installed on the gasket cutter with a screw down guide ..'to hold the gasket, material In position at the measurement required. A 1/4" x 2" round peg is located on the end of ' -the measuring bar with a hold down nut on top. This holds gasket material on measuring--bar. The cutting blade works :; oh an up and down lever. A handle is attached to cutting blade. This serves not only to cut the material, but to -turn the gasket material into the cutting blade. b. HOLE CUTTER A hole cutter is provided with the gasket cutting machine. A sleeve on the cutter rod has an up and down sliding motion. Two stops on the cutting rod about 12" apart stop the sleeve on the up and down motion. The . sleeve and bottom stop serves as a hammer when cutting a hole. Place the gasket material on the block of lead . . provided for cutting,. Holes may be cut by placing the "cutter rod on the gasket material and bringing the sleeve down against the bottom stop sharply. o. CUTTING GASKET ' ' -..(l) Cut a square piece of gasket material slightly larger ' than the OD (outside diameter) of the gasket to be cut. Locate the center of the piece of gasket material. Cut a hole in the center of the material with the hole cutter provided, at the work bench. Cut off the corners . . of the gasket material to within a slightly larger GD of the gasket to"be cut9 7Set the measuring bar at 1/2"the GDnofvthe"gasket- being cut/ lock the guide In position. Set the center holeof the gasket material on the . ' measuring bar peg and Install hold down nut; (if Is . recommended that a measurement be taken from the cutter : blade to the center hole to assure the gasket cutter Is in adjustment). Lower the cutting blade onto the gasket material. Turn cutting hand in a clockwise motion to - cut gasket. - - ! WA--TEX 004044 WA-TEX004044 ITEM NO. B*13 TRAINING DETAILS PAGE 117 . hole to assure the gasket cutter is In adjustment./ Lower - : .the cutting blade onto the gasket material. Turn cutting . hand in a clockwise motion to cut gasket. - ,! . . . = ' CAUTIONS ALWAYS CUT THE OUTSIDE DIAMETER OP A . ; ` GASKET FIRST * . (2) After the gasket has been cut to the 0B. size., remove .'. . excess gasket material leaving the gasket attached, to 'the measuring bar. Unlock, measuring guide on the . measuring bar and set' at 1/2 the measurement of the I.D. / "(inside diameter) of the gasket being cut. Then follow the cutting procedure. - ' ' ' d. PORTABLE GASKET CUTTER . . A portable gasket cutter is provided' at the pipe shop for cutting small gaskets. A measuring bar is built in the gasket cutter with a centering peg on __ _ one end and a'"lock screw'to. hol'd measuring har on the proper- dimension. A retractable cutting blade is built in the gasket cutter, A gasket cutting board is also ' provided at the portable tool room. A center hole is ' drilled on this board to fit the measuring bar centering peg. The centering peg is pointed on one end to penetrate the gasket material, allowing the gasket Gutter to turn in " -.a rotating motion. . e. CUTTING GASKET . - Set the measuring bar at l/2 of the QU of the gasket - : to be cut and lock the guide in position,. Measure in from , / .. two sides of the gasket material- allowing enough material - *> 'for 1/2 the OD of gasket being cut and mark an "X" for the ''center hole. Punch, a hole through the gasket material at the "X" with the pointed centering peg. Place gasket ' ; material on cutting board, with gasket cutter on top of material. Put centering peg through guide bar, through ' V' center hole in gasket material and into center hole or 'cutting board. Turn gasket cutter in clockwise motion to .. = cut material. To cut the I.D. of the gasket, -set the measuring bar at 1/2 the I.D, and follow the cutting in ... instructions above. . ' ; CAUTION; DO NOT CUT METAL GASKETS WITH THESE ' ' GASKET CUTTERS. - | WA-TEX 004045 ) WA-TEX004045 'TEXACO INC. - pnget~sound PLANT PAGE 118 O TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION! PIPEFITTER (TRAINEE) DATE: JUDY 1, 1970 ITEM NO. B-14 SUBJECT: USE HAND TOOLS a. CARE OF HAND TOOLS (l) Knowledge of the proper tools to use and how :;o use them Is necessary to good handling of pipe ?nc, ' fittings. Select the right type and right size tool 'for each piping Job,. . . t ` , (2) Wrenches are used on practically every piping job., ` and if used Improperly can cause serf ans damage to materials and' topis. They also cause accidents, (3) Tools should be kept clean and stored in an orderly '- fashion in a pipe fitters tool box. . (4) Tools should be regularly Inspected for worn or . damaged parts, and replacements made as necessary. ' (5) When tools are lost, a lost tool slip must be filled out by the pipefitter and signed by his Craft Supervisor before the tool will be replaced by the Main Tool Room. A broken or damaged tool slip must be filled out and signed by the pipefitter for replacement of such tools. b. -USE OP HAND TOOLS . CD The pips wrench is designed for use on pipe and A. screwed end fittings. Due to design of the-wrench, the jaws have a squeezing action. If sufficient pull is applied, this squeezing action does severe damage to valve bodies, particularly the softer alloys such as brass. . . Note: Never use a pipe wrench as a hammer. (2) Strap wrenchs are designed for use on polished or ; plated surfaces to prevent marring. They are also useful in close places that won't accomodate a pipe wrench. (3) Pipe tongs are of the chain type or scissor type, - and are generally used for large pipe diameters. w Open or box end wrenches and socket wrenches are necessary when tightening flange bolts. It is importantto use the right sise wrench sinee slippage is ' dangerous to personnel and damaging to material. When possible, use a box end wrench for tightening bolts and the open end for a back up. ` Note: Never pull on a wrench directly toward your . ' face. If the wrench slips, it could cause ,' serous injury. . ' '' ; WA-TEX 004046 WA-TEX004046 ITEM NO. B-14 TRAINING DETAILS PAGE 119 {5) There are two types of'common vises ,, The pip.: vise Is "'' tised to hold pipe only. The combination vise may be ubed for other purposes. Valves or fittings should never be placed In the vise to make up a joint. There is too much danger 'of", distorting the fittings or forcing valve parts out of workingalignment. .. , . -t-Note;- Always open a valve part way before screwing /v ! it on a pipe joint. If a nipple or' jc-int of pipe"is screwed too far Into a valve* damage is done to the paddle seat. If the 'valve is in the closed position* this would locit the ... . . valve closed. Always place the pipe in the vise* then make up the fitting. Place the wrench on the end of the fitting next to the joint being'made up. " This lessens'possibility of distorting the fitting and gives better leverage. t. j WA--TEX 004047 WA-TEX004047 TEXACO INC. PUGET SOUND JPLANT PAGE Z?0 TRAINING DETAILS DEPARTMENT: PIPE classification! :PIPEFITTER (TRAINEE) ITEM NO. B-15 SUBJECT: DATE: JULY 1, 1970 SHARPEN TOOLS , a. ' GRINDING U) Stand aside from the wheel when starting it up. ^ (2) Use.the work rest whenever possible. It helps to hold . ;:,the work and gives added protection. t (3) If the tool is too large to be .sharpened with the work * " ':_r_esfiJh plac^e^ , rem___ove Jit t entirelyH.O /a\VnadW Mre./SpM.l'tace iitti. ra-.-&f4t-er \the,. jobis' finished.' Make sure the rest is properly adjusted /.nd. securely tightened. : \ . ' (4) Don't use the side of the wheel for heavy removal of : ; stock; The side/of a wheel, should be used only '.when .it'"Is necessary for/finished grinding of an object that .'must be 'flat and smooth." If the sides become grooved from `abuse,, they will'be useless for that purpose In the future. /!J, (5) ..When a great amount of stock Is to be removed, use only a moderate pressure against the wheel and move . ...jfche work from side to side across the face of the wheel. This i will cause the wheel to wear evenly and prevent grooving .When-grinding" thin material; such as sheet metal, t-*':- * V ...... ` jzn'i. JU. ~ -3 --^-3 rr. ~**;-.+.*A. *r* \ pointed" end near the work rest. The work may become .-wedged between the wheel and the work rest, pulling your . hand into.the wheel arid causing a serious injury. . r-. "' ^ . ' This type of-work'whould be held with the thin edge:up or.at least.45 above the horizontal and with the hands/in a. safe position so that they will not.be pulled into /the wheel.- ' . '. '' v/.-;- ! (7). : When grinding the contour of thin metal objects v;,'.'- - I; such as shims, hold the work firmly and flat against .-.-the work" rest. Vnder no circumstances tilt it up. The. .. . -wheel will knock it.out of your hands and may cause an injury. ,1'If 'the rest is not convenient, hold It above the rest and ' tilt-It slightly downward or turn It 9 and grind In a ..vertiele position.- '' . CAUTION: ' EVEN THOUGH GOGGLES ARE WORN, A GRINDER SHOULD NEVER BE USED UNLESS IT IS . PROPERLY EQUIPPED WITH A GUARD. IN CASE ,! WA-TEX 004048 WA-TEX004048 ITEM NO. B-15 TRAINING DETAILS PAGE 121 THE.WHEEL SHOULD BREAK* ' THE GUARD DL. ..L HOLD THE PIECES FROM FLYING OFF AND CAUSING A SERIOUS INJURY. . Do not use gloves for holding small objects or at any .other time that the hands must be held near the grinding wheel. If the gloves get caught in the grinder, they will pull the hands In with them. ' (8)' Grinding friction creates an enormous amount of heat. A'metal object held firmly against a grinding wheel ' may.be seen-to.turn red at the point of contact in a short time. (9) The heat generated by grinding is detrimental to both .` .- the work and the operator . The heat makes the work hard 'to hold if the object is small and the operator is ' attempting to-hold it in his hands. . - ' " 'Ordinarily this would not cause an unsafe condition, although'it may spoil the work due to .the operator turning the work"loose when 'ha burns his fingers. But 'if the work is being ground on the side of the wheel;,-when the operator drops it* it may fall inside of the guard, in which case* it will cause Quite, a commotion and may even break the wheel. '' (lO) Hold small work in some clamping device* preferably ` ... the self-locking pliers. Ordinary pliers will not hold. The high frequency rate of vibration will gradually work.the piece out of the grip of ordinary pliers. * :'i (ll) The'heat from grinding Is harmful to the work because ' - it causes expansion at the point of heat whicn may cause the work to crack. , , [12) Be especially careful when grinding sharp edged tools. -I- ;If `the metal heats to the point that it becomes colored, the temper of the tool will be ruined. .. , (l3) Keep the tool cool by immersing in. water often. Do not cool suddenly from a high temperature as this will'cause the tool to "check.11 Checking is the formation of many tiny cracks too small to be seen with the naked eye* which nevertheless weakens the edge to such an extent that it.chips away under, the least working strain. i WA-TEX 004049 WA-TEX004049 TEXACO INC. PUGET 'SOUND TfiNT~ PAGE 122 TRAINING DETAILS ' DEPARTMENT: PIPE CLASSIFICATIOlfi PIPEFITTER (TRAINEE) DATES JULY 1, 197Q ITEM NO. B-l6 SUBJECTS CLEANUP SHOP AND WORK AREAS The Shop should be kept clean and orderly at all times. In addition to the general departmental housekeeping practices listed on pages .10 and 11 of this manual, the following practices will be observed by every pipefitter and pipefitter helpers 1. All pipe and fittings will be returned to the proper bins after use. ' 2. Each pipefitter's personal tool box will be kept at the designated area, clear of all walkways when it is in the shop. WA-TEjs. 004050 WA-TEX004050 TEXACO INC. PUGET SOUND PlANT PAGE-123 - TRAINING DETAILS DEPARTMENT: PIPE .. CLASSIFICATION: PIPEFITTER (TRAINEE) DATE: JULY 1, 1970 ITEM NO. B-17 SUBJECT: TIE KNOTS AND HITCHES There are many different knot3 and hitches that a Pipefitter should know in order to do a particular job most effectively and safely. Following are several illustrated examples with instructions on the proper way to tie the various knots and hitches that are most commonly used in Pipefitters work. USEFUL KNOTS AND HOW TO TIE THEM IN KNOTTING--A Rope Has 3 Parts 1. THE END is the end of the rope with which you are working when you tie a knot. 2. THE STANDING PART is the inac-. tive length of the rope. - 3.. THE BIGHT is the central part of Ystjmdins the rope between the working end and the standing part. , AN OVERHAND LOOP is. made by crossing the end over the standing part. AN UNDERHAND LOOP is made by crossing the end under the standing part. - A TURN is taken by looping the rope i around an object--often another see- Jjw tion of itself. * A ROUND TURN is taken by looping the rope twice around an object, as C J shown. "OVER-AND-UNDER" SEQUENCE. In tying a knot, whenever two sections of xffh the rope cross each other, one must go over and the .other, under. Be careful . to follow this "over-and-under" ar ^*1uw rangement exactly--otherwise you get either an entirely different knot or no knot at alL "DRAWING UP" Once formed, a knot must be "drawn up" or tightened, ' slowly end evenly to make sure that all sections of the knot arrangement keep their place and their shape. Quick or careless tightening may result in a useless tangle AND--YOU'LL FIND IT HELPS TO NOTE HOW ROPE IS CONSTRUCTED STANDARD ROPE has three strands. A strand is made of-a number of yarns twisted together. THE LAY of a rope is the direction in which the strands are twisted. Most 3 STBflNO HlGHT tAia rope is "right-laid" -- the strands spiraling upward to the right--when you hold it vertically. WHIPPING KEEPS ROPE ENDS FROM UNRAVELLING A A good rope deserves good care. One way to keep your rope in good condition is to "whip" or bind the ends to prevent unravelling. In Splicing the sep arate strangs of the rope are also whipped for the same reason. To make the whipping, a fine yarn, marline or spun- yarn, Is generally used. The ordinary whipping is made by placing the end of the yarn at the end of the rope and then laying a.loop along the rope. You then wind the yarn tightly around both loop 'arid rope, thus binding them together. Wind to a dis- tance roughly equal to the diameter of the rope you are whipping. .. The whipping is finished by putting the winding end B through the loop--then pulling end A tight, until the loop is drawn back out of sight Both ends are then cut short to make a neat finish. ` . ' WA-TEX 004051 WA-TEX004051  ITEM NO. B-17 TRAINING DETAILS PAGE 124 unSTOPPHt KNOTS to keep hope ends from slipping THROUGH AN OPENING End or Stopper Knots are generally tied to keep a rope end from slipping out of a hole or a pulley-- also to stop a rope end from sliding through the loop of another knot and thus untying. Stopper Knots are often used to keep the ends of cord or twine from fraying. thk OVERHAND KNOT This is the simplest and smallest of all knot forms and the beginning of many more difficult ones. In general, use it only on small cord and twine, since it jams and is hard to untie, often injuring the fiber. To Tie: Make an overhand loop. Pass the end under and up through the loop. Draw up tight. the FIGURE EIGHT knot This is much easier to untie than the Overhand Knot--is larger, stronger and does not injure rope fibers. It is the best knot to use to-keep the end of a rope or "fall" from running out of a tackle or pulley. To Tie: Make an underhand loop. Bring the end around and over the standing part. Pass the end under, and then up through the loop. Draw up tight use BINDING KNOTS TO TIE ONE OR MORE OBJECTS SNUGLY TOGETHER E THE SQUARE or reefknot Used at sea in reefing and furling sails--ashore as the universal pack age knot for parcels and bundles. Though often used, it is a danger ous knot for tying two ropes to gether, since it unties easily when either free end is jerked. To Tie; Pass the left end over and under the right end. Curve what is now the left end towards the right. Cross what is now the right end over and under the left Draw up tight. DON'T TIB THE WEAK GRANNY KNOT Remember that the Square Knot pre sents -two ends lying together under one loop and over' the opposite loop --while the Granny presents, one end under and one over on both loops. Watch out for the Thief Knot, too. This has the two loose ends coming out of opposite sides -- instead of from the same side as in the true Square Knot. the SURGEON'S KNOT Often used for twine--chiefly to keep the first tie from slipping before the knot is completed. To Tie: With one end, take three turns about the other end. Bring both ends up. Pass one end over and under the other end. Draw up tight. WA-TEX 004052 WA-TEX004052 ITEM NO. B-l? TRAINING DETAILS PAGE 125 v LOOP KNOTS H TO HOtO TO AN OBJECT WHEN SECURITY ... .. COMES FIRST .. A loop knot; like a Hitch, fastens a rope to another . . object But usually, the loop Knot is first tied in ' the hand and then placed over the object--while the Hitch is tied directly around the object In general, the loop Knot is a more secure and permanent type ' of knot than the Hitch, because properly tied and . drawn' tight, it will not slip. Also, since it does not lose its shape, the same knot may be used many, times over. r . . ; ?. - SOME USES OF THE BOWLINE BOWLINE --USED FOR MOORING, HITCHING, LIFTING, AND JOINING- Sometimes called the' "king of knots", the Bowline never jams or slips if properly tied Generally tied ' in the hand, it can also be used as a hitch and tied directly around the object To Tie: Make an overhand loop with the end held toward you. Pass the end up thropgh the loop, then - up behind the standing part--then down through the loop.again. Draw up .tight .. .. ' Too inMocttndyootines eon he used toJoin mo/topes together The Boofinr It Tiedin o Hnostr end Thrown outre Post when Uooring A Bootine a Bed in the end ofoffop'e for Hoisting - A BooHnecmhetiedosoHiUhdirtcHf cmundofbstor offing when mowing e boot orhiithlng o horse. the DOUBLE BOWLINE MAKES A GOOD SEAT SLING . To Tie: Make an overhand loop with the end held to ward you, exactly as in the ordinary Bowline. The differ ence being that you pass the end through -the loop twice, --making two lower loops, A and B. The end is then passed behind the standing part and down through the . first loop again as in the or dinary Bowline. Pull tight Outside loop B goes under the arms -- inside loop A forms the seat WA-TEX 004053 j WA-TEX004053 ITEM NO. B-1T TRAINING DETAILS USE THE ON TO LIFT AN INJURED MAN PAGE 126 To Tie: Double the rope, make over hand loop C, and draw Jpop-end D up through it. Then pass loop end D, to wards you, down and oyer loop sec tion A. Bring up in back until D lies behind-standing part A. Draw loop D tight by a slow even pull on upper right side of loop A. To use, one leg is put through each loop and loop D passed under arms as shown at right. THE LIFTS A MAN OR SLINGS A LADDER USED FOR TOWING AND HOISTING Form three loops, as shown, in any central section of the rope. Turn the large center loop A-B down. Enlarge it so that it encircles the smaller loops C and D. Put your hands through each of the small loops C and D, grasp each side of large loops A and B . . . pull up through to com plete the knot. Used to lift an injured man. like the Bowline on Bight, above--or to sling a ladder as shown. This is a simple, convenient Hitch which does not jam, and come undone readily when the pull ceases. It is used, mainly to tow or hoist cylindrical objects, such as logs, spars, etc., also in handling cargo, to hoist small crates and bales. It is used with one or more Halt Hitches made with the standing parts, for towing a spar or hoisting a timber on end. To Tie: Pass a rope around the object and take aturn with the end around the standing part. Then, as shown in the diagram, twist or turn the end back on itself. Three turns back are sufficient and they should follow the lay of the rope. MA-TEX 004054 WA-TEX004054 PAGE 187 ' TRAINING DETAILS DEPAKTmT? PIPE . CMSgXPltolGWr^PlPEPOTEfT IfjfflZilEl DATE? JULY ls 1970 ' " - -- ~ ITEM MOo B-18 ~" SUBJECT? RIGGING AID HOISTING OF MMlAL:%di^AN!r^ EQUIPMENT RIGGING : Rigging is a v^ry important Job and extreme care must be taken in doing the job. The right size choker with enough capacity .to do the Job must be used. Never put choker around an "I" beam, angle or-channel without a wooden block between choker and sharp edge. Check choker and cable capacity and methods for rigging as illustrated here or in rigging book in pipe library. HOISTING . Du allowance must be mad for all variations and unusual conditions of operation of the particular sling application. As in all wire rope practice,, the handling of the load shopld provide .a slow smooth start with no Jerksj, and the rate of acceleration anddeceleration must be within reasonable limits. All slack in the sling should be carefully taken up before beginning the lift, as slack taken up suddenly will affect the sling much as a bundle wrapper snaps twine, fuch damage is done to slings by carelessly attaching over rough or sharp corners. Therefore, suitable blocking should be used. ' i I WA-TEX 004055 WA-TEX004055 ITEM NO* B-l8 C3 CO CO LU --1 CSS . s: TRAINING DETAILS PAGE 128 5MC 0OC.2A e>= 3S . Q a mwvj-ino^Mcngw^^oao ^1 _ -8g ^fHC4c\ia>fo^f'ttf>u>Nooa>o i^ M w S> M o 0 CM in M w q m W3DS uHX X r< H aO. HtMCeASl , <(. * ' *^4r4c\ic4co^t'ocoH*^H,t,NH* o <9 loi* OOJ 25tAB #o. CUA* -MO*luj o 7h*- % 1 H <: {o S <*. in to in H H H Ol "SoONNON'tONOq ZD - 33w>Wbio o<a. u atel 5K ted COA "Ka 25 IS PD O"* S w S n m w -A. + w cn m. w * * * * * p -4 t-j soi oi ^ ^ rtCjJncOMtooiDWtnMajoro ' 'HHNMW'tSNO--tNH Straight Pufl u> to to to _ __ LoQOUS. i u iflm - ETER COHtH,COHNH^^0 5. rtMHWI>rt3?inwN r* HHH +* ^ UgE| cthO-JTS3 5 W X OT TJ "5 Ji > .2^ c *|2c 2i 3 CL'S? J2f W o> vA | IS >s--^aDoE. ,rltis>oT* m s!E 8 h9* ,8 s w S*a ffl'g-- 2 -(15 TJOO C 3TM5 T3 rt r .wC rt w _ * *"to-- a*a ,g5gf IS <3 BsSg c > co cogg T.c,.eCobOoaH*.o"? 5t f ^-Ss. "Sglg i*=d sW als U3fl0 S .9 3 r O 2 +-- INCHES 1 0 03 0 0- CD S3 ra o Si (D .001 p +3 U P P 01 0 cm Q> s< O Si CO -P m 03 p >> to * S0J<tMIH0 003 o di i--i 3 >3 0) bO P P S3 S3 P (0 O C/2 3 S3 53 co -P O 0) 3 P x; O >sP 3 -H Si Si Si Si 03 CO P bQ> owe 3PP 3 H H (tf O H KJ |>i-H -0 C CO O <U O O 0 > P O -o S3 0 0 fOfi 03 S3 OP 0 G. S3 s O Ei rl P 1 r-| o ro <D O H0 0 B O O 03 0 W P 0 Si C 3 S< p <*H .01 P PO -0 0 03 P Si 0 bCO bCO 0 P co S3 W ^ rl X p P H CD O0 JT-3) l-0J1 a) C co 03 3 si C ^ 0) S ~p a> co cp <u Si 03 s.isi osi a <d p S3 p~ 3: CO Si P P Si Si E P C o CD m S ri 'h 3 0 O CD p OS o iC-Dt bO C Pattfol CD S3 OP an bO bO S3 C co p cZn* B co pO a> * W o co xi i--! rl Pu c Si CD C/3 P. P ho CQ -H 0) TD S3 * *0 *CHO'OCD *CH r-i xn CO P C < *H r-1 a> CD O CO bO 3 .02 P CO X3 P in bO U0 cop- S3 P -0 03 bO U S3 0 -03 S3 S3 bO c P > CD T3 0 .P S3 0P 3 OO .P 0> PO Si 0 0 0 o CQ 02 3 r"t H Q) CD CQ r-i si c 0 0) 0 -o 0 0Q <D :s 0 -P P 0 CQ 0} CQ s p CD ro w O s o U i--i CQ X C o c O asj *rl Q> . E2.m^i g A--^es-J K|S 2co w.] OCMmCJOlh'C3t;03WO< OOOMrou>r^Mir>or^t;OC inininif>inm.0 0i^i^wgc Q3 g^l / N M o w o to o to o to o in o tn o r^T-HtMCJcoco'ct^inuno j WA-TEX 004056 WA-TEX004056 ITEM NO. B-l8 TRAINING DETAIIiS PAGE 129 SUN& Hated Capacities m Tons of 2,000 pounds f Hope Diameter Inches ** s' K Mis 3u fl? 5,' J Hu IX Single Kltng Straight Choker Pull , Hitch .10 .14 29 .22 .52 .39 .80 .60 11 .82 yL6n 1.2 1.5 2.6 2.9 32 2.4 4.5 ' 3.4 6.1 4.6 7.9 30.0 12.3 5.9 7.5 9.2 T vo Legs or [Jaskcl Hite h* Vcrticat 30" 45 60 1 A /I /I .38 .58 1.0 1.6 2.2 3.2 4.0 5.2 .33 .50 .86 1.4 1.9 2.8 3.5 4.5 .27 ,41 .71 1.1 1.5 2.3 2.8 3.7 .19 .29 .52 .80 u J.G 2.0 2.6 6.4 5.5 4.5 3.2 .9.0 7.8 6.4 4.5 12.2 10.6 8.6 6.1 15.8 20.0 24.6 13.7 17.3 21.3 11.2 14.1 17.4 7.9 10.0 12.3 Loop Dimensions \V Inches US .22*a 3 3H 4 4*4 5 6 . 7 8 290 L Inches 3 3 45 6 7 8 9 0 22 14 16 15 20 j WA-TEX 004057 WA-TEX004057 ITEM NO. B-l8 TRAINING DETAILS PAGE 130 Measurement for Lengths of Rope with Fittings on the Ends There are .many requirements for' slings with, de mand for innumerable designs, but a very large pro portion of sling use can be adapted to use some more ,or less standard types. A separate pamphlet showing numerous designs covers this specialty more fully. Factors of safety may run from 4 for some special cases to 8 or more -- usually averag ing 5Yz. First consideration, however, must be given to the angle at which the slings depend the load from the lifting hook. The sketches below show how sling stresses in crease with shortening the distance between the load and hook, the load lifted in each ease being tho same. 11 0> *3 j mom | 0S 1 >000 AngU 9mg H*kt W.th HenIMUl, <PUwfeltLtotm4 Per Cent ol Lott Crrjfd by s 5736 10 2878 15 1631 8.7 17-3 25.9 20 1460 25 1183 30 1000 34.2 42.2 50.0 35 872 40 778 45 707 57.3 (54.3 70.7 50 053' 76.5 55 611 81.8 60 577 S'J.G 05 552 70 538 75 518 90.6 93.0 90.5 80 508 98.4 85 502 99.fi 90 500 100.0 j WA-TEX 004058 WA-TEX004058 ITEM NO. B-l8 TRAINING DETAILS PAGE 131 STANDARD CRANE SIGNALS For use with power equipment and rigs. SIMM& on Boom or PACK c;On BRIDGE ^ CRANE Circular motion with hand with fingers pointing downward Circular motion with hand with finger pointing upwards Hand outstretched with finger pointing direction of travel 7 JTRAVEL K'l] HA ADS ME ,, ; ^ wtroureo m $Kii : JMCKCTMO Of 0 <-) TRAVEL thumb indicating boom down thumb indicating boom up Rotate hands in direction of travel desired hand and make circular motion. Use preceding and in conjunction with regular signal. Hand outstretched palm down wave hand back and forth Both hands outstretched palms down and wave back and forth m-TEX 004059 WA-TEX004059 GOOD AMD BAD DIGGING PRACTICES ITEM NO. B~l8 TRAINING DETAILS C WA-TEX 004060 WA-TEX004060 PAGE 132 TJsff o f ftrim M . m vvA knife* P<xiV arm tn rn fd rtn t m ma p p l ic a t io n o s rove WA--TEX 004061 WA-TEX004061 Knot B ow line on a THsiht TEXACO BSC PLANT"" PACE 134 TRATH-INg'DETfiTIiS DEPARTMENTS PIPE ,, x CLASSIFICATION s PIPEFITTER (TRAINEE) DATES JULY 1, 1970 ITEM NO, B-19 CHECK TOOLS A Pipefitter should periodically go through his toolbox and inspect the tools that have been assigned to him for use in his personal job performance. Inspect fors 1, Chisels with mushroomed heads, 2, Loose hammer heads, % Pipe wrenches with worn out jaws. 4. Channel locks that either have a loose rivet or worn out adjusting positions -er-Jboth. 5,, End wrenches that are stripped or cracked. 6. Dull hacksaw blades. If any of the above are detected, they should, be immediately replaced All tools should always be cleaned after use and before putting them away in your toolbox ! WA--TEX 004062 WA-TEX004062 TEXACO INC. PUGET "SOUND PLANT ' PAGE 135 DATE; JUDY I, 1970 ITEM NO. B-SQ SUBJECT; INSTALL AND REMOVE BLINDS AND ORIFICE PLATES ii-'igaw^n----w^wpi mwii wm ` ' BLINDS (1) Blinding is a large portion of the pipefitters work at a refinery. It is py blinding that we are able to enter and work on various types of equipment. , . (2) A Safety Work Permit must be obtained. (3) Blinding is done by loosening the boltB on flange and taking out one less feha&. half; of the bolts, spreading the flange with a wedge pr flange sprs^fe'r, removing old gasket, cleaning both flange faces with seasaper, putting panbakd blind or figure eight blind in between flanges With gasket them evenly on all four sides first and then going back and 8 tightening all bolts .sufficiently-. .- (4) Be sure to loosen the bolts on the opposite side of the' flange than you are on. This way the pressure will blow away from you. ORIFICE PLATES ' (.1) Orifice plates are normally; inspected during shutdown of the units. Pipefitters remove and Install them after, calipering,. . , , i (2) A Safety Work Permit is required. (3) Installation and removal of orifice plates require the samei' procedures as blinding noted above. ' W&-TEX 004063 WA-TEX004063 TEXACO INC. PUGET SOONl) TEkht~ PAGE 136 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION: PIPEFITTER (TRAINEE) DATE: JULY 1, 1970 ITEM NO. B-21 SUBJECT: UNHEAD AND HEAD-UP VESSELS AND SIMILAR EQUIPMENT ' Heading and unheading equipment ia done by having the..; right tools for the job, knowing the size bolts and nuts, and having the right size gaskets for the head. Be sure the surface of the heads are clean and properly lined up. When working on vessels and similar equipment there are certain safety precautions to be taken. First, obtain a Safety Work Permit, Form Rr24l-A* The permit will state the precautions that mdst be taken to unhead equipment, ;. ^ i WA-TEX 004064 WA-TEX004064 ITEM NO. B-21 TRAINING DETAILS PAGE 137 SECTION 1 ' ; Heat Exchanger Homendature * . N-2 NOMENCLATURE T MEAT IXCMANER COMPONENTS ' , For the purpose of establishing standard terminology. Figure N-2 illustrates various types of heat ex :. ; changers. Typical parts and connections, for illustrative purposes only, are numbered for identification '' 'in Table N-2. TABLE M-2 1. Stationary Head--Channel ; ' 2. Stationary Head--Bonnet : ' 3. Stationary Head Flange--Channel or Bonnet ` 4. Channel Cover 5. Stationary Head Nozzle '6. Stationary Tubesheet . . 7. Tubes ' 8. Shell . -9. Shell Cover ' 10, Shell Flange--Stationary Head End 11. Shell Flange--Rear Head End 12. Shell Nozzle - . 13. Shell Cover Flange - . - 14. Expansion Joint . ` . .. 15. Floating Tubesheet - : . 16. Floating Head Cover . '' ; 17, Floating Head Flange 18. Floating Head Backing Device 19. Split Shear Ring 20. Slip-on Backing Flange 21. Floating Head Cover--External 22. Floating Tubesheet Skirt 23. Packing Box Flange 24. Packing . 25. Packing Follower Ring 26. Lantern Ring 27. Tie Rods and Spacers 28. Transverse Baffles .or Support Plates 29. Impingement Baffle 30. Longitudinal Baffle 31. Pass Partition 32. Vent Connection . 33. Drain Connection 34. Instrument Connection 35. Support Saddle 36. Lifting Lug 37. Support Bracket 38. Weir 39. Liquid Level Connection FIGURE N-2 4 STANDARDS OF TUBULAR EXCHANGER MANUFACTURERS ASSOCIATION WA-IEX 004065 WA-TEX004065 TEXACO ISC* FGgfPSffWmST"- PAGE 138 ` TRAISXSG 'PETRIES DEPARTMENT; PIPE eiASSIPiCATCOS; PIPEFITTER (TRAINEE)' DATE; JULY 1, 1970 . ITEM SO. B-22 ' . SUBJECT; MOVE AND ASSEMBLE QMS AND TWO STAGE SCAfrFOtoS ' ' The following illustrations give in detail the proper assembly of SafWay scaffolds iano accessories. All planking mbst be Qi* sound quality, rough grained and free from knots* Also it should overlap at least 12 inches and be cleated at both ends* X i WA-TEX 00406.6 WA-TEX004066 Safway equipment is designed and Constructed with the utmost consideration for safety. However the high degree of safety constructed into the equipment cannot offset carelessness on the part of the erector Or workman. With this thought in mind the manufacturer call? attention to the following rules and regulations which should be strictly adhered to. 1. Provide sufficient sills or under-pinning in addition to standard base plates and all scaffolds to be erected on filled or otherwise soft ground. ' 2. Compensate, for unevenness of ground .by .using ad justing screws rather than blocking. 3. Be sure that al! scaffolds are plumb and level at . all times. . '"X Anchor running scaffold fa wall approximately every -28' of length and 20' of height. Use additional care - ' when using pulley arms. .5. Do not force braces Jo fit. Adjust evenness .of scaffold until the proper fit can be made with ease. ' 6. Guard railing should be used on all scaffolds regard less of heighf. ' 7. Use fodders when climbing scaffold rather than the cross braces. " 8. Do not use putlogs as side brackets without putlog supports and thorough consideration for loads to be applied. ' 9. Never tie two putlogs together to accommodate sp.ans of greater than 20/. No putlog should have less than 12" of overhang af point of support. 10. Always use pOtlog supports where spans are greater than W. -- 11.'When using 16' and 22' putlogs in parellel, be sure to brace between them. 12. Do not omit or fail to tighten all baits and wing nuts that Ore a part of the scaffold. Horizontal bracing should be used to prevent racking of the structure. '1-4. All planking used on a scaffold should be of -sound qualify, straight groined, and free from knots. All planking should have at least .12" overlap or be cleated at both ends. Secure all exterior planks to scaffold. 15. Handle all rolling towers with additional core. [a] Towers of a height greater than three times the minimum -base dimension must be guyed at all times. " (b) Apply all caster brakes when not in motion. . (c) Do not ride towers. {d) Look where you are going .with a rolling tower. (e) Don't attempt to move a rolling tower without sufficient help. fiaf `it m... \t '0".HtpymHi C :T--K |f) Provide unit lock arms on all towers. (g) Do not extend adjusting screws more than 12". |h) Use 5" casters on lowers under 36' in height and 8" casters on -everything .over 30', (i) Horizontal bracing is to be used af -the bottom, top and af -intermediate levels of 30 feet. (j) Do nof use brackets on rolling towers. Id. Guy all fixed towers every 30' of elevation. 17. Do nof attempt to use Safway Scaffolds as material hoist towers or for mounting derricks without first determining the loads and stresses involved. 18. Inspect all equipment before -using. Keep all equip ment in good repair, avoid rusting--the strength of rusted material is not .known. 19. Never use any Safway equipment .that is damaged or deteriorated in any way. , 20. If in doubt .as t,o ability of Safway to do a particular job, consult the Home Office. Don't take chances, 21. Familiarize yourself with the Safety requirements of the State Codes and be governed accordingly. 22. Contractors .do nof rent or loan Satway equipment to others. 23. Do not permit Safway equipment to be used by any one not familiar with these rules. . . .24, Establish the location of oyerhead ELECTRIC POWER LINES on every' job where scaffolding is to be used. CALL POWER SERVICE COMPANY FOR ADVICE WA-TEX 004067 WA-TEX004067 SAFWAY STEEL PRODUCTS, Inc.,, originated .. . sectional tubular steel scaffolding with the F-5 mason frame, which was designed to eliminate the hazards of wood scaffolding. Through the years, Safw.ay developed almost two dozen other types of frames and a complete line of accessories to. meet every scaffolding requirement. Each frame is constructed from highest quality structural steeT tubing,. fabricated under quality controlled conditions, and tester and approved by the Pittsburgh Testing Laboratory'-find-: Underwriters' Laboratories, Inc. ir.~rt~--.rr F-3 Frame 3'0" high, 5'0" wide Used primarily, with other Safway frames to obtain intermediate planking heights. As with other f'F" .frames, the F-3 may .be used upside down or right side up for either an 13" or 36" planking height. Has 2' stud centers for braces. F-5 Frame z'Cj' higlb'S'O" wide Basic Safway frame with 4' stud Centers. Can be used with all other 5'wide frames. >: FO-6 Frame j II FO-6L Frame.' - ' ' 6'4'-' .high, 5'0" wide ~ , Open end frames allowing head room clearance along entire platform for person nel-ana materials movement. Have three levels for over hang brackets. FO-6 With heavier^ -tubing than the FO-6L is recommended .for your .higher jobs. 4' stud centers .for braces. F-46 Frame 4'6'' high, 5'0" wide For'specific use in those areas requiring a 4'6" planking height. 3'6" stud cen ters take the B-736 brace only, making a scaffold section 5' x7` X 4'6" high. ALUMINUM SCAFFOLDING Where extreme light weight or extra go.od appearance is .desired, Safway offers the following frames and accessories in aluminum (the prefix "A" indicates aluminum): AF-3, AF-5, AF-6, AFL-5, AFL-6, ALSB-1, ALS-5, ALS-6, AB-72, AB-74, AHB-5, AGR-1, AGR-5, AGR-7, AAL-1, ASU-5, ASU-6, AP-22 and ACP. -~l`-y.Fdr utmost rigldtysafety'-dhd ieliobijUy^wingnut.asseinbty^, forAottaching-apss-.fcracesvis' jtill favbjed in many .areas.r.. KpAn:unlhreadeA.leod-irr'makes'-wiflg.rtut attachment'quick;i jyb'n'd ecsy. Deep threaded studf-and ieompfete.'tfeMntents"-'; the^framd pVovide safe, 'ithblc -ConnecKorts-.vAU:frames.?: ^.^illustrated in this catalog are-shown'.with standard Safvtay KlViS metis' Unless `'Quick-L-oel(s'' ,ar*' specific,,jplrframe ; (vit-bldets will be-shipped with wincfnuf.atfridimerits. :".\- WA-TEX004068 ITEM SO. B-22 r < ' ' ' i i ni j i 4i * .FL-3 Frame 3'0" high, 5'0" wide 1 Ladder frames provide multiple planking levels within each frame. The FL-3, low* est of the group, has 18" or 36" levels. May be used with other frames for inter mediate planking heights. Has 2' stud centers for braces. TRAINING DETAILS . f 1 ; ji i ____ __ _______ I ... ............... . p FL-5 ri jeno !i'0" high, 5'f;" j i t | This size of frame is preferred by most scaffold users as basic equipment. May be used with all other Safway frames. Has 4'-stud centers for braces. nfr I -1 ! i RAGE 141 ! r i 15-3 IS-1 : FL-4 Frame 4 0" high, o'O" wide Provides three planking levels.. 4' high mason frame is preferred in many areas. Has 3' stud centers for.braces. . r> i; i 1 i i 1 i [ ' ..... j i ________________ - i i FL-46 Frame 4'6" high, 5'Q" wide i Ideal as a mason frame in those areas desiringa 4'6" high lift'between full plank ing levels. Has 3 '6" stud centers for only the B-736 brace. -j i FL-6 Ftomc6'4" high, 15 0" wide Provides head room clearance between full planking levels and three inter mediate planking levels. Permits per sonnel movement along entire platform length. Has 4' stud centers for cross braces. LADDER SECTIONS 2' wide ladder sections may he assembled into separate scaffolds ar used with 5' wide frames to fit around obstruc tions. Ideal for narrow working areas. The LSB-1 wide base .section permits building higher independent rolling towers. .Ladder section frames accept all standard Safway accessories. Specifications: LS-3. ...............3' 0" high, 2' 0" wide............. 2' stud centers. LS-5.................. 5' 0" high.S' 0" wide.______ 4'.stud-centers. LS-6...........,, 6' 4" high, .2' 0" wide............ - 4' stud centers. LS-10..............10' 1" high, 2' 0" wide............. 4' stud centers. LSB-1.......... .3' 7" high, 4' 0" wide.... ...2'stud centers. I.S-Sf'-. c QL QUICK-LOCK For fastest possible scaffold erection, Safway's Quick-Lock stud is ' highly recommended. The built-in gravity latch locks the brace in place with the frame either right side up or upside down. With Quick- Lock you can attach cross braces .with only one hand. Just slipping the brace .aver the stud (even from a lower level) locks the braces firmly In place. To remove the brace, raise the latch and the brace comes .oft. All Safway frames are available with Quifk-L.ocks or /A WA-TEX P04069 tse-1 WA-TEX004069 I I I i i I i Gess i'.z-e: ! Cross braces join together any two Safway I frames of the same size, attaching to the r frames with wing nuts or Quick-Locks. All Safway tubular steel braces are center piv i oted with aircraft-type rivets, increasing i stability and load distribution. Stud centers on each frameand thedistanee to bespanned i between frames determine the proper size i of cross brace. Specifications: Frame Brace Distance Stud i Height Number Spanned Centers i B-32 Br42 For B-52 i 3' high - B-62 frames B-72 i B-82 B-102 i For 4' high frames B-73 .3' 4' 5' 6' 7' 8' 10' T 2' 2` 2` 2' 2' 2' 2>\ .- 3' For 4'6" high frames B-736 T 3'6" B-34 - B-44 For 5', B-54 6'4" - B-64 and lO'.i" B-74 high frames B-84 B-104 3' - 4' 4' 4' 5' 4' 6' 4' V 4' 8' 4' 10' 4':. Coupling Pin. . <Q& Connects two frames vertically. Of stighdy smaller. diameter than the frame legs, coupling pins fit into ' t legs. Legs of the next higher frai^> fit over the pins. Pins extend 4" into 1 each leg, providing a safe, stable n connection. The 1" swaged collars on the pins separate .the frame legs and must be considered when figur ing height of desired scaffolds. Semi fixed .coupling pins -available upon CP requesr. isnsf Lock Arms Positively lock two vertical scaffold legs b.y connecting to gether the studs on each leg with a steel strap. ULA-5 locks -together .3', 4', 4'6" and 5' high frames, and any oftheseframes on top of 6'4" frames. UL.A-6 locks <5'4" high frames together or to any smaller frame below. ` li .....T,T7-T-^... 'ni rv, , f' ' ` . _. ;' ; S ; FE-l provides extra 5" high -planking platform when placed upon coupling pins at highest work level. Extension posts (FE-3 -and FE-4), Used with the appropriate sleeps size (EE-5), provide 2" increments of height adjustment up to 2?` Extension posts and sleet. ^ -also may be used on lower scaffold legs to adjust for un even ground. _ r: Extendable end frames ar.e specially de signed to permit getting scaffolds through small openings for normal sized assembly * within, such as setting up scaffolds within boilers. Frame horizontals extend to limits . -of the couplers, from 2'3" to 6': C-23.-.,...........1................................ 2'3"to;3' 1 034.............. ............................................. 3'to4' ` -.-4045....'..................................................4' to5'` . ^ ^T-S6.............. ,.............................. ............5' to6'i Two.ofeach neededperframe. j* A-\ r i & e~ ac__ i <" i i i j i i i. Reinforce scaffolding subject to unusual stress. Provide increased rigidity and i stability, particularly on.high towers- Sub i stitute for cross braces when open areas between frames are desired, provided each i adjacent bay is cross braced. Specifications: i H8-5, 7 and 10....Horizontal BraceS..,- 5', T and 10' long. i HBS-5, '7 and 10....Spring-loaded Hpr- izOntalBraces... .5', 7'and 10' long. i HDBS-5, 7 and It)....Horizontal Diago i nal-Spring-Loaded Braces....5', 7' and 10' long. W2V-TEX .004070 Fit into legs of all.Safway frames to provide a stable footing for built-up-scaffolds. Osorf ground, sills are recommended unt base plates. BP-I is used on level grouncj BP-2 on sloping ground; BP-3 for offsetting frames to reach receding structures, i. e., spires, obelisks, etc; BP-4 is same as BP-3 with extra.long flanges; BP-5 permits setting two frames close together; BP-6 permits setting two frames close together on top of another frame; BP-7 permits setting frame leg dose to walls or obstructions. WA-TEX004070 ITEM HO. B-22- TRAIHING DETAILS PAGE 143 Putlog Rangeis Used as structural spanning members between scaffold towers, reducing need for solid built-up scaffolding. Also used to pro vide caniileveredjplatfpr.ms.and to erect finely adjusted staggered towers- built upon other .scaffold towers. Four sizes of putlogs are available: 8',. 12', 16'and 22'Jong. Each putlog requites two putlog hangers to attach putlogs to frame scaffolding. ' SirpcRk- ` fWs; i'-vs Ptf-S PH-3 PH-1 permits mounting putlogs parallel to any horizontal frame member. PH-2 permits .mounting putlogs at right angles to any horizontal frame member. PH-3 permits mounting guard rail posts .on .8' and 12' putlogs,.and on end sections of 16' and 22' putlogs. . PH-4 permits mounting guard rail posts on deeper center sections of J6' and 22' putlogs. PH-4 ` PH 3 Putlog Support Used for putlog bracing as extra safety equipment. Heist? Substitutefor cross braces to provide open .area betweea frames. C' Useful for building platforms over fixed equipment or obstruct ions. One type for 10' spacing (ST-10); two types for '7' spacing, one with single horizontal bar (ST-7S), other with double horizontal bar (ST-7). A<~j.ustab!e Sett-sty Jctcks Used to level scaffolding on uneven terrain and to finely adjust scaffold shor ing under formwork. .Have maximum adjustment range of 18". AL-lA has removable handle and is recommended pearpedestrian traffic or confined areas. Both jacks can be used with .casters or base plates. AL-l AL-1A I------------ i I 3 3 >, I :1 Combtn.~*ion Adjustable Jack ancJ Base Plate Frequently used .where repeated "usage allows the AL-2 to be used and stored in the set position. Has maximum adjustment range of 5". f 1 1 l- ~ -A AL-2 f i i I ? i f Jt i i .4 t .1 l rt-d H-2 Light duty hoists attached to standard Safway scaffolding bring materials to work ing platform .at waist level. H-l attaches to standard guard rail post. .H-2 and H-3 at- vawk va or~r . 0'-*ifior,g Brackets .Fit on any horizontal frame member to provide additional work platforms or extended material platforms at various height levels. Help locate planking between pilasters, oyer beams or around other obstructions. Three sizes of side brackets attach parallel to the frame, anjd.two sizes of end brackets fit at right angles to the frame. WA-TEX004071 Swiveling Caste/s Inserted into the legs of frames, casters provide rolling scaffold towers. Double brakes lock both wheel grid swivel. When re leased, casters roll and swivel .easily through 360. Available in 5", 6" and 8" wheel diameters; steel, solid rubber or com position tires. Aluminum and Steel F'tciiik Sturdy, lightweight steel or aluminum plank have rough, raised surfaces for safe, secure tread. Made for 6'.or 7' Spans. Ideal for rolling towers. AP .... aluminum plank. SP .... steel plank. PUiitlt Cit,*:- hocks planking where desired on scaf fold as extra safety precaution. Also a quick, simple means for attaching toe boards.to guard rail posts. ' ' Cell'd K*s*; Ksst Provides support for two guard rails, 22" and[40." above frame legs, with a base similar to a coupling pin,`the posts fit into the top of frame legs. .Guard rails attach to posts with standard wing nuts. Many areas require guard .rails for scaffolds oyer 5' high. Guard Reds GR--(Sc-iiQtb pf-sp.a .Attach to guard rail posts with wing nuts. Available in 2', .3', 4', 5', 6', 7',-8' and 10'lengths. Safety chains are,sup- - plied for spans over 10'.long. *=* -- 1 ~~ 'R-5 ' Gfi-l G|7._7 12. .... GRC Guard Rail Gti-s'-a Provides a wing nut and stud for attaching guard rails or .cross braces to any part of a scaffold frame or accessories. Ftiiefing Device Attaches over wing nut stud, permitting assembled scaffold sections to fold into narrow units for pass ing through such openings as doorways, etc. Particularly useful with rolling towers. FD-1 must be attached to each frame stud. Special diagonal braces, PB-57 for 7',spans and D15-510 for.10' spans, iockthe scaffold sections in position. FD-1 Climbing L-adders With their equal distance between rungs, climbing ladders are recom mended for climbing and descending scaffolds. Individual sections fit to gether to form a continuous ladder as high as the scaffold. Self-locking de vices securely attach the ladders to the end frames. Five ladder heights offered; 3', 4', 4'6", 5', 6`4". LA-5 pu l* Jf *jr'\ t i i SU-5 Steel Stair Unite A/' Provide-an interior stairway within scaffold.bays. SU-5 is designed for 5' high frames, SU-6 for 6'4" high frames. Both' units ar.e .built for '7' long spans. SUH-5 hori zontal braces must be .used on the bottom frame for at taching (be lowest stair unit. i'e.' 1 kf high, ii'O" wide By insertion in the top of frame legs, the SF-2 provides a "foot scaffold" or storage space for mortar boards or other materials at a good working.height. Curved plank supports preyeijt planks from sliding off. May be used on either frame leg. ki SF-2 -4 f?c;cc Gamp Steel clamp for tying adjacent frame legs to gether. May .be .used on all other adjacent parts of Safway frames. "L" Erpee Brocket Permits attachment of guard rails or cross .braces at right angles to the frame. Also used . .for "tying in" with guard rails. Korfesnta! Btoce Bracket Allows Cross braces to be placed horizontally between frames -where additional rigidity is desired. HBB attaches to frame studs. For use with .B-7-f braces WA--TEX 004072 WA-TEX004072 TEXACO INC. PUGET^OgNir 'PfaNT-' ' PAGE 145 TRAINING DETAILS DEPARTMENTS PIPE CLASSIFICATIONJ PIPEFITTER (TRAINEE) DATE; JULY 1, 1970 ITEM NO. B-23 SUBJECT; INSTALL LUBRICATORS Oil lubricators are installed in service air lines to lubricate air operated tools. Lubricators used at Puget Sound . Plant are screwed and must be placed in line in the upright position Just before the service connections. j WA-TEX 004073 WA-TEX004073 TEXACO INC. PUGET SOUND PLANT PAGE 146 TRAINING DETAILS DEPARTMENT.; PIPE CLASSIFICATIONs PIPEFITTER (TRAINEE) DATE s JULY 1, 1970 ITEM NO, B-24 SUBJECT; LAY.OnT AND PREFABRICATE PIPEWORK ' Layout and prefabrication of piping is covered extensively in Basic Training Item A-1'5 and Item A-1.7. In addition, you should always remember the following; ' ' A. Welded When you are fabricating welded pipe, leave a 3/32" gap between all fittings and pipe to be welded so that a welder can get good penetration. Also, all fittings and pipe are to be plumbed, leveled and square. B. Screwed , When you are .fabricating screwed pipe, put the right amount of threads per inch on the pipe. Set dies so they don't cut too deep a thread. You should be able to screw fittings.three turns by hand. WA--TEX 004074 WA-TEX004074 TEXACO INC. PUGET SOUND PLANT PAGE 147 TRAINING DETAILS DEPARTMENTS PIPE OLASSIFICATIONT^PIPEPITTER (TRAINEE) DATE? JULY 1, 1970 ITEM NO. B-25 SUBJECTS OPERATE PIPE MACHINE PIPE MACHINE (1) The pipe machine Is used to put threads on pipe. Our pipe , machines thread 1/2" to 2" pipe. The dies for the machines . are adjustable and there are three sets for each machine. . ' They are :l/2" and 3/4", 1" and -1-1/4", and 1-1/2" and 2". ' Extreme care should be taken when threading pipe to be surf '-^g^pfare set for the right pipe size. (2) Listed below are standard*pipe threads* Nominal Diameter Inches, 1/3 1 1-1/4 1*1/2 '2 Threads Per Inch 27 18 18 14 14 11-1/2 11-1/2 11-1/2 ` 11-1/2 WA--TEX 004075 WA-TEX004075 TEXACO INC. PWGETSOTJN3T PLANT PAGE 148 .......TKAINlNg' DETAILS DEPARTMENT 8 PIPE CLASSIFICATIONS PIPEFITTER DATEs JULY 1, 19T0 ITEM NO. B-26 SUBJECTS BEND PIPE Bending pipe is a good method of installing pipe* there are fewer fittings required, therefore, less time is required for the installation and there is less resistance to produet in the line, primarily, pipe bending is used on lines for catalyst and steam tracing. The following pages illustrate the operation and application of pipe benders. j WA-TEX 004076 WA-TEX004076  - ITEM NO. B-26 . TEXACO INC PAGE 149-- METHOD OF USE .. OF THE Newly designed Attachment for Making 180 Bends With Tai Pipe Benders ' The 180 attachment consists of the following parts: #100 . 4 Guiding Plates, 2 on each side. #101 #102 4 Rbllers and 4 Roller Pins .2 on each side. ' front and rear. #41-1 .2 Corner Formers and #38 2 Corner Former Pins 1 on each side. #105 Pipe Release Pin #104 2 Spacers to be used jwith 3" Pipe Bender. One under .each corner former. , i m-TEX .004077 s K. WA-TEX004077 ITEM NO. B-26 TRAINING DETAILS PAGE-150^,..^ Before starting bending, 180 attachment should be set up as in Illustration 2, with rear rollers and pins (#101-102) out. j WA-TEX 004078 WA-TEX004078 "ITEM NO. B-26 TRAINING DETAILS raur. x?x Bend to approximately 130 and release ram. Rotate guiding plates bringing short side in front. Insert rollers *with pins (#101-102) on both sides and complete bend. Allow for spring-back by bending past 180. .............. ` WA-TEX 004079 WA-TEX004079 ITEM NO. B-26 TRAINING DETAILS PAGE 152. In the event that the pipe lodges in the former due to an oversize condition, use pipe release pin (#105). Insert pin (#105) through the back of former, anchor former to frame. Place blocks (W.B.) under former bringing same in right position against pipe bender ram. Proceed to pump pipe out. : WA-TEX 004080 WA-TEX004080 .. COPYRIGHT 1956 BY TAL BENDING EQUIPMENT, INC., MILWAUKEE 2, WISCONSIN "ITEM m. B-26 TRAINING DETAILS . PAGE 153 , ......... . ......... '=""~.........BBND1NG~~INSTRUCTI0NS.......... . ' "............ "' . for PIPE, TUBING, and CONDUIT when using TAL HYDRAULIC PORTABLE BENDERS The1 following- illustrations, table, ana examples will simplify -the . calculations for obtaining dimensions to measure and mark the right locations of BEND starting points* Locations of these BEND starting points are to the center of completed bends converted to straight pr linear figures for lay-out and marking on a straight length-. It is important that after straight lengths are marked with the bend ` locations these marks are centered on the Ram and Former of the Tal Bender. To obtain dimensions for the location of the bend start point's it is necessary that the following are known. "A* angle of bend "B" or nC" distance to completed bend "R" radius of bend With these values known, and with the proper use of the, table, the bend setting dimensions can be obtained for marking on straight lengths for a multiplicity of bends in any plane in any one length before any bend is made so that all bending can be done successively one after another, or one at a time by measuring and marking from a bend already made, making the new bend and repeating, for as many"as can be accommodated in a single length. Above illustrations are for single and multiple bends tvhere nAn angle of hend is 90 degrees. Since "LB represents the bend setting location on a straight length, then since SDW represents the diameter of the pipe or tube, and "B" the bend radius both are known. BBn or "Cn are also known since they locate the completed bend which is governed by your requirement, L -- B -4- x WA-TEX 004081 L-- G - y The values for x and y are obtained from the Table on Page 3. Example: A 2" pipe Is to be bent. The radius is 8n (R). The distance to the bend is nBl,=s 10" or "G*1 =18s whichever can be determined most con veniently. Then by finding x or y in the table and substituting num bers for the letters . L* 10* + and or L -- WA-TEX004081 ITEM NO. B-26 TRAINING DETAILS PAGE 15^ BENDING INSTRUCTIONS To obtain straight line dimension for laying-oat 180 bends . . q S^B^Sx The values for q and x are obtained from the Table on Page 3*. Bend Starting polntAon straight lengths* Plae on <. of Ram L and Former, --y To obtain straight line dimen sions for iaying-ont OFFSETS to angles shown In Table on Pag 3. z ! -- -- ?sC-f x.n+2* The values for' z, k, and f are obtained from the Table on Page 3 This Illustration shows the multiplicity of bends that can be made by the use of all of the preceding instructions to find "L". "Ttt or ttStt which are the linear or straight line dimensions for locating in the Ran and Former, in any plane besides that shown. 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B-26 TRAINING DETAILS PAGE 156 TNKTRUCTIONS FOE OPERATION OF THE TAL COPPER TUBE BENDER- ` Your Tal Copper Tube Bender comes to you assembled with . one former in place. . , TUBE BENDING OPERATION: ' : Assuming the bend is to be Right Hand, swing the roller p to the left side approximately 90 to center line of : machine s Remove the Radius Key, push the Slide Bar. out and " place the tube under the Slide Bar and Ring Gear between : ' the Roller and Former Shoe. '. , Press the tube firmly back into the Former Shoe groove, ' at the same time holding the tube as level as possible j: with the machine.' Move the Slide Bar back into place and insert the ' Radius Key. Gace the tube against the Grip Bar Shoe, press the . ip TJ-Clamp down over the tube and Grip Bar Shoe. ' REMOVING FINISHED BEND.: '.Before removing the handle, return the Former Roller to its br- starting point. Remove Radius Key and Grip U-Clamp drop fefini8hed,,bend out of machine. ; v. PROPERATOR MUST STAND ON FLOOR PLATE WHEN INSERTING AND REMOVING TUBING AND DURING BENDING OPERATION. TO CHANGE OVER FROM- ONE SIZE TO ANOTHER; k` Remove the Spring Key from the Center Post.. ' Remove Slide Bar and Ring Gear, , Remove Former Shoe end replace with desired Former, making sure same sets down over the Angle Pin. " DO NOT use a hammer on the Radius Key or the Grip U-Clamp. Pipe _ Size %" V w To make a 180 bend, it is necessary to bend the tube more t^an 180.,. allowing for "Springback." ' WA--TEX 004084 CHART GAUGEFACTOR Degree Plumbing and Pipe ofBend Healing Electrical Size GAUGEFACTOR Degree Plumbing and Pipe ofBend Heating Electrical Size GAUGE FACTOF Degree Plumbing and . of Bend Healing Eleclri 22% 45 90 1" 3" ' i" 22% 3%" 3%" 2" 22% S%" 5% 45 4%"^r 4%" 45 7" 7Vb 90 7%" 90 lOVi" 10% 22% 45 90 ZVb" 3" 4%" VA" 22 Vz 4" 4" 21/z" 22i/2 6Va" 6% 45 5%"&# SVs" 45 9" 9% 90 * 8" 8%" 90 1414" 14% - 22% 45 v AAO 2%" 3%" ei4." m" 22% 4%" 4%" 3" 45 6V4"&& e%" on QVo" 22Vi 45 an 7" 10" ' 3 5Vi" 7" IOVb 15*4' WA-TEX004084 ITEM NO. B-26 TRAINING DETAILS PAGE 157 No. 3 PH - ; - 3" PIPE BENDER Bends standard pipe to 3" 'X to 2 Vi". XX to I'i"). Includes SEVEN short radius bending shoes %" to 2" (Box III. plus two stand ard radius: 2Vi" and 3"* ibelow) Heaviest part 57 lbs. i No. 2 PH - 2" PIPE BENDER Bends standard pipe from %" to 2", tX to 2", XX to 1 Vi"). Includes SEVEN short radius Bending Shoes %" tn 2" (below). Heaviest part 39 lbs. No. 2 CT - 2" COPPER TUBE BENDER Includes FOUR bending shoes, bars, and clamps FOR HARD & SOFT COPPER TUBING K & L: 1" to 2". Heaviest part 39 18s. No. 3 PHX Tncl. ports Specs, of Rodion* for Rodiont Hoot. Heof Shoos on page 4. jSevcn Short Radius Shots for pipe. All No. 2 & No. 3 benders have only two main parts: ONE hydraulic unit and ONE universal frame (page 4>. They are assembled with a U key in less than ONE MINUTE THIS IS THE BASIC PIPE BENDER USED WITH ALL VARIATIONS shown . *12 Some bender used os Copper (Cl) or Steel Tube (EMT) bender. Some bender with Remote Control RC [pogc 4). Same bender v/ilh Moior pump No. MP--26 ' (poge 4\. No. 3C -- 3" RIGID CONDUIT BENDER Includes FOUR bending shoes FOR RIGID CONDUIT: l"to 2" (Box V), plus TWO: 2 Vi" and 3"* (Box I). For extra long radius bending shoes see page 6. Heaviest part 57 lbs. No. 2C -- 2" RIGID CONDUIT BENDER Includes FOUR bending shoes FOR RIGID CONDUIT: 1" to 2" (below). Heaviest part 39 lbs. For ex'tra long radius bending shoes, see page 6. For bending Bus Bar with No. 2 bender, order No. BB 2 <Box IV _ No. 2 EMT--2" THINWALL CONDUIT BENDER Includes FOUR bending shoes, bars and clamps FOR THINWALL CON DUIT: 1" to 2" '(Page 6). Heaviest part .39 lbs. . No. 3 C BB for Rigid Conduit " e*` ,,,, _ No. SB 3 Rite Krtr Dim four Stondord Elbow Radius Shoos m-TBX 004085 No. RC 2 EMT shown with remota control. WA-TEX004085 ITEM NO. B-26 TRAINING DETAILS PAGE 158 No. 3 CT -- 3" COPPER TUBE BENDER Includes 4 bending shoes, bars and clamps FOR HARD OR SOFT COPPER TUBING K & L: 1" to 2", and TWO 2'A" and 3"* (shown). Heaviest part 44 lbs.. Benders for 2'A" and 3" Copper tubing have a special frame (shown). Larger Sizes obtainable. WITH FRAME NO. 1533 I No. 2 PH/CT - COMBINATION 2" PIPE & 2" COPPER TUBE BENDER ! Incl. 7 short radius-shoes: %" to 2" (Box ID, plus 4 bending shoes, bars, and clamps FOR i COPPER TUBING type K & L 1" to 2" (Box III). Heaviest part 39 ibs. No. 3 PH/CT - COMB. 3" PIPE & 2" COPPER TUBE BENDER Inch 7 short radius shoes: %" to 2" (Box II), TWO: 2%A" and 3"* (Box I), plus 4 shoes, bars and clamps FOR COPPER TUBING: I" to 2" (Box 111). Heaviest part 37 lbs. i No. 33 PH/CT - COMB. 3" PIPE & 3" COPPER TUBE BENDER ! is as No. 3PH/CT above, plus extra Jframe No. 2533 (Box VII) and parts for 2'A" and 3" copper ' tubing.......................................... . USED AS PIPE BENDER USED AS TUBE BENDER . No. 2 C/EMT -- COMB. 2" RIGID & 2" THINWALL CONDUIT BENDER ' lad. 4 standard elbow radius shoes FOR RIGID CONDUIT: I" to 2" (Box V). plus 4 bending shoes, bars and clamps FOR THINWALL CONDUIT: 1" to 2" (Box 111). Heaviest part 39 lbs, I. , No. 3 C/EMT - COMBINATION 3" RIGID & 2" THINWALL CONDUIT ! BENDER ` Includes 6 standard elbow radius shoes FOR RIGID CONDUIT: 1" to 3" (see Box IV & V), plus 4 shoes, bars and clamps, FOR THINWALL CONDUIT: .1" to 2" (Box III). Heaviest part is 57 lbs. -. USED AS PIPE BENDER USED AS TUBE BENDER No. 2 PH/C - COMBINATION 2" PIPE & 2" RIGID CONDUIT BENDER Includes 7 short radius bending shoes FOR PrPE: %" to 2" (Box II), plus 4 shoes FOR RIGID CONDUIT: 1" to 2" (Box V). Heaviest part 39 lbs. No. 3 PH/C -- COMBINATION 3" PIPE & 3" CONDUIT BENDER Includes 7 short radius-shoes FOR PIPE: %" to T (Box IIi.'plus 6 shoes Tor RIGID CON DUIT: 1" to 3"'(Boxes IV & V). (2A" and 3"=f shoes have same radius for pipe and conduit.^ Heaviest part 57 ibs. Patented QUICK RELEASE SHOES Short radius for Piping Std. radius elbows for Electr. rv No; RC 3 PH/C with Remote Control No. 2 PH/C - CT-EMT - COMBINATION 2" PIPE, 2" RIGID CONDUIT 2" COPPER & 2" THINWALL CONDUIT BENDERS . Includes 7 short radius shoes FOR PIPE: %" to 2". plus 4 shoes FOR RIGID CONDUIT: 1" to 2" plus 4 EACH bending shoes, bars and clamps. FOR COPPER TUBING AND THINWALL CON DUIT: 3" to,2". Heaviest part is 39 lbs. Shown with motor pomp only. No. 3 PH/C -- CT-EMT - COMB, 3" PIPE, 3" RIGID CONDUIT, 2" COPPER & 2" THINWALL CONDUIT BENDERS Includes 7 short radius shoos FOR RIPE: *V* to 2". plus Cf FOR RIGID CONDUIT: !"to3~s=. plus 4 EACH shoes, bars and clamps FOR COPPER TUBING EMT: 1" to 2" Heaviest*, part 57 lbs. No. 33 PH/C - CT-EMT is as No. 3 above, plus parts for 214" & 3" copper tubing ,, _ and special frame as .shown In Box VII. No. RC 3 PH/C--MP with remote control Cnd motor pump. > WA--TEX 004086 ) WA-TEX004086 ITEM NO. B-Sb TRAlfllftU u&'l'hhz> xnuxu xjy Ho. 99 Standard '25 Ten HydrauSSs Unit and Rnmiand No. S8-KM ALL PURPOSE FRAME No. 58-2XU for all 2" Benders (neJ wgt. 28 lbs.) No. S8-3XU for all 3" Benders (net wgK 57 lbs.) ' '. No 99 Hydraulic Unit (net'wgt. 39 lbs.) and No. 58 ALL PURPOSE FRAME arc the TWO main parts of all No. 2 and 3 Benders. LESS THAN ONE MINUTE to assemble these two parts, ready for use. Change over from one size to.another In HALF A MINUTE. A ONE MAN OPERATION. . Standard model No, 2 or 3 used os PIPE BENDER Slondord model No. 2 or 3 used ns. TUBE BENDER 'I- No. 58/3 XU . All BENDERS CAN BE HAD "WITH MOTOR PUMP MP26 AND/OR WITH HYDR. UNIT NO. 99 OR WITH RE MOTE CONTROl NO. RC 10 (below) For Rodiant Heoj No. RC 10 REMOTE CONTROL 10 TON, 2 SPEED, HYDR. JACK INCL. SEPARATE RAM, 6 foot hydr. hose and coupling. These powerful, lightweight units can be used with all No. 2 and 3 benders, in any position. Wgt. 37 lbs. .Same price, whether benders are ordered with the standard hydrau-lie unit No. 99 (above), or with the RC 10, shown. No. 12 COMPLETE QUICK SELF SEALING COUPLING Inel. No. .12 M male and No. 12 F female part (%" pipe thread). i&Sthfr For Bus Bor No. RC 11 10 TON, TWO SPEED HYDR. JACK The LIGHTEST EVER BUILT. Net wgt, 10 lbs. Pressure up to 10.000 p.s.i. for any 'mtg's. hydr, bender, arbor or punch presses, wheel pullers, pulley pushers, clamps for forms, etc. For pushing, pulling, lifting, straighten ing, pressing, etc. No. RC 123, same as RC 11. includes coupling and hose. No. 14 SIX FOOT HYDR. HOSE with coupling connections No. MP 26 - 'A HP LIGHTWEIGHT HYDR, POWER PUMP Incl. 6' Hydr. hose and couplings. In creases production up to 10 times. Highly recommended with hydr. benders from 2" to 5". or any other hydr. system. Pump develops maximum pressure -- for inter mittent service 10,000 p.s.i., -- for con tinued service 5000 p.s.i. with Hp 110-115 V. AC/DC motor, 1750 RPM. Gr. Wgt. 70 ibs. No. MP 30 2 HP POWER PUMP Incl. 6' hydr. hrtsc and couplings. Is the power unit for 6" & 8" benders, or`for any other hydr. equipment. The double-piston, single valve, high pressure pump, with two V-belts, is driven by a 2 HP, 60 cycle, 3 phase motor 1750 RPM for 220-440 volts, de veloping up to 10,090 lbs. pres sure. Gr. wgt. 355 lbs. RADIANT HEAT WINGS & SPECIAL BENDING SHOES FOR ONE SHOT 180 These wings for any bender, make complete 180' bends in many different centers, IN ONE SHOT, & IN LESS THAN ONE MINUTE (with motor): WINGS No. 82X for No. 2 Bender No. 83X for No. 3 Bender No. 84X for No. 400 Bender ISO* bending shoes can be ordered separately as per re quirements in the following pipe sizes and centers: Centers: 6" Pipe sizes: '/>'--%" ________ 9" 1" . 12" 15" & 18" 1" 1"--1%" 1 'A"--1 Mi" No. IBA 123/2 or 3 Connecting Ports for Tube Benders consist ing ok No. T8A-3-2 or -3 Hydr. Unit Connection No/TBA.T.2 or -3 Holler No. TBA-2 No. 115/2 and No. 50/3 Ram Extension No. 38 Pair End Casting pins for No. 2 and 3 No. 37 U locking pin for No. 2 & No. 3 No. 43B End Costing pins No, 441 Pair End Castings WA.-TEX 004087 WA-TEX004087 ITEM NO. B-26 TRAINING DETAILS PAGE lbO ALL LARGER BENDERS HAVE MANUAL OPERATION AStSD PROVISION FOR TAL POWER PUMP WITHOUT MANUAL OPERATION, ON REQUEST ONLY /OR: PIPE IX S XX), RIGID AND THIN WAIL CONDUIT, COPPER, STEEL AND ALUMINUM TUBING, BUS BAR, RADIANT HEAT (180") BENDS, SHAPES, ETC., ,IN SIZES FROM TO &" AND UP, COLD, WITHU FILLING OR MOVING THE PIPE Very Important The Pmmeevs She Portable "One Shot" TAL Benders Offfer the Folloyring Exclusive Features: . O THE ONLY PORTABLE BENDER powerful enough to tend in one shot X pip*, antS adaptable for XX pipe. 9 BENDING IM CLOSE QUARTERS! Provided with casters for easy mov ing, also while bpnding. Benders will rotate with one end of the pipe, while the other end con remain stationary. THREE MAIN PARTS ONLY: One hydraulic unit inch ram and two Iramo plates assure easy and quick assembly. MOST ECONOMICAL PRICE-WISE and fh PERFORMANCE: It lake* 3 min. actual bending time -- on Ih* job -- to complete a 90 bend in 8" XX pipe. w SAVINGS UP TO 90% on welding or threading end on expensive handling and assembling of unecessary cut-up pipe with costly fitting?, dhows, couplings and nipples. ^ WITHOUT EXPERIENCE perfect, identical bends are guaranteed be cause of: Patented, tight-fitting, quick releasing bending shoes. Bend*Indicator and Bending Chart. (Copyright 1956). MANUALLY OPERATED, HAS A BENDING RANGE FROM W TO 4" CONDUIT OR STD. PIPE (X or XX). Bending shoes not included; to be selected from the sets listed on next page. For 4" XX Pipe, stronger 4" shoe and frame available, ACTUAL BENDING -TIME for 90" Bend in 4" XX Pipe: Wo. 400/26 with 'k HP motor, 5 min. No. 400/30 with 2 HP motor, 1 min. No. 400 hand operated, 18 min. Note; Max. radius for 90" elbows IN ONE SH.PT in afiy'pipe size is 30" (with appropriate bending shoes.) MANUALLY OPERATED, HAS A BENDING RANGE FROM %" TO 5" CONDUIT OR STD. PIPE (X or XX). Bending shoes not included; to be selected from the sets listed on next page. This bender has a small extension-ram to make full 90" bends in 5" pipe with out moving the pipe. - ACTUAL BENDING TIME for a 90" Bend in 5" Conduit: No. 500/26 with Vz HP motor,- 6lk min. No. 500/30 with 2 HP motor, 2 min. No. 500 hand operated, 25 min. ' Note: Max. radius for 90* elbows, IN ONE SHOT in any pipe size is 30" (with the appropriate bending shoes). NO. 400 MANUAL OPERATION NO. 400 MP WITH % H.P. MOTOR PUMP .. (non-manual -operation) NO. 500 SAME A5 NO. 00 BELOW Proportionally smaller WITH 2 HP MOTOR PUMP, HAS A BENDING RANGE FROM %" TO 6" STD. PIPE (X or XX). Bending shoes not included; to be selected from the sets listed on next page. For .6" XX Pipe, stronger 6" shoe and frame available. ACTUAL BENDING TIME for 90' bend in 6" XX Pipe; No. 600/30 with 2 HP motor. 2 min. Note: Max. radius for 90* elbows IN ONE SHOT in any pipe size is 36" iwil* the appropriate bending shoes). 16--Sec. B Sec See. C for email remote control tsnd "'til KA-TEX 004088 < NO. 00/30 WITH 2 H.P. MOTOR PUMP AND MANUAL OPERATION' WA-TEX004088 ITEM NO. B-26 TRAINING DETAILS PAGE 161 /~*. INCLUDING 2 H.P. MOTOR PUMP, AN AN W BENDING SHOE . jf- 1 I (Requirements for other sets of shoes, from %" and up, to be selected from the list below). MADE ON THE SAME PRINCIPLES AS ALL OTHER TAL HYDRAULIC BENDERS. ' FOR ITS OUTSTANDING FEATURES see under "LARGER ONE SHOT BENDERS" on page '5. _. For 8" XX* stronger 8" shoe and frame available. ACTUAL BENDING TIME for complete 90 Bends in 8" XX pipe is 3 MINUTES. The hydraulic ram has a bore of 4t4". travels 56" and operates at a pressure of 5000 psi. The double-piston single valve pump operates at 10.000 psi intermittent, or 5000 psi constant, has'2 V-belts. has a Universal 2HP. 60 cycle. 3 phase motor for 220/440 volts. The Bending Frame consists ot 4 sections connected to an upper and lower plate. and fastened with pins to the hydraulic unit. The overall width is 1ftVfe'. THIS FRAME CAN BE FOLDED TOGETHER ONTO THE HYDRAULIC UNIT, IF STORED. THE FEW PARTS CAN BE ASSEMBLED IN 30 MINUTES. BY FAR THE SMALLEST, LIGHTEST AND MOST ECONOMICAL PIPE BENDER IN THIS CAPACITY EVER MANUFACTURED ANYWHERE. SAME AS ABOVE BUT WITH TOP WINGS FOLDED TOGETHER Size SPECIAL LONG RADIUS FOR CONDUIT I* _____ .-.iSSIl Radius W o Z SHOES, BARS & CLAMPS FOR THIN WAU TUBING /V (copper, sleel. EMT, alum,) J m Nom. No. She Radius 'So fi] v FOR STD. CONDUIT ELBOWS. TAL manufar' - fo your specs. ONE SHOT SHOES IN ANs oi/ii e.g. Conduit elbows up to 48", 180 loops, etc. 2245 2244 2243 2242 2282 2283 U4" HV 2" 2IV* 3" 5-3A'7-1/4' 10" 15" 15" ^ ^3 XM -5V-- The snug fitting, PATENTED, TAL SHOES, assure o Z perfect bends and have easy pipe release. Set 20 EMT- V. 1V\ 1V2", 2" > thin waif _ Ui Sc* 25 EMT: Mi", tw. a- / conduit. i WA-TEX 004089 ! Set 20 CT: w' W. 2*8' 1` Sot 35CT: |i8". W'. 2,,o". 23o", 3f>/ WA-TEX004089 tI i X' >+ f I'Op plAtE pf Frctfrto ^ i>>**rtkAg oc ^ i X '- <S \ ' jNp&i i^ * * * '" w.**?! y^s^-WKvkSs'irm?*.-.. i:\<uW<sv*.,,*,TM> ,,\h $ * fc. S' v\b-} ^ ^ ,<,>*< ^- ! ',V\ ^ >K ---- s:.StfV\WV.V`SVy ' s WITH QMS K^ 1 CO A^IkkcVV'^V.'.:: '% i\ ^ Sf, ^;4||||ffc<(> m ^ ^ahu-'t f ( >\ "jdafttii -. . a-' t. ' y - )i'5i(al j ..Wj. ,, ,, ** >& * ^ FCU fhfX ' fc 189* gftaphm^nt> tor n>tiny jri/a^v ONH $H0fr* tojiiftnt sk ^If-1 1V \x * > ; . `4ftH * V ">.....* ` '#* H'iilmrt ` ' f>m m ^* "(i "' \ %^|?il ' "v flligilsl * ! -, 5 V I :/Uj- *.>..*>.-sqr *V *<* - f |M? '-'/0J>. X^i't'bf>imi'!iijilti'^fifflieiHl';fb)|amlbitriji I pA-fSX-jj v * > f\^ \f: pOii C*BB iFo ^r<yJtf vCondQifx w^rf ? ^bQsrhQr.-.v. WA-TEX004090 ITEM NO. B-26 TRAINING DETAILS PAGE 163 Here's the ANSWER to ALL your RADIANT HEAT & OTHER COPPER TUBING JOBS . . . with SOFT OR HARD COPPER TUBING, K or L In many different radii. Produces SMOOTH, CLEAN bend's right on the spot. Basic machine available with all or any of th'e following rollers and bending forrfiers: Roller Sizes %W" %" 1" Bending Formers Centers 4" 0" 6" 9" 12" 6" 9" 12" 9" 12" Simple, light weight, easy to carry. In sturdy wooden tool box. BENCH ATTACHMENT AVAilABlE. Without TAt With TAt BENDS ON WE FIOOR OB BENCH FLUSH TO WAtL AND CORNER Bends %" and %" O.D. HARD AND SOFT COPPER TUBING Has one Forming Section with Two Grooves for Both Sizes. EASY QUICK EFFICIENT LOW COST The bender is made of light we!ght aluminum with ONLY TWO LOOSE PARTS. Nominal Tube Size %" %" Outside Diameter of Tube %" ' Radius to Center of Bend FOR EMT THINWALL & RIGID CONDUIT Makes perfectly smooth uniform Bends and Offsets W & %" Thinwall and Rigid Conduit. Up to 90 with one pull. No flattening or other Distortion. A great money saver when used on Open or Slab Work, or any other jobs requiring a larger number of identical Bends. Bench Attachment available. Light weight, easy to carry. - GUARANTEED AGAINST BREAKAGE "FOR LIFE"! An EXTRA STUB HOLE for bending very short offsets and for.straight ening or bending conduit protruding from concrete. ITS SIX WAY NON-SLIP SHORT BENDING JAWS make it an Ideal tool for all types of bends. PERFECT FOR BENDING IN CLOSE QUARTERS! The long SAFETY NECK avoids accidents caused by breakage. > ' Nos. Size Weight 50 W 3 lbs. 75 5 lbs. WA-TEX 004091 " inn 1" 8 lbs. WA-TEX004091 ITEM NO. B-26 417 4 2 5 TRAINING DETAILS PAGE 164 WA-TEX004092 6 " HYDRAULICPIPE BENDERPARTSDRAWING TAL BENDINGEQUIPMENT, INC., MILWAUKEE2, WISCONSIN TEXACO INC. PUGET"^UND "PLANT PAGE 165 TRAINING PETRIES DEPARTMENT: PIPS HT,ASSIffICATIO?rr"PIPEFITTER (TRAINEE) DATE: JULY 1, 1970 ITEM NO. B-27 SUBJECT: FABRICATE TUBING SENDING (1) Building of tubing should be done with extreme care as it is easy to crimp or flatten the tubing, (2) There are four sizes of tubing benders: these being 1/4", 3/8", 1/2" and 3/4". The settings are marked on the tubing bender for the angle you desire the bend to be. (3) It is important to start on one end of tubing fabrication and continue to measure and bend tubing In one direction until fabrication is complete, WA-TEX 004093 WA-TEX004093 ITEM NO. B-27 TRAINING DETAILS PAGE 166- TUBE BENDERS IMPERIAL tubing. tubing. HAND TUBE BENDERS,. Designed to simplify bending of larger sizes of Bender .may be locked in vise 11 desired. Center pin may be lifted to release wt. Dir3/4 lbs. ea IEK Ind. CAE Ret. ea 12.75 364FH Bends 3/8** tubing to radius of 15/16" 364FH Bends 1/2" tubing to radius of 1 !" 364FHA Bends 5/8" tubing to radius of 2Z" 364FHA Bonds 3/4" tubing to radius of 3" V4 lbs. 1% lbs. 1% lbs. 10 lbs. 11 lbs. TKRE CYK TYRI TK 1C TQAK TUCA RTQK ADEK RAUQ AUCE 15.40 14.85 24.50 32.50 52.00' 1MPEEFAL HEAVY-DUTY TUBE BENDING TOOLS. Long leverage and adjustable operating lever makes it possible to apply force with little effort, avoiding sudden strains which might Injure tubing. The smallest bends are made with perfect accuracy- ip the heaviest tubing. Right or left hand bends. Removable handles. Furnished in steel chest. 3,/6n0PFMH BBeennddss 3d//88" .11//,2. ",,5/8",. 3//4" O.D. sizes Wt. ea 2e0a lbsQ.UKY UAUK ealOO. .O. D TUBE BENDER. Imperial. External spring type. Budget priced tools for hand bending soft tubing to any shape. Keeps tube perfectly round. Special spring steel. Nickel finished. End is belled for quick tube removal. ize Is for outside tube diameter. No, DJ02F Size 11//44"" 5/16" 3/8" . Length 100"" '' 10" 10" Wt. 3 oz. 3 4 _ ea , Af A1 DY _. "DDAA ea .57 DA .57 DC .66 7/16** 1/2" S/8-*' 12" 12" ' _1_2" 6!4 6!4 . 8 EY QT QK QY QK QY .92 .99 .99 RIDJIG. Ridge Tool Co. Designed to hold copper tube' in place while being soldered. O.D. capacity 3/6" through 7/8". 71 Packed 12 in display carton 1-1/2 lbs.' ea TKD TRK ea 1.56 ALUMINUM TUBING ALUMINUM TUBING. Pacific Metal Co. AGA approved. . 3/8" OD X .035 x 50.ft. For gas heater and range connections. Soft Full ^ ^ ^ ^ 100 ft TEY1 TfUK ft .23 ' COPPER DRAINAGE TUBING DWV COPPER DRAINAGE TUBING is for-Soil, Waste,'and Vent Lines, - above ground Size M/4" 1-1/2" 2" Wall thicknes .040 .042 .042 ' Wt. per ft. .650 lb. .809 1.07 .045 . 1.69 ' Dealer loss 1000' cut eft YQIKQ ITQU VUYTD CREU VTKRTQ TYREC V.TQTEQ TCA i U Retail Full laih* 102.09 115.71 153.24 ft 242.34 Rotcut K23 1.39 1.84 2.91 t' DWV 1000 ft or more- less TK% Imperial Hand Tube Bender 3B0FH Bends tubs wilMmt coliapsine w*'ls I02F Basic Stock Turnover Item WA-TEX 004094 5/3/6 WA-TEX004094 Texaco INS.. PAGE 167 /TMs GAINING DETAILS DEPARTMENT % PIPE 1 CLASSIFICATIONs PIPEFITTER (TRAINEE) DATBs JULY 1, 1970 ITEM NO. B-28 SUBJECT % INSTALL BELL AND SPIGOT FABRICATE ' You must have piping aligned properly with spigot all the way Into the hub. You theft. put .enough oakum around spigot to seal the Joint. Lead is thenr-ppured into hub to seal and- look oakum in the Joint. .. ,, (a) When Joint is ready, you put in one small oakum ring at a time. Using cgulMng toOl and-hammer, you. go around Jdint tamping lightly after each ring. You do this until you come to within one inch of. hub end. Increase tamping pressure as you come to end of hub. *" (b) When oakum is within one inch of the end of hub. ; rpour lead Ip to fill the hub. The lead is then , . ready to be caulked with caullrig tool which .makes,.: the Joint .tight and helps seal the iHHam. INSTALL . *- To use bell and spigot piping for sewer and drains, pure to have the proper'fittings and the proper drop in the line to gravitate- the material-.and* still float it also. The right ; *. amount of dpop to get proper gravity flow and still float the material is one~eighth inch drop to two feet of pipe. Attached is a commer|^il standard regarding dimensions,'1 tolerance and Installation of will and spigot pipework. \ ' j WA-TEX 004095 WA-TEX004095 ITEM NO. B-28 TRAINING DETAILS =PAGR r63' COMMERCIAL STANDARD CS138-66 Supersedes CS188-59 moncast soil pipe and fittings [EfFecHve July 1, 1966] 1. PURPOSE AND SCOPE 1.1 PURPOSE.--The purpose of this com mercial standard is to establish standards cov ering material, principal dimensions, and dimensional tolerances for extra heavy and service weight cast iron soil pipe and fittings, in accordance with general needs of producers, distributors, and users. It is intended to serve as a basis for common understanding between buyers and sellers. Through certification, the purchaser may receive advance assurance that the provisions of this standard are ful filled. 1.2 SCOPE.--This standard covers pipe and fittings of the following patterns and, when so designated, may apply to any other pat terns that conform with the requirements given herein. Pipe: Extra heavy, 5-foot and 10foot lengths Service weight, 5-foot and 10foot lengths Nominal Shipping Weights-__ Outside dimensions (for de tailing)-- Tables 1,3 2,3 55,56 Appendix Fittings: Vi bends; long V* bends_______ 4,5 Long low-hub Vi bends_______ 6 % bends, low heel; high heel abends7,8 Vt bends, short sweep; long sweep 'A bends________ 9,10 Abends_______________ 11 16 bends; long Ve bends_ 12,13 % bends; long Va bends_ 14,15 Ms bends_____________ 16 Y branches___________ 17 Y branches, cleanout- 18,19 Y branches, inverted__ 20 Y branches, combination 14 bends_________________ 21 Y branches, combination 14 bends, cleanout_ _ 22 Y branches, upright1. 23 Sanitary T branches__ 24 Sanitary T branches, clean out._____ ___________________ 25I Fittings:--cont'd Tapped sanitary T branches.. T branches, tapped T branches T branches, cleanout Ventbranches--------------- _ -- Offsets, regular Offsets, 14 bend______ Double hubs, long double hubs Reducers Increasers S traps; full, %, 14------------------Running traps Screw plugs (brass)---------------Plugs, for hub Iron-body ferrules. Side inlets--------- ------------------Tapping bosses--------------------- Nominal Shipping Weights-- 26 27,28 29 30 31-35 36-40 41,42 43 44,45,46 47,48,49 50 51 52 53 53 (note 2) 54 57-106 2. REQUIREMENTS 2.1 GENERAL REQUIREMENTS 2.1.1 Material, general.--The pipe and fit tings shall be iron castings suitable for instal lation and service in drainage, waste, vent and sewer lines, and shall meet all applicable re quirements and tests given herein. 2.1.2 Cast iron.--The castings shall be made of gray cast iron, produced by an estab lished commercial method that provides ade quate control over chemical and physical properties. The castings shall be sound, true to pattern, and of compact close grain which permits drilling and cutting by ordinary methods. The interior surface snail be rea sonably smooth and free from defects which would render the castings unfit for the use for which they are intended. 2.1.3 Marking.--Each length of pipe and each fitting shall be plainly marked with the manufacturer's initials or registered trade mark by which he can be readily identified, and with letters to indicate the proper weight classification, as follows; XH_______ Extra Heavy SV_______ Service weight If pipe is marked on the barrel the marking shall begin about 2 inches beyond the base of the hub and extend along the barrel not more ' I WA-TEX 004096 \ WA-TEX004096 ITEM NO. B-28 TRAINING DETAILS PAGE 169 than 12 inches. On fittings, the markings shall be located away from the spigot end so as not to interfere with proper joining upon installation. The marking may be cast, sten- ' died, or otherwise applied on the pipe, so as to be clear and legible at the time of installa tion. The marking shall be cast on fittings. 2.1.4 Coating.--The pipe and fittings shall be uniformly coated with coal tar pitch, or similar bituminous material suitable for the purpose, that is adherent and without a ten dency to scale or become brittle. The coat ing shall be applied to all surfaces except in threaded openings. 2.2 PIPE.- ,, 2.2.1 Ends ofpipe.--Single-hub pipe shall have a hub at one end and a spigot at the other. Double-hub pipe shall have a hub at each end. Hubs shall have lead grooves. Spigot end may be either with or without a bead, and inner end of hub may be either with or without a centering recess, all com binations of which shall make a satisfactory leakproof joint. Hub and barrel shall be cast in one piece. (See Fig. 1.) . shall not exceed 1k inch for sizes 4 inches and larger, nor exceed % inch for smaller sizes. . 2.2.4 Weight ofpipe.--The weight of indi vidual lengths of pipe, without coating, shall be not more than five percent (5%) under the nominal shipping weight as listed in tables 55 and 56. 2.3 FITTINGS.- . 2.3.1 Dimensions of fittings.--All fittings shall conform to the dimensions specified for hub and spigot ends in tables 1 and 2, as ap- licable. Fittings of the patterns specified erein shall conform to the applicable dimen sions in tables 4 to 54, inclusive, and to the tolerances in table 3. Other patterns 1 shall conform to tables 1 and 2, as applicable, for hub and spigot dimensions, and for wall thick ness throughout, and to dimension R', tables 24 and 26, for the minimum radius of any drainage inlets-that such fittings may provide. All fittings shall have spigot ends of sufficient length to provide adequate room for making proper joints. All dimensions given herein shall apply to fittings before any coating is applied. . nHUB -H LEAD _ groove k--UHlUB BEAD HUB- - BARREL S1NGLE HUB PIPE -------- BARREL-------- SPIGOT SPIGOT BEAD-Z7 -HUB DOUBLE HUB PIPE Fiona* 1. Slagle hub ami double bub cast iron roll pipe. 2.2.2 Dimensions ofpipe.--Single hub pipe 2.3.2 Water seal of traps.--Traps shall shall be of 5 foot and 10 foot nominal laying provide water .seals as follows: lengths. The laying length shall be meas ured as shown in the figures above tables 1 Minimum and 2, and shall be within the tolerances on laying length specified in table 3. Double Trap Size Water Seal hub pipe shall be of the same overall length as single nub pipe of the same size. Its laying length shall be 5 feet minus the telescoping length (dimension Y), or 10 feet minus the telescoping length (dimension Y). Other dimensions shall be as specified in tables 1 inches inches 2________ ______ _____ .............. 2 3 to 6, inclusive______ ...............2Vz 8 to 12, inclusive-___ . ________ 3 15.____________ _____ .............. 3'/a and 2 as applicable, and be within the toler .2.3.3 Ends of fittings.--Hubs shall have ances specified in table 3. The dimensions lead grooyes and spigot end may be either shall apply to pipe before any coating is with or without a bead and inner end of hub applied. may be either with or without a centering 2.2.3 Straightness ofpipe.--Pipe shall be recess, all combinations of which shall make /-"x straight to the extent that any deflections in a satisfactory leakproof joint. Tapped open the barrel of a 5-foot length of pipe shall not ings shall conform to 2.3.4. exceed 14 inch for sizes 4 inches and larger, and shall not exceed Vie inch for smaller sizes; for 10-foot lengths, deflections in the barrel Such as, for example, fillings known In the trade as '`specials/' when designated as being in conformity with this standard. i WA-TEX 004097 WA-TEX004097 ITEM NO. B-g8 TRAINING DETAILS PAGE 170 ' . 2.3.4 Pipe threads.--Screw plugs and tapped openings in fittings shall have Ameri can Standard taper pipe threads. The threads shall be in accordance with the American Standard for Pipe Threads, B2.1\ or with the National Bureau of Standards Handbook H28, Screw Thread Standards for Federal Services,2 3of the current issue. 2.3.4.1 Internal threads shall be cham fered at the entering end approximately to the major diameter of the thread, at an angle of approximately 45 with the axis of the thread, and the entering end of external threads shall be similarly chamfered approxi mately to the minor diameter of the thread, for easy entrance in making a joint and for protection of the thread. The chamfer shall be concentric with the thread and shall be included in measurements of thread length. 2.3.5 Weight of fittings.--The weight of in dividual fittings, without coating, shall be not more than five percent (5%) under the nom inal shipping weight as listed in tables 57 through 106. 2.4 METHOD OF SPECIFYING FIT TINGS.- 2.4.1 Method of specifying sizes of fittings of more than one size.--The sizes are desig nated by the order of listing, as follows: (a) Branch and tapped fittings: (1) Size of run.1 (2) Size of branch. (b) Reducers, increasers, and offset fittings: (1) Size of inlet or run.4 (2) Size of outlet or offset distance. (3) Length, if supplied in more than one length. 2.4.2 Method of specifying hand of fittings with side inlets and outlets.--When placed in the position described below, if the side inlet or outlet appears on the right, it is a right hand fitting; if on the left, it is a left hand fitting. (a) Bends and offsets: Place the fitting with the hub facing toward the observer and the spigot end lower than the hub. (b) Branch fittings: Place the branch toward the observer and the spigot end lower than the hub. (c) Traps: Place in the position in which the trap is installed with the hub toward the observer. * Copies may be obtained from American Standards Associa tion, Inc., 10 East 40th Street, New York, N.Y., 10016. 3 Copies may be obtained from the Superintendent of Docu ments, U.5. Government Printing Office, Washington, D.C., 20402. * The Ton is that portion of the fitting which forms part of the main drain, waste or Vent line. The spigot end is ordinarily the outlet. 2.4.2.1 The fittings illustrated have right hand inlet or cleanout. Left hand fittings have these openings on the side opposite to that shown. 3. INSPECTION AND TESTING . 3.1 Inspection and test by the Manufac turer.--Pipe and fittings shall be thoroughly inspected by the manufacturer before ship ment. The manufacturer shall make all tests as specified herein, and the results of the tests shall be furnished to the purchaser upon re quest in accordance with mutually acceptable arrangements. ' 3.1.1 On the sample pieces selected for test, the inside diameter of the hub and barrel and the outside diameter of the spigot end and barrel shall be checked by suitable gages. 3.1.2 Fittings shall he inspected for sound ness and brittleness by methods generally ac cepted as standard by the manufacturer and purchaser. 3.1.3 The minimum internal diameter of pipe and fittings shall be that dimension re sulting from the subtraction of two times the nominal wall thickness from the minimum outside diameter using the dimensions and tolerances shown in tables 1, 2, and 3. WA-TEX 004098 WA-TEX004098 TEXACO INC. PUGET ~SOUND PLANT PAGE 171 TRAINING' DETAILS f'\ DEPARTMENT? PIPE CLASSIFICATION: PIPEFITTER (TRAINEE) DATE? JULY 1, 1970 '! ITEM NO, B-29 SUBJECT? INSTALL PIPE AND FITTINGS A . WELDED To Install welded pipe and fittings you should have a blue print which: would indicate where the installation is to be made and the type gaskets, bolts, etc, to be used for the Job, , }' In order to do the job safety and efficiently, be sure to use the proper tools and equipment, - , u Bo SCREWED To install screwed pipe and fittings you should the location pipe is to be installed and the type of gaskets*## bolts to be used. Use the right kind of pipe joint compound for the pipe threads before screwing into fittings. The pipe should be screwed Into the fitting until pipe threads are about flush with threads in fitting. Different fittings and manufacturers may cause pipe to screw more or less into fitting. C. PLASTIC ' When installing plastic pipe the most important thing is to prevent breakage. When installation Is under ground, sand must be under the pipe as well as over it. When being Installed above ground the pipe must have several hangers on it or a hanger runway constructed beneath. There are two ways to fabricate plastic pipe ~ screwed and cemented. When threading plastic, you must use extreme care. All materials should be Schedule 80 and a wooden plug put into the end of the pipe to prevent breakage and off-center threads. Be sure to use plastic threading lubricant. When screwing fittings onto pipe, tighten with strap wrenches. One or two threads past hand tight is adequate. . When cementing joints, all pipe ends must be square, saw mark3 and burrs removed. Follow all the other Instructions on illustrated material shown herein. i WA--TEX 004099 WA-TEX004099 ITEM HOo B-29 TRAINING DETAILS PAGE 172 Btew to JIbs Piping One of the more important features of industrial thermoplastic pipe is the ease with which it lends itself to a variety of fabricating techniques. This versatility, plus the wide selection of fittings and other components now available, makes possible fast and economical installation, mainte nance and modification of industrial pipe lines. Solvent Cementing The generally preferred method of joining rigid thermoplastics such as PVC and PVDC, solvent cementing gives a stronger joint than threading and is also considered faster and simpler. Addi tionally, solvent cementing permits the use of thinner walls, when compared to threaded con nections, for equivalent pressure ratings. Threading As is the case with metal pipe, threading reduces the effective wall thickness of thermoplastic pipe and introduces notch effects which lowerstrength. Threaded connections should he used with Schedule 80 or heavier pipe. The chiefadvantage of threading is the ease of disassembly it offers. Thermal Bonding THERMO-SEAl IP Cat Hoot Tool Pal. 3,147,7*4 By taking advantage of the thermoplasticity o the materials, Cabot Piping Systems has perfect ed an advanced method of joining solvent-re sistant thermoplastics such as polyethylene. Pen ton, polypropylene, etc. The Cabot Piping Sys terns' THERMO-SEAL tool applies regulatec heat uniformly and simultaneously to pipe anc fitting mating surfaces so that true melting occur! on the surfaces. Only hand pressure is needed t< join the components and as the material cools, < permanent homogenous bond results. Th< THERMO-SEAL tool may be used on a stanc for pre-fabrication or as a portable unit. Flanging One of the earliest methods for joining thermo plastic piping, flanging continues to be used extensively for process lines. Thermoplastic flanges and flanged fittings are available in a ful size range and may be attached to pipe by solvent cementing, by threading, or by thermal bonding as required by the particular thermoplastic ma terial. Wlherstiial BonJei Joints ipenton, polypropylene) ` *"Terapljfik"--T. A\, Tempil Corpofolioc Saw pips to desired length using either o hand saw and miter box or power sow. A square-cut end is of utmost importance.*Remove sow marks and burrs with fife, sharp knife or sandpaper. While the tool is heating, spray heating element contact surfaces hghtiy with siJicone release agent to prevent hot plastic material from sticking to the male and female tooi pieces. The THERMO-SEAl heat tool should be chocked periodically with 'Tempilstiks" to ensure the prop, er temperature ronge. Caution.* Heating element reaches 510 or more; avoid touching. r\ Place pipe and fitting squarely and fully on heating elements so that t.D. of fitting and O.D. of pipe are in contact with heating surfaces. Rotate components slowly and avoid overheating. Remove pipe and fitting from fool simultaneously and immediately insert pipe--squarely and fully --into the socket of the fitting. Hold or block com. pleted faint In place and avoid relative motion be* tween components for at least J5 seconds. It is important that the toot pieces be kept dean as possible. The small amount of residue left on the too! pieces should be removed with a cloth. At the end of each day, further cleaning may be done with fine steel wool. Caution; Hot plastic material can cause severe burns} avoid contact with if. WA-TEX004100 ITEM NO. B-29 TRAINING DETAILS Cemented Joints (pvc. PVDC) PAGE 173 Make certain pips end is square. Smooth with fine. Clean connecting surfaces of both the pipe and tooth file. Remove sow marks end burrs with sharp fittings with either methyl ethyl ketone or acetone. knJfo,or sandpaper. ' . * Apply CPS Solvent Cement liberal!/ with clean brush . .first to fitting and then to plpo (O.D. and end}. Cement should be applied to oU of pipe O.D, to be covered by fitting. Allow V* 'to r/2* lap for better seal. \: * ' Join pipe ond fitting... be sure pipe is WELL SEATED into fitting ... twist Vi turn to distribute cement. I# correct1/ assembled, a small "fillet" or bead wUl appear between pipe and fitting. * ' When making Sch 40 PVC joints, fellow above procedure except Sch 40 .Solvent Cement fs applied fo the pipe only, not the fittings. Tfaracided Joint's iail material, sch so pipe only) Use standard steel pipe threading equipment.' An Insert should be used in vise jaws to prevent scoring Of pipe, . .. Insert wood or aluminum plug (longer than cutting dies) info pipe end. This prevents distortion of pipe walls and avoids off-center threads. Dies should be clean and sharp# and those with 5t< 10 front rake angle give best.results. With powei tools# use 5 negative front rake dies. ^ Starting with entry thread, wrap Thread Tape tightly, covering all threads. Overlap each wrap a quarter-inch .... * or apply CPS Thread Lubricant to threads. It is Inert and acts as lubricant as well as a seal. When threading `'Penfon*1, vsa lubricant of 50% Lusoi and 50% water. Screw fitting onto pipe and tighten with straj Wrenches. Avoid excessive torque; one to two thread past hand tight is adequate. < WA-TEX 004101 WA-TEX004101 TEXACO INC * pugetWMplant PAGE 174 TRAINING DETAILS DEPARTMENTS PIPE CLftSSIFICATIOir^PIPEFITTER (TRAINEE ) DATES JULY 1, 1970 ITEM NO, B30 SUBJECT? REMOVE AND INSTALL VALVES A, GATE, GLOBE, COCK AND CHECK Before starting the job, secure a safety work permit* Form R~24l~A To remove and Install these valves you remove all but two bolts from the flange* put the rigging in place* remove the bolts* and then remove the valve. After the valve Is out* clean gasket surfaces of both flanges. Brush and clean bolts and then apply graphite to them. Install valve with proper gaskets and tighten flange evenly. Bo REGULATORS To remove regulators be sure that the instrumentation is first disconnected. Then proceed &s In Paragraph A, Co RELIEF VALVES Extreme ear should be used- when removing and installing relief valves0 A bump or a hard Jar can change the setting. Be sure to have proper equipment to handle the valve. Then* proceed as Paragraph A, All relief valves tied to the flare system must be removed with a gas mask. Follow the Instructions in Standing Instruction No, 21, i WA--TEX 004102 WA-TEX004102 TEXACO INC PACE 175 TRAINXNS DETAILS DEPARTMENTS PIPE CLASSIFICATIOffi~~''PIPEFITTER (TRAINEE) DATE* JULY 1, 1970 ITEM N0o B=31 SUBJECTS MAKE HYDROSTATIC TEST It Is the jpb of a Pipefitter to make hydrostatic tests on boilers, heaters, vessels, piping systems, etc. This consists of running test pumps, filling system with water, removing all air from the system and being able to follow out and know the system to be tested. Also the Pipefitter must be able to read testing diagrams | WA-TEX 004103 WA-TEX004103 TEXACO INC. ?mm^gQM5~Zkm PAGE 176 TRASHING DETAILS DEPARTMENT; PIPE CIASSIFIOATIOfflT""PIPEFITTER (TRAINEE) DATES JULY 1, 1970 ITEM NO. B-32 SUBJECTS RENEW TUBES The steps in changing a tube In an exchanger bundle are as followss (1) Cut tube on one end just inside tube sheet. Use internal cutting tool powered by an electric or air drI13 motor, (2) Remove the tube from the bundle with a hydraulic pulling tool. (3) Inspect the hole for cleanliness and Imperfections after tube and tube stub have been removed. (4) Install new tube using a plastic guide in the end. This will guide the tube through the baffles. (5) Measure the I.D. of the hole and also the I.D. and the O.D. of the tube. (6) After installation* roll the tube with a rolling tool on each end of the exchanger to a predetermined thickness. - { WA--TEX 004104 WA-TEX004104 TEXACO INC. PUGET SOTMirflAMT PAGE ITT TRAINING DETAILS DEPARTMENT? PIPE CLASSIFICATIONS PIPEFITTER (TRAINEE) DATES JULY I, 19TO ITEM NO, B-33 SUBJECTS BURNERS - GAS AND OIL A. REMOVE AND INSTALL Disconnect gas, oil, air and steam lines from burner, loosen nuts on packing ring around burner barrel, have proper rigging, remove burner from boiler or heater. After burner is cleaned and repaired, clean flange surfaces, unions and bolts. Then install burner in boiler or heater, connect gas, oil, air and steam lines. When flangingup gas, tighten bolts up evenly. Tighten nuts back up on packing ring, Bo CLEAN AND REPAIR When equipment is down we will go Into boiler or heater to clean gas burners. Clean scale off the burner tip, then get correct sized drill bit and angle of gas outlets. Insert bit In hand drill and carefully run bit through gas outlet being careful not to change the angle or size of the hole. When it is necessary to pull burner in order to clean, use the same procedure as above and then blow burner with air and steam. To repair burners, the Pipefitter will be Instructed by the inspector what has to be repaired or renewed. If bugner tip needs repairing, it is screwed on and then is seal welded, you have to grind off weld and screw off tip to repair, which in most cases would be a new tip. Screw tip on burner barrel, seal weld and It is ready for service. i { WA-TEX 004105 WA-TEX004105 T?n*m NATIONAL AIROIL BURNER : C-P TANDEM UNITS Established 1012---Incorporated 1917 ' ^ . ' . * *r s * * INDUSTRIAL OIL BURNERS, GAS BURNERS AND FURNACE EQUIPMENT ; .V . , k "* . :U 1284 E. SEDGLEY AVENUE PHILADELPHIA 34, PA., U.S.A. -. SOITOWJESTERN DIVISION--2S12 SOUTH BOULEYAUD, HOUSTON 6, TEXAS ' WA-TBX 004106 November. 195/ WA-TEX004106 ITEM NO. B-33 TRAINING DETAILS PAGE 179 WA-TEX004107 TEXACO INC. PUGW'loW'fEftMT PAGE 180 TRAINING DETAILS DEPARTMENTS PIPS CLASSIPICATIOirr^PIPEPITTER (TRAINEE) DATE; JULY 1, 1970 ITEM NO. B-34 SUBJECT; COILS A. REMOVE AND INSTALL In order to remove a coil it is necessary to either break bolts on flanges or have a welder cut the pipe with a cutting torch. To install a coil, flanges must be cleaned, then bolted up evenly. If pipes were cut to remove the coil, then the pipe must be cleaned of all slag and beveled before it can be welded again. B. REPAIR To repair a coil, either install a new pipe or ells in the coil. WA-TEX 004108 WA-TEX004108 : v*a;:-ck?y3? UGE!FsgiM>''~yiANT PAGE l8l TRAINING DETAILS DEPARTMENT; PIPE classipicatioWT"*"pipefitter (trainee) DATE; JULY 1* 1970 ITEM NO* B-35 * SUBJECTS STEAM AND AIR TRAPS A* REMOVE AND INSTALL To remove traps* make sure traps are out of service* then loosen unions on inlet and outlet of the trap. When install^ ing traps* be sure union faces are clean* then insert trap and tighten unions. B* The following information and illustrations describe in detail the design* operation and maintenance of various steam traps. ; WA-TEX 004109 WA-TEX004109 ITEM NO. B-35 TRAINING DETAILS ' PAGE 182 The Why and How of Steam Trapping Ntaijianktfyp? trap of By JOHN W. WELKER * MANY YEARS AGO Stearn was instantaneously when steam con allowed to blow free to the at denses, amounts to several times the mosphere because it was inexpensivseensible heat which is lost only slowly to produce. Later as costs became as water cools from the boiling point more of a factor, devices such as or to a lower temperature. It is therefore dinary cocks or simple valves were desirable to eliminate condensate as used in an attempt to trap steam in soon as formed. At this point about .process equipment, and at the same 75 per cent of the usable heat has time to allow condensed steam (con been lost, and condensate becomes a densate) to escape. These devices detriment to efficiency. were adjusted to function under av This article deals solely with non erage .conditions, but could not be return designs which discharge to counted on to function unattended pressures less than inlet pressures. as desired under varying loads. A non-return trap does not initiate In this article we will give a brief the action but allows steam pressure description of the main types of steam on trap inlet to force condensate trap in use today. They will not be and/or air through it to a disposal in any particular chronological order. or return system, and at the same A steam trap by definition, is an time it prevents escape of steam. automatic device for draining con Steam traps may be classified in densate and air from any space where several ways but the most practical steam is condensed. Steam condens classification is on the basis of oper ing in heating equipment must be ating principle. Thus: -- drained to maintain maximum heat Mechanical Type -- operates on transfer. Condensate in steam mains difference in density of steam and must be drained to prevent water condensate. (Open Bucket -- In hammer and other dangers created by verted Bucket --Closed Ball Float.) slugs of water. Air must be eliminated Thermostatic Type -- operates on to prevent dilution of steam, reduc difference in temperature of steam tion of heat transfer, and in some and condensate. (Balanced Pressure cases corrosion. At the same time in --Liquid Expansion -- Metallic Ex any of the above cases steam should pansion) not be allowed to escape. A good Thermodynamic Type -- operates trap meets all these requirements. on the difference between the be If condensate is allowed to remain havior of steam and the behavior of in steam-heated equipment, the ca condensate when passing through pacity of the equipment is reduced. two orifices in series (Impulse -- Condensate by filling possible steam Labyrinth); or operates on the differ space acts as an ihsulator between ence in the internal energy of steam steam and the material being heated, and condensate when passing through and has very little usable heat when a nozzle (Kinetic Energy). it is compared to an equal weight of There are certain combinations of steam. Heat required to raise water these basic types. The following de to the boiling point is sensible heat; scription of each type will provide a heat to change water to steam at the better understanding of how they are boiling temperature is latent heat. This latent heat which is lost almost Company . *'Application Engineer, Yarnall-Waring V- Fig.` 3.:Another. mechanical type ` i trap! Closed ball float design 5--,, . i- . j.,* * t. ' r'l-tt *, .,*'* is* -- v,- - POWER ENGINEERING : WA-TEX 004110 DECEMBER, 1955 WA-TEX004110 ITEM MO. B-35 TRAINING DETAILS PAGE I3 constructed and how each operates. trap body which means that valve charge is continuous. A ball float Illustrations are diagrammatic, and B is open. Condensate entering is sometimes guided so as to seal the in no way present details of design. through A drives air out of body valve itself, but most often it operates They are used to illustrate in simple through B. Air in the bucket escapes a lever system as shown. Closing terms the basic design and opera upward through the fixed orifice C in power is a function of the weight of tional characteristics. the bucket top. After residual steam the float; opening power is a func Mechanical Traps in the bucket condenses, condensate tion of the buoyancy of the float com ultimately fills_ the trap body and bined with the mechanical advantage The mechanical trap differentiates bucket, and discharges through B. of the lever system when used. These between condensate and steam by If steam reaches the trap it displaces factors combined determine capacity virtue of the difference in weight be the condensate in the bucket, and and operating pressure ranges. , tween the two fluids. . even though a small amount of steam The valve opening, at any load escapes through C, the bucket be within its rated capacity, is a func Open Top Float, Bucket Type (Fig. 1) comes buoyant and valve B is closed. tion of the rate of flow of condensate Condensate flows into the trap at As condensate follows, a point is into the trap (a function of the load, A, and is usually deflected downward again reached where buoyancy is lost, in fact). by a baffle B. The body of the trap and valve B again opens to allow con Alls with condensate, and the empty densate discharge in cycles. The size Thermostatic Traps bucket G is buoyant and floats up of the orifice C determines at a given The thermostatic trap differen- , ward closing the valve C. The bucket operating pressure the air handling tiates between steam and condensate is now at its highest position and as capacity. Steam loss through this by virtue of the temperature dif additional condensate enters the trap orifice is determined in an inverse ference between the two. it begins to spill over into the bucket at D. The bucket then fills to a point where it is no longer buoyant, and fashion. In some designs this orifice is closed by a simple thermostatic ele ment which must be sensitive to a Balanced Pressure (Metallic Bel lows) Design (Fig. 4). sinks, opening valve C. Steam pres small increment of temperature be These traps are operated by a sure at A then forces the condensate tween hot condensate surrounding sealed thermostatic element, usually out of the bucket through C, The the bucket and steam temperature called a bellows, having a flexible bucket again becomes buoyant and within. The weight of the bucket wall of a metal suitable for the rises before it is completely empty so opens the trap valve B, and its buoy operating conditions. that a water seal is maintained at E ancy when filled with steam closes The wall thickness of the flexible to prevent escape of steam. On start the valve. As with the open bucket, bellows is designed to give maximum up and frequently during operation the area of valve and operating ratios resistance to the pressure differen this type of trap will become filled are established by the weight of the tials it must withstand and, at the with air which must be released to bucket. same time, maximum resistance to permit sufficient condensate to enter trap to make it operate. An air re Closed Ball Float Design (Fig. 3) fatigue. The sealed element or bellows con lease valve F, usually manually op At start-up the float is at its lowest tains a liquid, which may be pure erated, is necessary. This valve is position, and valve B is closed. If water, a mixture of water'.and a suit opened to purge air, but must be there is a lot of air in the system, a able volatile fluid, or a volatile fluid closed to prevent steam loss. manual vent F must be opened to alone, depending on the character The discharge is intermittent and allow condensate to fill the trap. Al istics of the element design. the trap cycles at intervals deter most all ball float steam traps today One end of the bellows is rigidly mined by the amount of condensate are equipped with- high capacity fixed to the trap body; the other end handled per unit time. The weight of auxiliary air vents operated thermo has the valve attached and is free to the bucket, which is a constant, must statically or by other automatic move. When cold, the bellows has a oppose the force created by the valve means. These vents are designed to length permitting valve B to be open seat area multiplied by the operating release air at temperatures approach to pass air and condensate. As it be pressure. The weight of the bucket ing saturation temperature so that comes hotter the bellows lengthens, establishes one of two limiting pos they will release air on starting and and finally at a temperature ap sibilities-- the maximum operating during operation. proaching,that of steam the valve is ` pressure for a given seat area, or the To prevent steam blow through closed. maximum valve area for a given the trap, valve B is usually covered Because of the lower boiling point operating pressure. by condensate before the float rises of the mixture inside the bellows, a Inverted Bucket Design (Fig. 2) to open the valve. The float rises in vapor pressure differential between proportion to the amount of conden inside and outside is established just On start-up, the open-bottomed sate entering the trap, and so long as before steam temperature is reached bucket is resting on the bottom of the condensate flows to the trap, dis in trap body. The differential pres- ! j WA--TEX 004111 l WA-TEX004111 ITEM NO. B-35 TRAINING DETAILS PAGE 184 sure causes expansion of the bel lows and closes the valve to prevent escape of steam. Condensate in the trap must subcool to a temperature trol flow, and the annular space is the first of the series of two orifices through which it passes. The second is the control orifice in the center of where internal vapor pressure in the valve F. As condensate passes into bellows balances that oulsirle before chamber K and then through the the trap will again open. Vapor pres control orifice into trap discharge, sure temperature curves for water pressure is reduced. When hot water and the mixture in the bellows are under pressure passes into a lower essentially parallel. This fact insures pressure it will flash to a greater or a positive differential pressure avail lesser degree depending on initial able for closing the trap independent temperature and the pressure drop. of the operating pressure. ' . Balanced pressure elements filled The degree of flash determines the pressure in chamber K; this pressure with pure water are expanded by the in turn determines whether valve F spring properties of the bellows wall. is seated or open. Cool condensate Bellow straps are normally not flashes little, chamber pressure is low, recommended for superheat opera and the valve is open; this results in tion. Superheat creates excessive va the trap floating on the load and por pressure and tends to rupture the passing cool condensate as fast as bellows. Discharge from a bellows formed. The trap is designed so that trap is usually intermittent. Where condensate close to steam tempera condensate formation and tempera ture will flash sufficiently to raise ture are constant, continuous flow pressure in control chamber so as can result. to exert sufficient differential pres Balanced pressure traps do not sure between top and bottom of disk need auxiliary air vents, for they are to close valve before steam arrives at wide open when cold and freely trap inlet. Control flow through the release air up to temperatures ap two orifices in series continues at all proaching saturation. - Fig. 8, Above. A "labyrinth" type times and represents only a few per Metallic Expansion Design (Fig. 5) trap. Betow. An "orifice" type l ....... . .... ....................... . cent of total trap capacity. This now makes the trap continuously and im On start-up air passes through the mediately responsive to slow or rapid valve B. Condensate follows and as it valve, and as steam reaches here, the changes in medium reaching trap. becomes hotter tube T (which forms valve closes tightly. Gradually the a valve seat at one end) through which it is flowing, expands. This ul element cools, contracts and opens the valve once more. It will continue New High Capacity Impulse Design (Fig. 9) timately results in the seat being to sample the medium entering at A; Recent modification of the two- dosed against the valve. The valve is if steam is still at the trap the valve orifice-in-series design of Fig. 7 has adjustable to permit setting for clos will immediately close, but if conden resulted pipe size for pipe size in a ure just as steam temperature is sate is there it will stay open to a de much higher-capacity impulse trap. reached. Such a trap has good charac gree inversely proportional to con This design incorporates the same teristics so long as steam pressure is densate temperature. The adjust two-orifice-in-series principle for con constant. If pressure increases, the ment at F permits setting the trap to trol of trap operation. Howeyer, in trap will close prematurely because operate at a definite temperature. this design 100 per cent of flow passes closing temperature will be lower This type discharges continuously through the two orifices, instead of than steam temperature unless the except under light load when it has a only a small percentage as is true valye is reset for higher pressure (and sampling or intermittent action. Ca with the original design of Fig. 7. In temperature) conditions. If pressure pacity is determined by both steam Fig. 10, the trap is shown in the decreases, the trap valve will not be pressure and condensate tempera closed position. The two valves, one . closed when steam reaches the trap ture. It will close at a temperature conically-shaped A, the other flat- resulting in steam blow through the below 212 F (assuming atmospheric, disk B, are mounted on a common trap. In order to have appreciable ex discharge). valve disk which raises and lowers pansion for valve movement, the Liquid expansion traps should be as a lever at a fulcrum point C. metallic expansion tube must be long used only on applications where con When steam is turned on, upward which results in an abnormally long densate can be held in the heating pressure of air and accumulated con trap. Discharge is continuous and surface until it cools to below 212 F. densate lifts valve A and simul at a set pressure, it can be set to dis Unless this can be done, a cooling leg taneously valve B; the mixture of charge at any temperature up to must he provided between apparatus air and condensate passes from' line steam temperature. and trap to provide subeooling be pressure at trap inlet through the Liquid Expansion Design (Fig. 6) tween the desirable condensate tem perature and 212 F. This type consists of a liquid-filled thermostatic -element which expands Thermodynamic Traps and contracts on a temperature dif The operation of this type of trap ference between condensate and depends on thermodynamic proper steam. Liquid is used to obtain ties of hot condensate and/or steam greater expansion per degree of tem as either or both pass through some perature difference; thus greater form of orifice or orifices. valve movement and a more compact design is achieved than with metallic Impulse Design (Fig. 7) expansion. Whether valve F is seated on G or On start-up air passes through the open is determined by pressure in trap followed by condensate. As con chamber K above disk L. In either densate becomes hotter, the liquid position part, or (if valve is closed) in the thermostatic element expands. all of the condensate passes upward Piston B which is free to move slowly through the annular space between closes valve C against seat D as the disc L and tapered cylinder D into liquid expands. The thermostatic ele control chamber K. This portion of Fig. 9. latest impulse design for high ment is on the outlet end of the trap the condensate is known as the con capacity service WA-TEX 004112 WA-TEX004112 ITEM NO. B-35 TRAINING DETAILS PAGE 185 first or inlet orifice into the inter n-mediate pressure chamber D; thence / 'hrough the second or outlet orifice into the low pressure of the return system. ,,, . Opening and closing of valves is controlled by the intermediate press ure in Chamber D. This pressure varies directly as the thermodynamic state of .fluid passing through the two orifices in series. Therefore, as condensate temperature approaches steam temperature, flashing of con densate into steam increases m the lower pressure region on optiet side of valve B. This raises pressure in chamber D sufficiently to close valves A and B. In closed position, a small Fig. 10. Latest impulse design for low capacity services certain amount flashes into steam by virtue of an excess of sensible heat at the lower pressure. The closer the condensate is to steam temperature, the higher the percentage of a unit weight will flash. Any orifice placed in the flow path of condensate will tend to regulate flow in inverse rela tion to condensate temperature. Fig.. 8 shows two designs. In one there is a labyrinth followed by an adjustable orifice A; in the second there is a series of orifices Ai, As, At, At, As, A6. The second design has an expansion chamber between each ori fice. When steam is turned on, air "cascades" through the orifice series, taking a pressure drop at each stage, amount of condensate continuously flows through the two orifices to maintain control of trap operation. When condensate temperature drops a few degrees below steam tempera ture, the valves again open wide. Bapid discharge of condensate flow ing to trap is obtained over complete due to condensation of steam in chamber and slight control flow be- tween ground surfaces of valve and seat. Valve then reopens, condensate is discharged and cycle is repeated, with valve closing again when steam reaches trap. but eventually is discharged through the outlet. Cold condensate follows and also passes through. As the tem perature rises, flashing begins at a point determined by not only tem perature but also by clearances and expansion volumes. These last two factors are manually adjustable; if temperature range from cold water to Kinetic Energy Design (Big. 11) too wide open, no control is possible condensate near steam temperature. and even steam will pass through This trap -consists of a body and the trap. If the setting is too close, New Low Capacity Impulse Design cap, and a valve disk A. It employs only cool condensate can pass. This (Big. 10) the kinetic energy of the steam to design can he set to pass condensate The operating mechanism of this trap consists of a valve disc (A) mounted on a flat seat. This seat contains lai^e inlet orifice (B), lo , cated slightly off center, and four ' smaller discharge orifices opening close the valve. In operation, pressure raises disk A from the seat to allow discharge of air and condensate at steam tempera ture. Steam .follows, and its high velocity creates low pressure under just below steam temperature at a given pressure. At a given setting, if pressure drops, steam can pass; if pressure rises only condensate at a lower temperature can pass. Dis charge is usually continuous so long into annular discharge space below the disk and builds up pressure in as condensate reaches the trap. Con seat. (One shown -- "C") chamber F by reeompression. densate pressure and temperature At start up, when pressure reaches This pressure in chamber F, acting control the operation. Only a manual trap, the valve disc tilts upward or on the full top area of disk A, exceeds change in setting can upset these re rocks on its rounded fulcrum (D) the combined force of the incoming lations. edge, discharging condensate and steam and that in. the low-pressure air at full capacity. This tilting action is produced by the off-center force exerted on the under side of the disc due to the off-center location of the inlet orifice. As condensate nears steam temper area, thus immediately forcing the disk down and closing the inlet. As condensation decreases the pressure in the chamber, the disk is raised and the cycle repeats. The trap is de signed to close tight on no-load. ature, flashing occurs in discharge ports (C), choking the flow and- rais Other Orifice Designs (Fig. 8) ing pressure in control chamber (E) These traps are often called "laby above disc. The instant steam reaches rinth" traps. To understand the op trap, it develops greater pressure on . eration of this kind of trap it must upper side of valve disc and snaps 'be remembered that for a given valve shut. This in turn relieves the weight of steam the higher the pres back pressure in the discharge ports sure the less room it requires; thus if below disc and adds to the force discharged to a lower pressure, it will holding valve shut. expand. Similarly, if condensate at or Valve remains closed until pres near steam temperature and pressure Fig. 1 7. Diagram of kinetic energy type sure in control chamber is relievedI is discharged to a lower pressure, a . of trap tI WA-TEX 004113: WA-TEX004113 ITEM NO. B-35 TRAINING DETAILS - .. . <. PAGE lbb s:-- i.,w g 0 3 ISO #1 f IffiSsSX tm I: no t&v.V -'-y ;W'r" -..t ` ->* -A -V-c^^r -U-. ' l > <^,v V. ft iojE ij 7 f Ys sjS, ..eEuqJi yftp* teL ' ;.y=- ->. " iv ,W,, si 6 jTe** / y :%^k&"ikr'- ' 10 o w u 1- SATURATE D STEAM 0 30 40 SO 0 70 ABSOLUTE PRESSURE LBS PER SO IN : Mr' 8'.0 . --9--0------1*00' . -*. - J ."W ' V, *:'I> > Y' v--;, ~*v ^ 'r v ^ . *, _ ,V 'v,,7 . .'i, V , ' v A .Y . a'aa^'i - L ^ ^ . M n V- 4 *t. AiwKr V *"-.J|T| r Fig. 1. Relation between condensate handling capacity at various condensate temperatures. Curves based on test data far an orifice with area of 1 sq in. The Why and How of Steam Trapping Si. Selection-- Siting--Application By JOHN W. WELKER * Table I. Values of x = (T-t)/L used in text formulas for figuring trap loading Pressure, prig 5 to 15 20 25 30 35 40 50 60 75 too 125 150 175 200 40 0.042 .042 .042 .043 .043 .043 .043 .044 .044 .044 .045 .045 .046 .047 .047 .048 60 0.062 .063 .064 .064 .064 065 .065 .065 066 066 067 068 06? .070 071 .072 8b 0.083 .084 .085 .085 .086 'Temperature rise, F 100 120 .140 0.104 .105 .106 .106 .107 0.125 .126 .127 .128 .129 0.146 .147 .148 .149 .150 .086 .108 .129 .151 .087 .108 .130 .152 .087 .109 .130 .152 .087 .110 .132 .154 ,088 .111 .133 .155 .0.89 .112 .134 .156 .091 .114 .136 .159 .092 .115 .138 .162 .093 .117 .140 .163 .095 .118 .142 .165 .096 .120 .144 .167 160 0.167 .168 .169 .170 .172 .172 .173 .174 .176 .177 .179 .182 .184 .187 .189 .191 180 0.187 .18? .191 .192 ,193 .194 .195 .196 .198 .199 .201 .204 .207 ,210 .213 .215 200 0.208 .211 .212 .213 .214 .215 .216 .218 .21? .221 .224 .227 .230 .234 .236 .239 ormal selection of a N steam trap depends on the an swers to two questions: (a)...What type of trap can best be used? and (b). What is the correct size of trap to use? To answer these questions the trapping problem frequently requires detailed analysis. Each type of trap Has certain limitations. Here are some factors which govern selection, appli cation, and successful and continuous operation of a trap. 1. Pressure or range of pressure at inlet: Pressure and condensate handling capacity are directly related in ail traps. In some designs, varying pressure limits use. Only by change in valve parts can a bucket trap be used above a limiting pressure set by the weight of the bucket. In a metallic expansion trap at a giyen * Application Engineer, Yarnatt-War ing Company POWER ENGINEERING ; I WA-TEX 004114 JANUARY, 1?S6 WA-TEX004114 ITEM NO. B-35 TRAINING DETAILS rAiiJi xvi Table II. Data for use when heat exchanger has excess surface which heats liquid in less time than required by process Blu/iq 4-i Mtd** ft/hr Pounds per hour per square foot Steam pressure, psig ------- 60tf<I 5 25 50 100 150 200 250 300 350 400 450 500 10 20 30 - 40 280 930 1,900 3,100 . .28 .96 1.96 320 39 .97 1.98 3.23 30 1.00 2.03 3.32 31 1.02 2.08 3,40 32 1.05 2.16 3.52 33 138 222 3.62 33 1.11 2.27 322 34 1.14 232 328 35 1.16 236 3.85 35 1.18 241 3.92 36 1.20 245 3.99 37 1.22 249 4.06 37 134 253 4.13 38' 128 2.61 425 , 50 4,500 60 . 6,250 70 8,000 80 10400 4.65 6.45 8.26 10.73 4.68 651 8.33 10.83 4.82 6.69 857 11.13 4.93 6.86 ' 827 1140 5.11 7.10 9.08 1130 525 730 934 12.14 5.38 7.47 956 12.43 548 7.62 925 12.67 558 726 9.94 12.92 5.69 7.92 10.15 13.17 5.80 8.06 10.32 1340 5.89 8.18 1047 13,62 5.99 833 10.65 1335 6.17 858 10.97 1436 " 90 100 135 150 12,500 15,000 22,400 30,000 12.90 15.47 23,10 30.95 13.00 15.62 23.30 31.20 1337 16.05 23.95 32.10 1320 1644 24.55 32.90 14.20 17.03 2545 34.10 1450 1750 26.15 3520 14.94. 17.90 2625 35.85 15.24 18.28 2730 3650 1553 18.63 27.80 3730 1533 18.97 28.35 38.00 16.13 1934 28.90 3820 1636 19.64 2930 3930 16.65 19.97 29.85 39.95 17.15 2057 3023 41.15 175 200 250 300 40,000 50,000 82,000 100,000 4130 51.60 8320 103.30 41.65 52.10 8530 104.00 42.60 5350 8725 107.00 43.80 54.80 90.00 10950 4540 5625 93.10 11350 4420 5830 .9520 116.60 47.80 5920 98.00 11940 4825 60.90 100.00 122.00 4970 62.10 102.00 12430 50.65 6330 10320 12650 5150 6450 10520 128.80 5240 6550 10730 13150 53.30 66.60 10930 13330 5435 68.60 11.250. 137.00 ' * For copper, multiply table data by 2.0 ** Mean temperature difference, F = temperature of steam minur average liquid temperature For bran, multiply table data by 1.6 Heat transfer data for calculating this table obtained from and used by permission of the American Radiator & Standard Sanitary Corp. Table III. Radiation from heating surface H(tj -- ts)/l in lb of condensate /hr/sq ft used in formulas for obtaining trap,loads Steam pressure, psig temp, F Ui 2 5 10 15 20 25 50 75 100 150 200 250 300 350 400 450 500 600 32 53 54 57 .70 24 28 31 t32 1.13 130 146 120 136 1.97 2.31 241 252 2.62 3.14 50 .48 .49 52 .56 1 .68 ' 21 .74 .87 1.06 1.15 138 1.52 [ 124 135 1.96 2.06 241- 252 271 60 45 46 .49 .53 56 59 21 .84 1.02 1.10 1.34 147 158 1.80 1.91 2.00 235 2.46 2145 65' 44 45 47 52 55 58 .69 32 1.00 1.08 132 145 156 127- 138 1.9!7 2.07 243 2.62 70 39 40 45 .50 .53 ' .56 59 .80 0.98 1.06 1.21 143 154 125 136 1.95 2.04 239 2.59 75 38 39 44 49 52 55 58 .77 .88 1.05 1.19 140 152 1.62 133 1.93 2.02 2.11 256 Value of heat toss . 2.6. used (H) .23 33 - * Based on still airs far forced-air circulation mulUpty above values by 5 ' 3.5 325 4.6 . 45 Table IV. Overall coefficients of heat transfer. (Under many conditions higher or lower values may be realized) Type of heat exchanger Liquid to liquid setting, correct operation depends on a constant temperature which means constant pressure. An impulse trap is designed for a wide range of pressure without, adjustment or change of parts. ` 2. Amount of air to be handled: Bellows, impulse, orifice, metallic and liquid expansion traps all have excel . lent air handling capacity. Some bucket traps incorporate thermostati cally controlled air vents to permit handling large volumes of air. 3. Heat-up time required: If heat up time is not important, a trap can be appreciably smaller than if the abnormally high amount of conden sate formed on start-up must be handled quickly. 4. Type of discharge desired {con tinuous or intermittent): Ball float, metallic or liquid expansion, and impulse traps are suitable for appli cation where continuous condensate discharge handling is desirable. Bel- liquid to liquid Liquid to gat* Liquid to boiling liquid Liquid to boiling liquid Gas* to liquid Gas* to gas Gas* to boiling liquid Condensing vapor to liquid................... .. Condensing vapor.to tiquid Condensing vapor to fkjuid . .................... Condensing vapor to liquid............................... Condensing vapor t.o.... .. Condensing vapor to . boiling liquid*.............. .. Condensing vapor to boiling liquid Condensing vapor to boiling liquid *At atmospheric pressure. Free con Forced con vection, K vection, K Typical Fluid Typical apparatus 25- 60 150-300 Water 5- 10 1- 3 20- 60 5- 20 1- 3 0.6- 2 1- 3 20- 50 2- 10 50-150 25- 60 2- 10 2- 6 2- 10 08 Water 08 Uqutd-fo-ilquid beat exchangers Hot-water radiators Brine coolers Air coolers, economizin' Steam superheaters Steam boilers 50-200 150-800 Steam to water liquid heaters and- condenser* 10- 30 20- 60 Steam Jo oil 40- 80 ,60-150 Organic vapor to water 15-300 Steam-gas mixture 1- 2 2- 10 Steam pipes in air, air heaters 40-100 Scale-forming evaporators 300-800 Steam to water 50-150 Steam to oil ! WA-TBX 004115 WA-TEX004115 ITEM NO. B-35 TRAINING DETAILS PAGE 188 lows traps (except where flow and ally results in a lower pressure at the H - Heat loss expressed-in BtU/sq- temperature are constant) and bucket (rap in let winch reduces trap capacity !if-Vhr ` ~ ` " v traps normally .have an intermittent discharge. 5. Required discharge tempera when load is at its maximum. When the system reaches operating temperature, condensate formation t, -- Steam temperature at trap pres sure- - deg F ture of condensate; Some traps han may be relatively constant, or it may I*. --- Ambient air temperature -- F dle condensate at or very near to steam .temperature. Others require a differential in temperature called sub-cooling between closing on one cycle and opening on the next. Care vary considerably depending on tin; application. To compensate for some of these variables, a factor of safety .must be used as a multiplier of cab u- laled.load to determine the final fig iv ~ Coefficient of heat transfer (See Table IV) . Ci - Gallons of liquid heated per unit time ful review of a trap should be made ure to be used as a selection from w *= Weight of liquid being heated to determine condensate handling catalog capacity tables. -- Ih/gallon capacity at various temperatures be There are many methods to calcu low steam temperature. late load, but generally calculations The formulae and data given above - G. Back pressure in return system: involve! the use of formulas such as when applied to a specific problem Increase in back pressure will nor those listed below -- each formula will produce condensate load. The mally decrease discharge capacity designed for a specific type of appli load must then be multiplied by a and in the case of some trap designs cation -- safely factor before trap capacity such increase is a limiting factor oh (1)C = WSX Used for pressure tables can be used to size the trap. proper application. This detail should vessels such as retorts, autoclaves, These factors vary between 2 and 5 be checked with the manufacturer. etc., where steam is applied directly and take care of variations in steam 7. Available space: Space normally to solid materials being heated. pressure, discrepancies between as is not a factor, but dimensions such (2) C = WX + 970 fW-D)/L Used sumed and actual data (the latter of as the length of a metallic expansion for dryers, platen presses, etc., where which is rarely known), unpredictable trap may be significant. steam loses its latent heat indirectly and abnormal operating conditions, 8. Maximum temperature expected to solid material through metallic etc. Generally a factor of 2 applies at trap inlet: Bellows traps are not surfaces. io submerged coils discharging to normally recommended for use oti (3) C - AY Used for pipe coils to gravity, and pressure vessels. superheat, which places significance heat air such as found in unit heaters Dryers, pipe coils in air and sub- on maximum temperature to be ex and chamber dryers where steam nr'rg.-d surfaces draining to a trap pected at trap inlet. loses its laien t heat indirectly through above the surface take a fac 9. Installation cost: Cost is usually a metallic surface. tor el 3. Coils over which air is forced insignificant when compared to the (4) C = KAX Used for .submerged us'iiuiy take a factor of 5. savings a properly applied trap can surface where quantity of liquid Catalog recommendations should ' make. Certain types of traps that are heated is unknown. b-: followed for the type of trap se- comparatively large create excessive (5) C =- GWSX Used for submerged ! -i.-.-t' fr. is important to ascertain installation expense. surfaces where the quantity of liquid, t he temperature base on which cata 10. Maintenance cost: Simplicity heated is known. Here steam loses log capacity tables are calculated. of design, the number of moving its heat through metallic walls of Suns, capacity decreases with rise in . parts, whether a trap can bo serviced coil or other metal surface submerged condensate temperature, the lower quickly under pressure -- all are fac in a vessel when liquid is being thu temperature base, the higher the tors to be considered in maintenance. heated. Cookers, heat exchangers, fad or of safety must be. Once the type of trap lias been se etc., where steam loses its latent heat The relation between condensate lected, condensate load must be cal indirectly to a liquid through a handling capacity at various conden- culated to determine trap size. Trap metallic surface represent the typo of satu temperatures is shown in Fig. .1. catalogs tabulate capacity-pressure equipment involved here. 'These curves are based on test data relations, and a study of such tables lor .an orifice having an area of one shows that capacity generally does Symbols used sq in. if the area of a trap orifice is not increase in direct, proportion to the pressure differential across the C = Condensate lb per unit time kmnoi, these curves can be used to. approximate capacity (at a given trap. These tables will also show that, W = Weight.of medium being heated pressure) by multiplying the orifice body and pipe connection size are not in lb are:* in .sq in. by the rate of flow from true indices of capacity. In the case of the impulse design the manufac turer provides a very simple selector S = Specific heat of substance being heated riv appropriate curve, and then by appropriate orifice coefficient. ! icq neatly heat exchangers con bulletin. Trap sizes can he determined quickly by using this selector without the necessity of first calculating amount ol condensate. Load from X = (T-i).-L i Table I) (T-i) - Temperature rise of sub stance healed in deg F (See Table f; tain excess surface which results in hinting a quantity of liquid in a time tI'.a'n she process calls fori This .insults iti condensate being formed steam apparatus is expressed in lb per hr of condensate formed. Load char acteristics vary considerably. During L -- Latent heat of steam at fra;, operating pressure in BTU/lh at n in.'re rapid rate than expected, ripc.-nd varc should be taken to .-.fit the load under these condi- start-up load is heavy as air as well as D - Weight of substance boated t ion.-. .so i hat condensate is withdrawn '' condensate must be removed in large after drying -- lb ns soon as .it, is formed to maintain quantities. Condensate is forming at a rapid rate during start-up because A = .Heating area -- sq ft highest oiticiency. In these cases do i'oi use formulae 4 or 5 but multiply all parts of the apparatus and con Y --- Radiation from heating .t::-- .i lie. submerged area by the applicable . nected system must be brought up to faee H L in lb of condensate/ factor from Table II to obtain the temperature; and this condition usu hr/sq ft (See Table III) . WA-TEX 004116 WA-TEX004116 item no. b-35 TRAINING DETAILS PAGE 189 Tib Wtif and He's? of Steam Trapping .IMt-XCU MKUUKUSUtfSI t"" Fig, 2, Kfgfch Taking kt o/td ot/f frop fsmperafures w/rfi ca^farcr pyrometer III. Ifistaltetfeii -- Mointefissice -- Tsmefbie By JOHN W. WSiKSK* INSTALLATION must be correctly and avoid steam binding. made to take full advantage of a 13. When a group of traps dis trap. This must be followed by charge into a common header, install adequate preventive maintenance a check valve between each trap and schedules. A list of installation in the header to prevent reverse flow structions below can be used as a during shut-down. general guide to good trapping, .14. Install larger traps on the first 1. Carefully check piping and blow and possibly second coil of a number it out under full steam pressure before of coils which are in series wil h connecting traps. respect to air flow through them. 2. Check flow directional arrows or 15. J3e sure return line is no higher markings on trap bodies or name above trap than the level to which plates. the lowest. line pressure can lift con 3. Install a Dutch weave mesh densate. Multiply lowest.ime pressure strainer ahead of each trap. by 2 to determine maximum height. 4. Install test valve at a "T" fitting 16. Install unions on noth sides of in discharge line to check operation. a trap to facilitate removal. _ 5. Install traps at accessible loca 17. Never use piping snmlier than tions. the connections to the trap. 6. Install traps where possible at 18. Keep return line piping large lowest points in system. enough to prevent excoisi'. e back 7. Install traps (except thermos pressure. Use Pig. .3 to determine tatic types) as close to r-cguipment as return bin- size. finU-r chart from possible. ' left at orifice area. iVJi.-rr- t b ;s hori 8. Install shut-off valves on both zontal line intersects the "'pa w;:t inlet and outlet to enable isolation of raled.eapseiiy" iir.e -Vi me a vertical for maintenance purposes when re line upward to the appruj:! bars: quired. pressure line. Front- this kuersvetipn 9. Trap each coil or each heating draw a horizontal Hue to the right unit individually. .to the appropriate '"length of pipe" 10. Where condensate is to be line. Draw a line vertically downward lifted above the trap, install a check to determine return line mkv. For valve between trap and riser. more than one trap, wink each one 11. Install only self-draining traps through the chart and add ureas to when they are subject to freezing get over-all pipe size. The "percent conditions. of rated capacity" line is determined . 12. Pitch horizontal inter, lines to by dividing 100 per cent hy the factor traps to keep them full of condensate of,safety used. 19. Install a water seal to prevent steam binding when trap can only be installed above lowest point in apparatus. Water seal should be com bined with a check valve to prevent back-flow. , Here are some maintenance and trouble shooting suggestions: 1. Check all traps at least once a year for cleaning and possible repair. 2. Check internal parts .such as valves, seats, bellows, floats, etc., to be sure they are in good shape. 3. Clean or blow-out strainers at frequent intervals. 4. Certain tools are suggested for checking trap performance: (a) Thermometers can be placed in thermo-wells before and after traps to check temperatures at these points - indie-x of performance. <>>} Frr-s-iurii gage can be placed at inlet of trap to check actual pressure at trap which can in many cases be much lower than b.ofler pressure. The pressure at the trap inlet (not boiler pressure) determines trap capacity. '!<; A portable contact pyrometer is probably the best tool for checking trap performance. Temperatures on inter and outlet can be closely esti- Engineer, YnrnalUWar- istjti Curnpatxy FEBRUARY, 19S6 POWER ENGINEERING W&-TEX 004117 \ WA-TEX004117 ITEM NO. B-35 TRAINING DETAILS PAGE 190 Fig. 3. Chart for finding the return line size. All return lines must be kept large enough to prevent excessive back pressure mated by use of this instrument in contact with clean metallic surface. 5. A cleaning fluid is recommended for cleaning rust from trap parts. 6. A basic trap hook-up is shown in Fig. No. 1. To check performance of trap C (assuming valve M is open and normal pressure is at trap): -- (a) Close valve F tightly to pre vent return line interference. (b) Open valve E. (c) If condensate comes out at G, trap is draining. (d) At this point if equipment N is not up to temperature, the trap may be too small or the strainer B may be partially clogged, (e) If nothing discharges at G (no pressure) there are three logical pos sible conditions -- inlet valve M is closed Or blocked, line or equipment between M and C is blocked, or strainer B is dogged. (f) If nothing discharges at G with ressure at trap, the trap parts may e worn or defective. If a bucket trap is installed, pressure may be too high, orifice may be too large for the pressure or venthole in bucket may be plugged. If an impulse trap is installed, orifice may be clogged. (g) If steam discharges at G, there are quite a few possibilities. Trap seat may be worn- or wire drawn or the same, the trap 'is blowing steam. held off seat by dirt. Mechanism Fig. 2 shows a contact pyrometer in may be holding valve off the seat. If a use. bucket trap is installed there is a 8. If a trap drains continuously at possibility that there is no condensate, constant rate, there is a good possi in the trap body to float the bucket. bility that the trap is too small, or In this case close inlet valve to appa apparatus being drained, if heating a ratus for a few minutes to reestab liquid, is ruptured and liquid is leak lish prime. With an impulse trap, ing into the line to the trap. the trap may be too large or back 9. On observing trap discharge pressure too high. do not confuse flash steam with 7. If no "T" is available or trap live steam. When the pressure of discharges as shown at "D" in Fig. hot condensate is reduced as it passes No. 1, a "phantom" test is available through a trap, a certain amount of by using a contact pyrometer--an this condensate flashes into steam instrument used for measuring tem at the lower pressure. This is actually peratures of metallic surfaces. By a good sign of efficient trap perform taking a temperature reading on ance. Equipment cannot be kept hot cleaned surfaces at both trap inlet with cold condensate. No flash steam and outlet, trap performance can be indicates such a condition. analyzed. The inlet temperature Most traps .are small inexpensive should be.essentially saturated steam devices. If they are properly selected," temperature. The outlet temperature installed and maintained, they can should be lower -- the degree being contribute greatly to overall process partly determined by the. type of efficiency. Much large and expensive trap. Impulse traps for example dis equipment can only function effi charge almost continuously very close ciently by proper trapping. Thus to steam temperature. On the other trap application assumes a much hand, bucket traps accumulate con greater importance than is indicated densate which is discharged inter by the relatively small cost of the mittently resulting in varying outlet trap when overall economy of equip temperature. With any trap if inlet ment operation throughout a plant and outlet temperatures are exactly is considered. , WA-TEX 004118 WA-TEX004118 TRAINING DETAILS PAGE 191 , `ft?/-'--' ' v'J'-i ys: Condensatejpy / ' " - fV* * *'.$!*. .* \ in- ' " > . *". *: \'yP$.-t-t 1-: 'UV. You can sJep up the performance of steam-using equipment by seeing that Its traps are working correctly. Here are tips on their care {5.Trap manufacturers recommend that you inspect and, if necessary, main . tain your traps at least once a year. They believe this procedure helps you get best efficiency from your traps. In a small plant, trap servicing is simple. But if a plant has more than 500 traps, the project may revert to little more than breakdown maintenance. Steam waste is too common in plants using breakdown maintenance. Too often the bypass is left open or the trap fails in the open position. Equip ment may operate all right, but much steam is wasted. Soutine or preventive maintenance is .-''-'he best answer to these conditions. fere's a plan that gives the maximum in annual maintenance. You can vary it to suit your needs. When you make spot checks of the traps, only portions of the program may he necessary. Maintenance program. To get this program rolling, existing installations may need certain changes. Though conditions vary. Fig. 1, 2 and 3 cover most plants. For equipment, you'll need: a sur face-contact pyrometer, a listening rod or trap stethoscope, steam - pressure gages, colored marking tags, repair parts, assorted fittings, steam-fitting tools and an oyerhaul bench on a small truck. Checking traps. Use a sounding de vice like a listening rod or stethoscope to find out if trap opens and closes properly. Or you can do this visually, as shown in Fig. 1 and 3. Steps in checking are: (1) Close return-line block valve C, Fig. 1 and 3. (2) Open shut-off valve D from test tee. (3) Ob serve discharge. Type of discharge varies with trap make. Get to know the discharge to be expected and learn the difference be tween liye- and flash-steam discharge. Steps 1 and 2 are not necessary in Fig. 2 because the condensate is returning to an open drain or sewer. Trap-size check. Process changes or poor selection may result in a trap be ing incorrectly sized. When watching the trap discharge, yon may find an oversized trap remains closed for ex tended periods, while an undersized one stays open continuously. Oversized traps may become steambound, requiring much time to con dense this steam before a new load of .condensate can be handled. This re duces production efficiency. With an undersized trap, condensate merely backs up in the equipment drained. This also reduces efficiency. Have the manufacturer size your traps, or employ a consulting engi neer. Then you'll know your equip ment will be properly drained. They should also check the size of the re turn lines when new equipment is added io an old system in your plant. ! WA-TEX 004119 i WA-TEX004119 ITEM NO, B-35 TRAINING DETAILS PAGE 192 Trap hookups for plant jobs--1* Condensate returned to an open flash tank with the return line below the trap. 2: Condensate being returned to the atmosphere or an open sewer. 3: Condensate being returned to an. open flash tank with the eondensate line above trap. 4: Suggested test stand for traps that have been Over hauled. 5; Typical arrangement of the dirt leg, air vent and vacuum breaker for a heated kettle. 6: Bypass arrangements for single and double traps. A typical sample tag for identifying plant traps is shown below. (:1 5 ' Tog Color to indicateyear BY GIEN CHASE The Yarnall-Wariag Company /V Near trap S Servicedtrap O Overhauled trop 5 Month of N,Sor O Trap efficiency. Most traps lose ef ficiency when not serviced periodically, even though they seem to work fine. For example, if batch cooking of a product takes 30 minntes with new equipment, the operator can turn out 14 hatches in a 7-hr day. If .the trap loses efficiency to the point where a batch takes five minutes longer, there is a loss of two batches per day. When a number of kettles suffer from this trouble, the loss in yearly production can he tremendous. And it all traces to trap efficiency. Best time to find expected efficiency t---v with a given trap is when it and the - ` equipment it serves are new. To make this check: (1) Be sure the steam header is correctly dripped. (2) Be * cord inlet-steam pressure to the equip ' ment. (3) Measure steam pressure at trap inlet, valye B, Fig. 1. (4) Measure return-line pressure, valve D, Fig. 1. Take temperature readings with the pyrometer, zeroing it in at valve A, Fig. 1. Set pyrometer to read the saturatedsteam temperature corresponding^ line pressure. Take the readings on a clean surface. Take another pyrometer reading at the nipple ahead of the steam trap. It should equal or he close to the steam temperature corresponding to strainer blowoff pressure. Third reading should be taken downstream of the trap. It should equal or be close to the sat urated-steam temperature at the con densate-return-line pressure. These readings must he interpreted in terms of the size and type of heat-transfer area. Best equipment efficiency is ob tained only when the temperature ahead of it is equivalent to the temperature upstream of the trap. Record and file the temperature read ings. Attach a colored tag ahead of the trap, showing the year the' trap was in stalled in new, serviced or overhauled 90 Steam pressure at trap 331 Steam temperature at trap condition. See diagram for other tag data. Temperature recording on the tag may be necessary only for critical pro duction equipment. When your files show a number of failures on the same equipment type, or at the same location, analyze the traps to see .if they suit their job. Storting a program of this type takes work. But the yearly checks are much easier. Select a trap that is easy to service or overhaul while it is still in the pipe. Trap overhaul. "Use a shop test stand. Fig. 4. Overhaul the trap in the way the manufacturer recommends. Some times a thorough cleaning is enough (Continued on next page) 5 WA-TEX 004120 I ii WA-TEX004120 ITEM NO. B-35 TRAINING DETAILS PAGE 193 to bring the trap back to top perform ance. Each trap should be given an operating test in the test stand, as ex plained above. After the test, tag the trap for its pressure rating, overhaul date and suitability for use. Place trap in stock with other overhauled units. ` Radiator traps, usually the bellows thermostatic type, should be checked during the summer. Keep a stock of replacement bellows on hand. Check Vacuum breakers are used where temperature-control or motorized con trol valves are employed. In Fig. 5 the control valve closes after the process is up to temperature. Steam in the . jacket condenses, creating a vacuum. Without a vacuum breaker the conden sate does not drain out of the jacket for a prolonged period. Some traps may lose their prime without a breaker. Cheek valves are important, prevent can help. But if it is left open, it wastes steam. And if left fully or partly open, it either backs up condensate or wastes steam because a fixed orifice cannot handle variations in steam pressure and condensate load. Opening the bypass wide makes it impossible to maintain maximum pressure in "the equipment, reducing production capacity. Today many major steam plants do not use a bypass. On outside installa old bellows on the test stand. ing the discharge from one trap backing . Accessories. While checking trap up into that of another. When conden tions the trap can be bypassed by using the strainer blowoff. This acts as a sig efficiency, it is good practice to look sate from a trap must be lifted, a check nal, too, indicating the trap is out of oyer the installation to see if any of valve should also be-used, as in Fig. 3. service. If a trap cannot be spared the following -accessories are needed. While manufacturers recommend indi- while being serviced, it is advisable to Dirt leg, at A, Fig. 5, is easily in . vidual trapping of equipment for most use the double-trap bypass. Fig. 6. The stalled using a tee and capped nipple. units, check valves should be selected additional trap often pays for itself in It will catch most of the sediment form where individual trapping is not pos a few days, compared to standard by ing in the steam line and the equip sible or group trapping must be used passing. ment cavities. Clean the leg when trap Install a check valve in the discharge V/ctsfe heat can be recovered from is serviced. line from each section of the steam-con flash steam by a heat exchanger. The Air vent on the equipment trapped densing equipment, ahead of the trap. heat can be used to raise the tempera often gives better operation, steps up Fig. 6 shows the standard bypass ar ture of boiler-feed water, hot-water . output. In Fig. 5 the area lost to heat rangement. While the original idea of heater feed, or any other'preheat serv transfer when a vent is not used equals the bypass is good, too often an opera ice. Recovering this heat improves plant the product of D and the inside circum tor bypasses the trap, thinking he can efficiency. ference of the kettle. Using the air vent increase production. If the safety factor Routine maintenance of traps can greatly reduces the cooking time. for the trap is too low to allow the trap save money. Why not set up your pro to handle, the start-up load, the bypass gram today? POWER FEBRUARY t956 /"~\ ; WA-TEX 004121 WA-TEX004121 ITEM NO. B-35 TRAINING DETAILS PAGE 194 OPERATION OF THE ARMSTRONG INVERTED BUCKET STEAM TRAP Fig. 2-l``Bucket full of conden sate-trap dis charging Fig.2-2."Bucket full of steamtrap closed Fig. 2-3. A sort of inverted bucket Fig. 2-4. The educated stajnI e s s steel tomato can VENT HOOK ' a/ s.s. SHELL AND CAP WEIGHT AT END Fig. 2-5. 24 OZ. bucket in air Fig. 2-6. Wt. reduced to 21 oz. when full and submerged Fig. 2-7. Weight less bucket Fig. 2-8. Bucket is a float In the Armstrong Steam Trap an inverted submerged bucket opens and closes the discharge valve. More is- involved than the overly simplified slateineats, "When the bucket is full of cnurlt unite it sinks and opens the valve" and ''when the bucket is filled with steam, it -floats and closes the valve." Those hnlf-liuths do not do justice to inverted bucket trap operation. Let's do a little homework to see what really goes nr, in an inverted bucket trap. What small hoy has nnt Uuown an empty tomato can in the pond and ob served that the can wilt float upside clown because air is trapped in the can! And if ho was a good shot with a BB gun a puncture near the '-nd of the eon let out the air and the can sank to the bottom. The inverted bucket in an Armstrong Trap is an engmecur-d stainless- steel tomato can. When the trap is operating, ihe ``can" is completely submerged .in condensate. Under certs>in conditions the "etui" is a float that wii! in ,-<,,c the trap valve. Other cumlit;,re- muki- it u weight to sink and open ti.e --..ilvo. The Bucket hr, a Iftsigi-r, is Neutral, Is a Foal A No. 8/-f bucket ! t e\,t!i!pli.-, weighs 24 ounces in air. When compietidv lull of and submerged in cold water ihe bucket hook, shell anil c.rj iron weight displace 3 oz. of water. So the bin-in-; then weighs 21 oz. This is tie maximum puli that the bucket can cv< W -.(I ;!,e No. 8)4 trap `lever. Now if WC hitrodia-'- ei-uu gas, air or steam into the iunie 1>> ,,! [lie bucket to displace 21 oz. of waUi'. lb. inioy.uicy of the gas, 21 oz.. '-.ill i v.u i Iv hJunrc the submerged weight of si .c bucket. 21 oz. The bucket bos . Hi nr weight to pull down nor hiuivaucv 1hi up. The liquid level inside the hue! i Lai Ihe neutral line. Displacing more liquid v. at. ;:r, i.-.UISt % the liquid level to :> hr..-1 >i. -iHi.fi line. The buoyant;. <- v-ti c-eed 21 oz., so the l.-iv.-Kt--- v ,:i -. Vc .,,] lift the salve to -it.; s<wt. Thus our cuginei red .iLiioii tomato can is a weight, is nentrs*, or is a float. Honked <m in the \.*.lve lr\er in an assembled trip -In inveii, d sufi- nicrged bucket \i:f! < ! fin* calve or open the Valve depending on the water level inside of the- bin -Lei. How the Bucket Controls the Trap Valve In the 0-75 psi ,\'o. M-l imp m vjimtm opening or test piesnirn would he Fig. 2-9. 1. Trap is installed in drain line between steam heated Unit and condensate return header. Bucket is down and valve is wide open. The initial flood of condensate enters the trap and flows under bottom edge of bucket to fill trap body and completely submerge the bucket. Excess condensate discharges through wide open valve to return header. . acci',enra-a.-ta;,, 21 to 22 lbs., if the bucket were com pletely filled with water. There would he no m.-u-gin of safety for higher steam pressures or for orifice enlargement due to nnrmsd wear. To insure Jong service life, the trap is offered for a maximum working pressure differential of only 15 pounds. Similar safety margins arc pro vided in all si/.es and pressures of Arm strong Traps. Obviously af 15 pounds working pres sure differential the full weight of the bucket is not required to open the valve. Instead of the 21 oz. weight to open at 21 png only a 15-oz weight is required for 15 psig. Fig. 3-1 shows the water ievok in a No. 814 bucket required to open ihe valve at pressures from 15 psi down to only 1 psi. Operating drawings 1 through 4 show the operating cycle at 15 psi or maximum piy-.v.Miro ditfercnti.il. With a condensate load prupoi donate to trap capacity the nprinHon will he intermittent. But as the steam pressure is reduced to' the 0-2 psi range (;is with a temperature control t ! WA-TEX 004122 I WA-TEX004122 ITEM NO. B-35 TRAINING DETAILS OPERATION AT PRESSURES CLOSE TO MAXIMUM PAGE 95 . 2. When steam reaches trap it collects at top of bucket, imparting buoyancy. Bucket then rises and lifts valve towards its seat. Flow of condensate snaps valve tight shut. Air and carbon dioxide gas pass through bucket vent and collect at top of trap. Steam passing through vent is condensed by radiation from trap. 3. When entering condensate brings the condensate level slightly above the neutral line the bucket exerts a slight pull on the lever. Butthe valve does notopen until the condensate level rises to the opening line for the existing pressure differential between the steam and the condensate return header. (See Fig, 3-1) 4. At this level weight of bucket, times leverage, exceeds the pressure holding valve to its seat. Bucket then sinks and opens trap valve. Any accumulated air is first discharged followed by condensate. Discharge continues until more steam floats bucket and the cycle is repeated. MOTE: While the drawings above depict side inlet, side outlet traps, operation of bottom inlet, top cutlei traps is identical. * valve) the trap operation changes char acter--it usually discharges continuously. .-.j - * s '*.** .* 7 **>> "* Continuous Discharge from inverted Bucket Traps at Low Pressure The terms "continuous discharge" and "Inverted Bucket Trap" wilt scr-m con tradictory to many trap users. But an inverted bucket tnip will discharge con tinuously at very low pressures or with veiy high back pressure. Observation of a glass bodind/gias.s bucket trap shows that at very low pres sure there is no change in bucket con densate level and no change in bucket position, which accounts for ibe observed continuous discharge. Why? A No. 814 trap at .25 psi pres sure has a continous discharge capacity of 1400 lbs. per hour. Using a 3 .fn I safety factor for .25 psi operation this size would be selected (o handle 46fi pounds or 7456 oz. of condensate per hour. This is slightly more than two ounces per second.I Fig. 3-1. Liquid levels in bucket for opening a %" orifice No. 214 or No. 814 trap ar working pressures indicated. vV-*7 */-*<* *. . , Only .25 oz. of water is required to open the valve at .25 psi. Thus 2 oz. per second of condensate divided by .25 oz. of water to open gives 8 discharges per second to handle the load. Now a 21 oz. submerged weight bucket is not going to rise and sink eight times a second. The inertia of the bucket submerged in con densate prevents this rapid operation. So the bucket merely positions the valve to give ihe observed continuous discharge. High Back Pressure Operation High discharge line pressure affects the force required to open the trap valve just the same as lowered steam pressure. As back pressure approaches that of inlet pressure, discharge becomes continuous, just as it does on very low pressure differ entials. Back pressure has no adverse effect on Armstrong Inverted Bucket Trap opera tion other than capacity reduction due to low differential. The trap will not fail to elhsc and will not blow steam due to the high back pressure. II WA--TEX 004123 WA-TEX004123  ITEM NO. B-35 . ' . TRAINING DETAILS' ' " ' r ` PAGE -196. . --V , * ^ c " ``' - ` , . ** ARMSTRONG CAST IRON TRAPS FOR GENERAL SERVICE- DESIGN AND CONSTRUCTION The Armstrong inverted submerged bucket steam trap is a mechanical bap that .operates on the big difference in density between steam and water. Steam entering the inverted submerged bucket causes die bucket to float and dose the discharge valve. Condensate entering the trap changes the bucket to a weight that sinks and opens the trap valve to dis charge the condensate. But unlike other mechanical traps, air and carbon dioxide are vented continuously at steam tem perature. This simple principle of condensate re moval was introduced by Armstrong in 1911. In today's Armstrong traps this proven principle has been die beneficiary of more than 50 years of improvement in materials and manufacturing technology. The result is a trap that we sincerely believe is unmatched for operating effi ciency, dependability and long life. "Frictionless" Free-floating Valve Mechanism The heart of the'Armstrong Steam Trap is its unique leverage astern that multi plies the force provided by the bucket to open the valve against pressure. There are no fixed pivots to wear or create fric tion. It is designed to open the discharge orifice for maximum capadty. Wearing points are heavily reinforced for long life. The use of a different leverage ratio for each orifice size makes it possible to open the maximum size orifice at any given pressure. The result is a trap that delivers big capacity in a small, economi cal package. Long Life Parts Exceptfor valve seat construction in 1500 psi. and 2500 psi. traps, the mechanisms in Armstrong Traps for low and medium pressures are identical in design, work manship and materials to those in traps for 1050F, 2500 psig. Valve and seat are chrome steel hardened, ground and lapped. All other working parts are wear and corrosion-resistant stainless steel. Simplicity . Only two moving parts, the valve lever assembly and the bucket. No fixed pivots, no complicated linkages, nothing to stick, bind or clog. Choice of Body Styles 800 Series 880 Series No. 801 ' Fig. 4-1. 200 Series ' Easy to Inspect and Maintain Remove the cap and you lift out the en- tire mechanism. The body, full of hot . water, need not be removed from the fine. - In the side inlet series and No. 801, the pipe connections do not have to be dis turbed to service the trap. Reliable Capacity Data - Capacity ratings of Armstrong traps have been secured by tests with traps discharg ing condensate as close as possible to steam temperature under actual operating conditions. Guaranteed Quality See the back cover for complete "Assur ance of Satisfaction" which covers work- ' manship, materials, etc. : The "Frictionless" Free-Floating Valve Mechanism ' The' valve mechanism is the heart of the Armstrong Steam Trap. It makes possible high capacity in a small trap and long life with infrequent maintenance. .A unique two phase leverage system is used in Nos. 218-813 and larger cast traps, and in the No. 312 and larger forged traps. Here's how it works: Fig. 4-2. Valve in closed position.The buoyancy of the bucketwhen steam is present, in com bination with sys tem pressure,holds the valve tightly . against the orifice. Fig. 4-3. As condensate enters the trap the bucket begins to sinkand pulisdown on the valve. High leverage fulcrum "A" bears against the face of the valve seat to give the power required to open the largest practical , valve against pressure.. Fig. 4-4. Afterthe valve is well open, lower leverage" fulcrum "B" takes over,' -allowing the valve to travel further away from thaorifice-, to insure mini-' 'mum restriction- to. con densate flow. . st- n-furvrtx-r..* r.-js' .** . internal Check Valves Save Fittings, Labor and Money When either of the following conditions exists, check valves are needed between the trap and the unit drained: ' 1. Trap is installed above unit drained. 2. Sudden pressure drops may occur in the steam supply to the unit. Fig.4-6. Internal check valve In stalled intrap inlet. Armstrong spring loaded, stainless steel internal check valves screw directly into the trap inlet (Fig. 4-6) or into an ex ' tended inlet tube having a pipe couplmg at the top (Fig. 4-7). This simplifies in stallation and saves tune and money. Fig. 4-5. LeftArmstrong stain less steel internal check valve. Fig. 4-7. Internal check valve in stalled in top of trap inlet tube. uis'vU.-u.* .iv -Ti*tfrwc5cs"nn OPTIONAL CONSTRUCTIONS Traps With Thermic Vent Buckets Speed \ - Fig. 4-8. Trap bucket equipped' with bi metal controlled thermic vent. - - WA-TEX004124 ITEM NO, B-35 TRAINING DETAILS PAGE 197 L?ys^-riyyp~j*?".r,^*.Vv! "*1Ty~.:Vn T, ,',T*I?W2TWT,VT7rl7-Wip*'^r C 1'T7C-'V '?>* - V * Here's how Armstrong Inverted Bucket Steam Traps deliver everything you should get in trap '7P#rv^*-' V"** Fig. 5-1. 200 Series bottom inlet, top outlet Armstrong Trap. 1. No Steam Waste Discharge value is water sealed. Steam does not reach it. 2. Long Life and Dependable Service Valve and seat are chrome steel, heat treated, ground and lapped. Free floating valve mecha nism is "frictioniess." Wear points are heavily reinforced. 3. Corrosion Resistance All working parts are made of stainless steel. 4. Continuous Air Venting Vent in top of bucket provides continuous auto matic air venting. The steam passing through the vent is less than that required to offset radiation loss from the trap. 5. C02 Venting at Steam Temperature Fixed vent passes CO2 immediately--there is no cooling lag that would permit C02 to go into solution and form corrosive carbonic acid. 6. Operating Against Back Pressure Since trap operation is governed solely by the difference in density of steam and water, back pressure in the return line has no effect on the ability of the trap to open for condensate and close against steam. 7. Freedom from Dirt Trouble Condensate flow under the bottom edge of the bucket keeps sediment and sludge in suspen sion until discharged with condensate. There is no build-up of dirt. There are no close clear ances to be affected by scale. Fig. 5-2.800 Series side inlet-side out let Armstrong Trap. Equivalent sizes of 200 Series and 800 Series traps have identical mechanisms. -OR SPECIAL REQUIREMENTS feating When Steam Is Turned On Wherever steam is turned on and off, air . will accumulate in piping and steam equipment during the off period. A trap with a thermic bucket will discharge this air 50 to 100 times faster than a standard bucket, reducing heat-up time remark ably. Thermic vent buckets are available for all Armstrong traps for use at pres sures up to 125 psig. Where to Use: Single pipe coils; small on-and-oflF unit heaters; on-and-off mul tiple coils; drip points (particularly at { Vis of steam distribution mains); wher ever air will pocket and be discharged ahead of incoming steam. Operation of the thermic bucket trap . is described at the right. nv.ztAuisvftMF/nr . *1-- ',, ..v. T?,` \ r t -- *>< ' ifi . - 1. Trap cool. Air cannot collect at the top of the bucket because the large vent is wide open. The bucket stays down and holds the bap valve wide open allowing air to escape very rapidly until__ 2... . steam reaches the bucket. The bi metal strip is heated by the steam. This closes the thermic vent. Steam will then collect in fop of bucket to impart buoy ancy and close the trap valve. With thermic vent closed, the trap operates as a standard trap as shown in operating drawings on pages 2 & 3. WA--TEX 004125 WA-  ITEM NO. "B-35 TRAINING JJKTAXud ARMSTRONG CAST IRON INVERTED BUCKET TRAPS EOR r t ? *" * * ****' for pressures to 250 psig... GENERAL SERVICE capacities to 20,000 its!hr Table A-6. CAPACITIES, ARMSTRONG CAST IRON TRAPS Capacities given are continuous discharge capacities in pounds of condensate per hour at pressure differential indicated. Data based on repeated tests under opcrating conditions with condensate as close as possible to steam temperature. Trap No. 5 ' 10 15 29 25 30 8. M 5 50 a 0 8 7(1 if *80 100 125 200 250 BOO 880 801 450 560 640 690 460 500 550 580 635 660 690 640 680 570 -- 811 881 211 830 950 1060 880 950 1000 7T0 84Q. 900 950 EDO 860 950 . 810 860 760 812 882 212 1600 1900 2100 1800 1900 2050 1700 1900 2000 2200 1650 1800 2000 .1500 1600 1300 813 883 213 2900 3500 3900 .3500 3800 4000 3800 4100. 4400 3800 4000 3600 3900 3500 3200 3500 814 214 4800 5800 6500 6000 6500 6800 5000 6300 6800 6000 6400 6200 6700 5700 5300 5700 215 7600 9000 10000 8500 9200 9800 8300 9000 9500 9200 9700' 10400 10900 9500 9200 7000 216 14500 173UU 19200 18600 20000 18000 20000 18200 19800 18300 19000 18000 . 20000 18500 17500 1SOOO Fig. 6-3, Side inlet, side outlet traps. Cap and mechanism can be removed without disturbing pipe connections. Table B-6. LIST OF MATERIALS, ARMSTRONG CAST IRON TRAPS Name of Part Material Cap and Body 30,000 lbs. Mw. Tensile Cast Iron Inlet Tube* Gasket Alloy Sleei Pipe Compressed Asbestos Bolt and Nut Set No. 800. 801, 880. 811. 881. traps. 90,000 lb. tensile strength cap screws. Another cast body traps .80,000 lb. min. ,tensile machine bolls. Valve Seat . Heal Treated Chrome Steel Valve Heat Treated Chrome Steel Valve Retainer Stainless Steel ' lever Stainless Steel Guide Pin Assembly Stainless Steel Bucket Stainless Steel, Nos. 213, 813, 883 and larger buckets have cast iron weights. Body Thimble Internal Strainer Bushing Strainer Bushing Gasket Stainless Steel Stainless Steel Steel Stainless Asbestos *A'r)f standardin Nns. 800.H80 tind 801 traps Optional Accessories Jnternal Check Vatves are spring loaded ' unless steel and screw directly into the trap inlet or into an extended inlet tube having a pipe coupling at the top to save fittings, labor and money. Thermic Vent Buckets have a bi-metal controlled auxiliary air vent for discharg ing large amounts of air on start-up. Suit able for pressures up to 125 psig. No. SOI Trap with Right Angle Connections The No. 801 Trap has a side inlet and bottom outlet for use wherever right an gle connections will save fittings and in stallation labor. It is identical to the No. 800 in connections, mechanism and ca pacity. Like the No. 800 it is available with internal check valve or thermic vent bucket but not with both. Fig. 6-1. No. 801 trap with right angle connections. Fig. 6-2. Dimen sions, No. 801 trap. Table D-6. SERVICE PRESSURE RATINGS--ARMSTRONG CAST IRON TRAPS Trap 450F 800,880,801 150 psi 811-814 250 psi 881-883 211-216 250 psi Fig. 6-4. Side inlet, side outlet traps with integral strainers. This type costs less than standard trap plus standard strainer. Saves fittings. .. Fig. 6-5. Bottom inlet, top outlet traps. Cap and mechanism can be removed without taking body from the line. All dimensions are approximate. 1 WA-TBX 004126 1 WA-TEX004126 ITEM NO. B-35 TRAINING DETAILS PAGE 199 Table A-7, SIDE INLET, SIDE OUTLET CAST IRON TRAPS - Add suffix "CV" to Trap No. for internal check valve, "T" for thermic vent bucket Trap No. Pipe Connections Available "A" (Flange Diameter) "B" (Height) "C" (Face-to-Face) "D" (Bottom to C/L inlet) "T" (Body Wall Thickness) Number o) Bolts Diameter of Boils Weight ' Maximum Design Pressure, psi . 800* 811 812 813 814 Vi' or3/.' 3y,' 5Jfs' 5' 2)4' 6 14' 5 lbs. **250 14'or 14' 3)4* m" 5' w 3A" 6 H' 6 lbs. 250 id* or 54' 5%' 9)4' 614' 5%' ' 6 %' 15 lbs. 250 .14'or 1* 1" 1134' 734'. IVn" Va' 6 W 27 ibs. 250 1'or 154* 8' 1354' 9' 7%' 34' 8 34' 45 Ibs. 250 Fig. 7-1. Dimensions, No. 800-814 traps. , "Can NOT be furnished with both thermic vent bucket and check valve. *Maximum operating pressure: 150 psi Table B-7, SIDE INLET, SIDE OUTLET CAST IRON TRAPS WITH INTEGRAL STRAINERS Add suffix "CV" to Trap No. for internal check valve, "V for thermic vent bucket. Trap No. 880* 881 882 Pipe Connections Available Strainer Blow-Down Connections "A" (Flange Diameter) "B" (Height) "C" (Face-to-Face) "D" (Bottom to C/Unlet) "T" (Body Walt Thickness) Number of Bolls Diameter of Bolts Weight . Maximum Design Pressure, psi 14'or 14' 34' 334' 5%' 5- 3%* %t" 6 14' 514 Ibs. **250 54'or 34' J/' 334' 7Ms' 5" W 34r* 6 54' 6 lb's. 250 14*or 34' Vs" 554' 914' 614' 534' 54' 6 34' 16 Ibs. 250 `.Can NOT be furnished with both thermic vent bucket and check valve. Fig. 7-2. Dimensions, No. 880-883 traps. *Maximum operating pressure: ISO psi 883 34'. 1' or 1)4* 14' 7' 1234' 7)4" 714* .W 6 Vi" 30 Ibs. 250 Table C-7, BOTTOM INLET, TOP OUTLET CAST IRON TRAPS Add suffix "CV" to Trap No. for internal check valve, "T" for thermic vent bucket Trap No. Pipe Connections Avail. "A" Flange Diameter "B" Height "T" Body Wall Thickness Number of Bolts Diameter of Bolts Weight Maximum Pressure, psi 211 14' 454" 634' Ms' 6 Mi' 6 ibs. 250 212 14', 14' 514" 8" 14' 8 M' 12 ibSL 250 m V4',34*,i' 654' 1054*- 54' 6 34* 21 Ibs. 250 214 l'.l'/i' 714' 1214' 34* 8 34' 35 Ibs. 250 215 lMMMid" 8'/z' 14Mi' 34' 8 54' 47 Ibs. 250 216 114'. 2' 10Mi' 17' Mi' 12 !4' 78 Ibs. 250 /F"\7-3. Dimensions, No. 211-216 traps. Use certified print .for exact dimensions. . j WA-TEK 004127 WA-TEX004127 ITEM NO. B-35 TRAINING DETAIjLS PAGE 200 ARMSTRONG CAST MON TRAPS FOR LOW PRESSURE SERVICE- f\ For pressures to 30 psig.. mill^'AIPWUllLUlMCT^VCWCviW1 ,Sf *- WMHam'U:M3V3 nJJ /tl'.iaamB.mgJff-l. PHYSICAL DATA capacities to 6,800 lbs/hr Armstrong traps for low pressure service have been developedespecially fordrain ing unit heaters, preheat and reheat coils, converters, hot water generators, etc., where steam supply is intermittent. The design of these traps gives high air vent ing capacity on start-up and good con densate drainage characteristics. Successful drainage of steam heated units under modulated steam supply re quires careful attention to system design. See the following: Preheat and reheat coils, -pages 30 & 31 Unit heaters.....................pages 32 & 33 Water heaters........ ....................page 40 ITSSETZAH'OT-'flPKS Table A-8. CAPACITIES, ARMSTRONG TRAPS FOR LOW PRESSURE SERVICE Capacities given are continuous discharge capacities in pounds of condensate per hour at pressure differential indicated. Data hosed on repeated tests under op erating conditions with condensate as close as possible to steam temperature. Trap No. - Orifice Size J**--. in.*- .* .Go t-aS oS. Vs { 7) Vi (14) 34(21) 1 2 3 4 S 10 15 20 25 30 860T W Vi* 139 65 200 100 240 125 270 145 340 195 390 230 425 250 450 .275 560 350 640 400 690 440 460 500 861T VS' W 191 139 300 220 395 280 450 320 590 425 680 490 750 540 830 580 950 700 1080 .780 880 940 1000- 862T SM" 34" 350 191 580 380 740 500 850 500 1140 820 1320 960 1480 1070 1600 1170 1900 2470 2100 1690 1800 1900 2050 863T 864T Vi' vr W Vi" . 950 535 1400 950 1410 850 2160 1500 1618 1040 2600 1900 1880 1200 2900 2150 2300 1600 3700 2800 2600 1850 4150 3250 2780 2060 4500 3600 2900 2233 4800 3900 3500 .2800 5800 4800 3900 3200 6500 5400 3500 6000 3800 6500 4000 6800 Table B-8, LIST OF MATERIALS . Name of Part Materia! Cap and Body 30,000 lbs. Min. Tensile Cast Iron Inlet Tube* Alloy Steel Pipe Gasket Compressed Asbestos .Bolt and Nut Set . No. 860T and 861T traps, 90,000 lb. tensite strength cap screws. All other cast body traps 80,000 lb. min. tensile machine holts. Valve Seat Heat Treated Chrome Steel Valve HeatTreated Chrome Steel Valve Retainer Stainless Steel Lever Stainless Steel Gpi-HPin Assembly Stainless Steel B. ' Stainless Steel, No. 8B3T and larger buckets have cast iron weighls. Thermic Vent Bucket bi-metal Corrosion resistant "Duraflex" Body Thimble Stainless Steel *Integral raised inlet cast into body of No. Optional Internal Check Valve Internal Check Valves are spring loaded stainless steel and screw directly into the trap inlet or into an extended inlet tube having a pipe coupling at the top to save fittings, labor and money. Available for all sizes except No. 860T. Fig. 8-1. No. 860 Series O.F.&T. trap with internal check valve. No. 860T No. 864T Fig. 8-2. Open float and thermostatic steam traps with side inlet and side outlet con nections. Cap and mechanism can be removed without disturbing pipe connections. Armstrong 860T Series Traps The Armstrong Open Float and Thermo static Trap is an inverted bucket trap with three special features: 1. A thermostatic air vent for removal of large volumes of air encountered on start up. 2. Discharge orifices sized to remove large volumes of condensate at low pressures. 3. Pipe connections sized to meet pip ing requirements of low pressure service. So designed, the Armstrong O.E&T. trap provides the advantages of the in verted bucket trap in a "package" that is compatible with low pressure service re quirements. Most important among tlie.se advantages are: CONTINUOUS VENTING of air and car bon dioxide at steam temperature with out a cooling lag. SELF SCRUBBING ACTION handles dirt by keeping it in suspension in the turbu lent flow of condensate under the bottom of the bucket. CORROSION RESISTANCE is assured by all-stainless steel working parts (except for bi-metal strip of thermostatic vent). DEPENDABILITY is assured by the ability of the trap to keep itself clean and the use of stainless steel parts. Additionally, O.K&T. traps "fail open," a remote possi bility but an important safety feature. ,t WA-TEX 004128 WA-TEX004128 ITEM NO. B-35 TRAINING DETAILS PAGE 201. Table A-9. CAST IRON OPEN FLOAT AND THERMOSTATIC TRAPS Add suffix "CV" .to Trap No. lor internal check valve. Trap No. Pipe Connections "A" Ffange Diameter "B" Height ' "c" Face-to-Face . "D" Bottom to C/L Inlet "T" Body Wall Thickness Wo. Bolts Diameter Bolts ' Weight, lbs. Maximum Design Pressure, psi Maximum Operating Pressure, psi 860T 54' 354" SMs* 5* 2>Ms' %t' 6 54' 5 250 30 861T 1' 354' 6'Ms' 554' 4' 55a' 6 54' 6 250 30 862T 154' 554' 914* 654" 4'Ms' 54* 6 54' 15 250 3D 863T 154' 7' 1154' 8' 654' W 6 54' 28 250 30 864T 2' S' " 1354' 954' 1W 54' 8 54' 47 250 30 All dimensions are approximate. Use certified print for exact dimensions. No. 864T trap. With the con- 'f.denshte collecting in the drip : densateloadfor which this size legprevents steamfromreaehJ ' ' is used,'intermittent operation 'jng the trap.Thetrap body . .. _ v ... ........................... -would require more than six. . .and bucketfiU'withwatcr and -r v -. ; `- discharges per second. Obyi-', -: the discharge, valve opens i^mermid'veht'dosed, and operating pressure close .V; * . ously, this is impossible. So, wide.Condensate is discharged ni^dmilnL'.the' trap operates as a standard trap.', -'the bucket positions the valve -continuously with the trap operating drawings on pages 2 and 3. to give continuous discharge. . '' functioning as a h'quid seali i j WA-TEX 004129 WA-TEX004129 ITEM NO. B-35 TRAINING DETAILS PAGE Fig. 11-1. No. 312-416 screwed connections. Fig. 11-2. No. 312-416 socket weld connections. Fig. 11-3. No. 312F-416F flanged connections. ' Fig.ll-4.No.5133F, No.5155Fand No. 6155Fwith welded outietflange and integral inietfiange. No. 5133F is shown, others similar. **.' ,M Y'JT'.W--- ''"N Table A-ll. SOCKET WELD DIMENSIONS Pipe Size 55" %" V 154' U5' V Vh- 3' S2 .855 1.065 1.330 1.675 1.915 2.406 2.906 3.535 S-4 Min. 34' 55" Vi" Vt' W 34' %' 54' Table B-ll. FLANGE DIMENSIONS Pipe Size F-l F-2 F-3 P Pipe Size F-l F-2 F-3 P Vi" 334' 214" 134' Ms" 54" 4y<" 354" H6" 54* 3to v y/i3 y*" W 314" I'M.' W 3J4' V 114' SVi" 214" W '14s" <W 3to a y" 1" 114' 514* 554' 614' 314" I'M.' 4' 2' 414' 254' 1' 154' 154* soa IVi' w 414" 214" i` mr 5" 354' Vs" I" sl--t 114' 7" 454" 254" 114' 2* 614' 654' 334" 154' 900 lb . Std. 55' 54' i114" IVi' 2" w 5>/b" 5'/a" 614 ' 7" 834" 314' 355' 4" 444" 454' 614' 134" 1%' 2' 254" 254" 354" 54" 1" 114" 134" 114" 114' XJ to jj ' o o C4 . V-i same as l.D. of pipe size used. W y." i* l'/.' ,l>/r" 2* 514* 314' 554' 314' 614' 4'/.' 714" 5'/," 8" 554' 314' 614" 134' l'5is" 2" 254" 254" 354" IMs* 154' .134' 154" P/." 2' Trap No. SCREWED orSW Trap No. FLANGED Pipe Connections Avail. "A" Flange Diameter "B" Height, Screwed or S.W. "BB" Height Flanged "G" Body O.D. *`K" C/outlet to C/inlet "I" Body Wail Thickness Number of Bolts . Diameter of Bolts' Diameter of Bolt Circle Weight Scr. or S.W. Weight Ranged 310 310F 54V/*' 454" 7'%` 11' 314s' %" 34' 6 34' 354' 10 lbs. 12 lbs. Table C-ll. PHYSICAL DATA, FORGED STEEL TRAPS Add suffix "CV" to Trap No. for internal check valve. 312 313 312F 313F /z'.y." 54".y.'.r 614" 8" 10%" 1154' I0M." . ll'/z' 4ys' 554" l'/.' 15ii" %* 5i.' 68 54' Ye" 554" 654" 30 tbs. 47 lbs. 31 lbs. 49 lbs. 314 314F 1MV4' 855' 1354" 14%' 534' 154' 8 34" 714" 75 lbs. 78 lbs. 315 315F l',154",I54* 954" 15' 15' 634' 134' tft" 9 y." 8" 90 lbs. 95 lbs. 31S 31SF 155',2* 1U4" 1754' 1734' . 854" 254' "As" m 14" 10' 160 lbs. 163 lbs. 413 415 . 413F 5F 54V/.M" 1MV4',154" 854" m* 1154' 15" 13' 1634' 554' 614' IM.' %r 8 y.' 754' 134' Ms" 9 r 854' 65 lbs. 122 lbs. 73 lbs. 136 lbs. t41B 5133 5155 6155 ttlSF 5133F 5155F 6155F . 154",2' 54',34M" 34MM34* l',U4'. 1234" . i7y,* 1954" .8%' 855' 14'/,' . 1634' 534' 1034' 1655"- 20' 7' 1134' 2454' 2854' VAs 254' mr 134' 134' '"As 12 54' '/.* 1' 8 10 10 1" Fa" Studs 1" Studs 154"Studs 1055" 654' 8'/.' 934' 195 lbs. 98 lbs. 191 lbs. 295 lbs. 200 lbs. | 105 lbs. 208 lbs. 306 lbs. fabricated trap. All dimensions are approximate. Use certified print for exact dimensions. f i NA-TEX 004130 WA-TEX004130 - ITEM NO. B-35 TRAINING DETAILS ARMSTRONG DUCTILE IRON TRAPS PAGE 203 tor pressures to 400 pssg... capacities to 1060 ibs}hr Armstrong stocks one size of ductile iron trap in two body styles--side inlet, side outlet or right angle with side inlet and bottom outlet. Capacity is identical to the Nos. 811, 211 and 881 for pressures of 250 psi or less. At pressures from 250 to 400 psi capacity is the same as the forged steel trap No. 310 as given on page 10. Ductile iron traps may be substituted for the bottom inlet, top outlet No. 310 when straight through or angle piping is more economical. They are also used at pressures below 250 psi for those services where their exceptional shock resistance is needed for optimum safety. The mechanism is identical to that used in the No. 310 forged steel trap. Recom mended maximum working pressure on saturated steam or cold water is 400 psi. Maximum design pressure-temperature limitation is 400 psi at 650E . Table A-12. PHYSICAL DATA - DUCTILE IRON TRAPS Fig. 12-1. Dimensions, No. 711 , with horizontal straight through connections. Fig. 12-2. Dimensions, No. 701 with right angle connections. trap Wo. Pips Connections Available Bolting: 6--Ms* Weight .80 2 3- 125 5 g 200 1 a 250 S | 300 o- 400 701 711 VF'.K* 4' Carbon Steel Carbon Steel 120.000 T.S. 120.000 T.S. 7 lbs. 7 lbs. 800 950 .860 760 510 590 All dimensions Use certified print are approximate, .for exact dimensions. ARMSTRONG CAST STEEL TRAP WITH INTEGRAL STRAINER for pressures to '600 psi saturated steam . .. capacities to 4400 ibs/hr For services up to 600 psi where hori zontal in-line pipe connections are pre ferred, Armstrong offers the No. 983 cast steel trap with integral strainer. A choice of screwed or socket weld connections or welded-in flanges is offered. Capacity is the same as the No. 883 cast iron traps at pressures below 250 psi, the same as the No. 313 forged steel trap at pressures ' from 250 to 600 psi. The No. 983 trap body and cap are ASTM A-216 WCB cast steel. The mech anism is identical to that in the No. 313 forged steel trap. Recommended maxi mum working pressure on saturated steam is 650 psi. Maximum working pressure on cold water is 1000 psi. While the design pressure-temperature limitation is 600 psi at 750F, the No, 983 trap is not recommended for superheated steam service. Table 8-12. PHYSICAL DATA- NO. 983 CAST STEEL TRAP f1 l . Fig. 12-3. No. 983 trap with ' screwed connections. Fig. 12-4. Dimensions, No. 983 trap. Dotted lines show flanges Welded to body. Trap No. Pipe Connections Available Face-to-face (flanged) lh" pipe are Vt* pipe size 1'pipe size Shipping Wt. (Screwed Conn.) . 983 1W 1114' mr 45 lbs. Also avtiilahle until American Standard raised face or fiat face flanges or with tongue and groove, ring joint or concentric groove raised face flanges. All dimensions Use certified print are approximate, for exact dimensions. -J i14 ? i WA-TBX 004131 j *j WA-TEX004131 ITEM NO, B-35 TRAINING DETAILS PAGE 204 TRAPS FOR BmmmQ WATER FROM COMPRESSED AIR ' ' .................... ...........: '" ' ror pressures to WOO psig Armstrong compressed air traps are used to remove water from compressed air and other gases. They will not separate the moisture particles from compressed air but do provide dependable, automatic drainage of liquid from intercoolers, after coolers, receivers, separators and drips. Heavy Oil and Water Service Use Armstrong No. 213 BVSW Inverted Bucket Air Traps because the valve is at. the top. Oil is discharged first and the inverted bucket floats and sinks freely when the body is full of water instead of cold heavy oil. The No- 213 size is the smallest trap that will give dependable service on a heavy cold oil-water mixture. Operation. The No. 213 BVSW operation is quite similar to that of an inverted bucket steam trap (See page 3). How ever, the air that passes through the bucket vent cannot condense. Instead it is discharged intermittently ahead of oil and water. The volume of air vented is about 10 scfh. Water Only Service Use Armstrong Ball Float Compressed Air Traps. No. 1-LD Liquid Drainer. This modestly priced free-floating lever air trap assures positive drainage of moderate volumes of water at pressures up to 250 psig. Nos. 2-LD, 3-LD, and 6-LD Liquid Drain ers answer large capacity requirements for positive automatic drainage at pres sures to 250 psi. Available in forged steel as Nos. 32-LD, 33-LD, and 36-LD for pressures to 1000 psi. No. 21 Ball Float Trap. The ball float and other working parts are made of stainless steel for long life. No. 21 traps are used to drain small separators, low points in air lines and drip pockets ahead of risers. Maximum operating pressure is 250 psi. High Pressure Service. The No. 21-312, a forged steel version of the No. 21, but with a larger float, is good for pressures to 750 psi. Operation. The discharge from the No. 21 is continuous. The opening of the valve is just wide enough to remove the water as fast as it comes to the trap. Thus, at times, the valve is barely cracked from its seat. Grit Hazard. It is possible for grit or fine scale to lodge between the valve and seat of the No. 21 and thereby prevent clos ing when the load decreases. To answer this not uncommon problem, Armstrong offers the Snap Action Np. 71 Trap. No. 71 Snap Action Trap. In this design energy is stored in a flat stainless steel spring that replaces the conventional float Ieyer. When the trap is nearly full of water, the spring snaps past dead center, opening wide the valve. During discharge the process is reversed. Do not use the No. 71 when the load exceeds 120 Ibs/hr. High Pressure Service. The No. 71-315 is a forged steel trap with the .No. 71 snap action mechanism that operates at pressures as high as 1000 psig. DETAILED INFORMATION ON LIQUID DRAINERS IS GIVEN IN BULLETIN NO. 401, AVAILABLE ON REQUEST Fig. 14rl. No. 213 BVSW, cast iron. Fig. 14-2. No. 1-LD, cast iron. Fig. 14-3. Nos. 2-LD, 3-LD, & 6-LD cast iron. Fig. 14-4. Nos. 32-LD. 33-LD, & 36-LD forged steel. Fig. 14-5. No. 21. cast iron. Fig. 14-6. No. 71. cast iron. Fig. 14-7. No. 21-312. forged steel. Table A-14. PHYSICAL DATA ARMSTRONG COMPRESSED AIR TRAPS ' . In ordering, specify trap number and maximum operating prcssuie and stale "for water discharge." Inverted Bucket Model Number 213 BVSW Pipe Connections, in. "A" Diameter, in. . "8" Height, in. 54,54.1 m m Weight, ibs. 21 Max. Pressure, psi IOOF Htztr ! 100 -p. in Ibs. of is 250 Cold wator g 500 per Hour ^ 259 9100 6000 5000 Guided Free Floating Lever Drainers Cast Iron (ASTM A-278 Class 30) Forged 1030 Carbon Steel 1-LD 2-LD 3-LD 6-LD 32-LD 33-LD 36-LD 54f >A,3A %. 1 1!4,2 54,54 54,1 m, 2 m 554 .6y. lO'/is e% 8 Ilk 5!4 8 10Vs 17 lOMs 11% nvz 4 15 22 80 31 49 163 250 250 250 250 500 900 1000 375 3700 9500 45.000 ,3700 9500 45.000 950 2500 6000 24.000 3150 6000 24.000 900 1800 (225)5000 22.000 2450 3850 18.000 2600 3400 17.000 (900)3500 14,500 Fixed Lever Drainers Cast Iron Forged Steel 21 71 21-312 71-315 54,54 6y. 5'A y<,i m 1m 55.54 654 10Ms 54, 1,154 1554 8 29 30 92 250 250 750 1000 1900 (Ms")* 2500 800 ('/")* 1630 550 (Mr")* 1150 980 (mmMsy"y)* (Ms)** (Ms")* *For optimum spring life snap action traps should not be used where load exceeds ISO pounds per hour. toutlet connection All dimensions are approximate. Use certified print for exact dimensions. j WA-TBX 004132 I WA-TEX004132 ITEM NO. B-35 TRAINING DETAILS PAGE 205 MENTS FOR DiSCHARGING AIR FROM LIQUIDS ity-vm,-\rArn'i -.vr'* *.y.n n r > . .* 'v* . .*.'fryiTJaffw"WtW9urwisv'"t/'*'F*. for pressures to 1000 psig Armstrong float type air vents are de signed to vent air from hydronic heating systems, water service lines, water storage tanks, centrifugal pumps, gasoline lines, solvent filters, etc. Operation is com pletely automatic. Simple design and quality mechanisms make operation trou ble-free and maintenance infrequent. A variety of sizes and designs are avail able to meet service requirements: No. 1-AV Automatic Air Vent is a com pact vent designed and huilt for positive action and the overall reliability essential to automatic venting. Its float and freefloating lever are stainless steel. Valve -. and seat are heat treated chrome steel. It may be ordered with a K" drilled and tapped test petcock connection in the cap, wfth or -without petcock. Nos. 2-AV, 3-AV, and 6-AV Automatic Air Vents are cast iron, free-floating --%ver vents for larger capacity require ments at pressures to 250 psi.`Float and mechanism are stainless steel, valve and seat are heat treated chrome steel. Available in forged steel as Nos. 32-AV, 33-AV, and 36-AV for pressures to 1000 psi. All sizes utilize a guided free floating lever that provides reverse leverage on closing that multiplies the closing force to assure tight shut off of the valve. No. 21-AR Automatic Air Vent is the deluxe vent that is widely used in critical services. The valve seat is fitted with a resilient Viton-B insert that assures leak proof operation even if a particle of dirt or grit should become lodged in the valve. The .float and direct acting single lever are stainless steel. Available with forged steel body as No. 21-312-AR. More Detailed Information: Bulletin No. 451, Venting any gas from any liquid Bulletin No. 454, No. 1-AV Vent Hook-Ups of Air Vents KEY: Water (j Air ' Fig.15-1. After float closes valve,capacity of vent is limited to amount of air that can rise through water in connecting pipe A. Fig. 15-2. With the 2-pipe hook-up shown, valve can open wide and air can enter through . vent line to give capacities .shown in Table A-15. Fig. 15-3. No. 1-AV cast iron vent. Fig. 15-4. Nos. 2- AV, 3-AV, & 6-AV cast iron vents. Fig. 15-5. Nos. 32- AV, 33-AV, & 36-AV forged steel vents. Fig. 15-6. No. 21AR cast iron vent. Fig. 15-7. No. 21 312 AR forged steel vent. Table A-15. PHYSICAL DATA ARMSTRONG AIR VENTS In ordering, specify vent number, maximum operating pressure, sp. gr. of liquid and'state "for air venting," . Node! Number .Pipe Connections, in. . "A" Diameter, in. "W1 Height, in. . Weight, lbs. {Max. Pressure^ psi 100F. SCFM at pressure g. shown, with traps 4U back-vented, as A 250 shown in Fig. 15-2. " gnn 1.00 sp.gr. liquid jjjjjjj ' Guided Tree Floating lever Vents Cast Iron (ASTM A-ffl Class 30) Forged 1030 Carbon Steel 1-AV 2-AV 3-AV 6-AV 32-AV 33-AV 36-AV 54, 54* 54.54 54,1 154,2 54.54 54.1 B4,2 3H S'A 6% Wu 654 8 11% 5% 8 10% 17 lQYis IWu 17% 3V, 13 22 80 31 49 163 150 250 250 250 550 SOO 1000 4.3 8.0 . (150) 24 27 32 39 70 72 88 315 289 352 27 50 61 (550) 64 70 72 88 . 91 (900) 104 315 289 352 460 460 *5" outlet connection . AH dimensions are approximate- Use certified print for exact dimensions. Fixed Lever Vents Cast iron Forged Steel 21 AR 21-312 AR 54, 54 54,-54 654 654 5% ioyJ6 8 30 250 680 13 8 9 13 12 22 23 > WA-TEX 004133 WA-TEX004133 ITEM NO. B-35 TRAINING DETAILS PAGE 206 STEAM AT WORM *. - how the heat ofsteam is utilized Heat always flows from a higher level to a lower level. Starting in the combustion chamber, heat flows through the boiler metal to the water. When the higher pressure in the bpiler pushes steam out of the boiler into the distribution system, the steam in the pipes will be at a higher temperature than the .surrounding air. Heat then flows from the steam through the walls of the pipe to the air. This lass of heat causes some steam to change back to water. Steam distribution pipes are in sulated to minimize this wasteful and undesirable heat transfer. ' When steam reaches the unit it, is in tended to heat, the story is different. Here the transfer of heat from the steam to the :u'r passing through an air heater, to the water in a water heater or to the food in a cooking kettle is highly desirable. Noth ing should interfere with this heat transfer. 100 psig 337.9T EOT F*rt (--1 KEY: Condensate fBjSteam J__ j Vapor PRV 50.3 PSi 297.97? Cv CONDENSATE DRAINAGE... why it is necessary Condensate is the by-product of a steam system used to distribute and transfer heat. Condensate forms in the distribu- _. tion system because of unavoidable heat losses. And condensate forms in heating and process equipment because of heat transfer from the steam to the substance heated. All of this condensate must be removed. The Need for Draining the Distribution System Steam moves fast in mains or supply lines--often at 90 miles per hour or faster. A build up of condensate in these lines can be pushed along by the fast moving steam and turned into a battering ram that can damage pipe fittings and regulat ing valves or at least cause annoying noise. It is essential that this condensate be removed as a "heavy dew" before it can grow into a dangerous slug. Fig. 20-2. Coil half full of condensate can't work at full capacity. . The Need for Draining the Heat Transfer Unit Obviously, condensate in the heat trans fer unit takes up space and, in effect, re duces the physical size and capacity of the equipment. It must be removed promptly so that the equipment can be kept full of steam. See Fig. 20-2. Water Hammer. Hot steam in contact wirti condensate that has cooled below Fig. 20-3. Condensate allowed to collect in pipes or tubes is blown into waves by steam passing over it until it blocks steam flow at point A. Condensation in .area B causes a pressure differential that allows steam pressure to push the slug of con densate alonglike a battering ram to cause water hammer. the temperature of steam may produce water hammer which is annoying and can shorten the life of coils and tubes. See Fig. 20-3. - The Need for Removing Air and C02 The drainage problem involves more than just condensate removal. Air and carbon dioxide gas must also be removed. Air may be in the boiler feedwater and it is always present on start up. Car bon dioxide gas is released in the toiler from dissolved carbonates that may be in the boiler feed water. Effect of Air on Steam Temperature. Table A-20 shows temperature reduc tion caused by various percentages of : st-strata Table A-20. TEMPERATURE REDUCTION CAUSED BYAiR Pressure Temp, of Temp, of Steam Mixed with psig Steam, No Various Percentages of Air rtirPresent (by Volume) 10% 20% 30% 10.3 240.1 234.3 228.0 220.9 25.3 267.3 261.0 254.1 246.4 50.3 298.0 291.0 283.5 275.1 75.3 320.3 312.9 304.8 295.9 100.3 338.1 330.3 321.8 312.4 WA--TEX 004134 WA-TEX004134 ITEM HO. B-35 TRAINING DETAILS PAGE ai>T HOW TO TRAP STEAM MAMS ' r,ft'*rafttfwram-n*^sjaMgamea?.wwwroawiw<wBPKaHufc^*g:c . ^^Selection of trap sizes to drain steam . !iains depends on the warm-up method that will be used--Supervised or Auto matic. Supervised Warm-Up is widely used for initial heating of large diameter or long mains. Such mains may be warmed-up "only once in a life-time." The engineer tabes no chances with such mains. The "drip valves for free blow to the atmosphere" as called for by the Amer ican Standard Code for Pressure Piping are opened wide before steam is admitted to the main. These drip valves are not closed until after all or most of the warm up condensate has been discharged. . Then, the traps take over the job of re moving condensate that may form under operating conditions. Warm-up of principal piping in a power plant will follow much this same procedure. Automatic Warm-Up. Here the boiler is fired, letting the mains and some or all equipment come up to pressure and tem perature without manual help or super vision. Trap Selection for Automatic Warm-Up Trap Spacing directly affects trap sizing. Under conditions of full pressure and low steam velocity, condensate will flow by gravity to the low spots in the main. You must provide drip legs and traps at all low spots or natural drainage points such as: Ahead of risers Ends of mains Ahead of expansion joints or bends Ahead of valves and regulators Where there are no natural drainage points, drip legs and drain traps should be provided at intervals no longer than about 500 feet. Bemember, steam main condensate should be drained while it is a "heavy dew" rather than a dangerous slug. Drip Legs are provided to: 1. Let condensate escape by gravity from the fast moving steam. 2. Store the condensate until the pres sure differential is great enough for the steam trap to discharge it. Size of Drip Legs. Automatic warm-up systems should have drip leg the same di ameter as the main and long enough to: ft Table A-26. THE WARMING-UP LOAD, Schedule 40 Pipe. Steam Pressure, psig Pipe Wi. of Pipe Size Per Ft (lbs.) 1' 1.69 114' 2.27 U4* . 2.72 - 2' 3.65 ' 2!4* -5.79 3' 7.57 M` . 9.11 4' 10.79 5' ; 6'' 14.62 18.97 -;-3' - 28.55 10' 40.48 12' 53.6. 14' . 63. 16'- 83. 18' 105. . 20' 123.. 24' 171: 2 .030 .040 - .048 .065 ..104 .133 .162 .190 .258 335 .504 .714 .945 1.11 1.46 1.85 2.17 3.02 15 30 60 | 175 180 D37 .050 .059 ' .080 .126 .165 .198 .234 .352 .413 .620 .88 1.17 1.37 1.81 2.28 2.68 . 3.72 Pounds.of Water Per Lineal Foot I .043 1 .057 .069 .092 .146 .190 .229 .271 .406 .476 .720 1.02 1.35 1.58 2.08 2.63 3.08 4.29 - .051 .068 .082 .110 .174 .227 . .273 .323 .439 .569 .860 1.21 1.61 1.89 2.49 3.15 3.69 5.13 .063 .085 .101 .136 .215 .282 .339 . .400 .544 .705 1.060 1.50 ' 2.00 2.34 3.08 3.90 4.57 6.35 .071 .095 .114 .153 .262 .316 .381 .451 .612 .795 U90 1.69 2.24 2.64 3.47 4.40 5.15 7.15 250 .079 .106 .127 .171 .271 .354 .428 .505 .684 .882 1.340 1.89 2.51 2.94 3.88 4.90 5.75 8.00 Table B-26. PIPE WEIGHTS PER FOOT fn pounds. >.., Pipe Schedule Schedule Schedule XX Size 40 80 160 Strong 1' mr 1.69 - 2.17 2.27 3.00 155' 2.72 3.63 2' 3.65 5.02 2M' 5.79 7.66 3'.: - 7.57 -10.25 3#' - 9.11 12.51. 4' 10.79- 14.93 5' .14.62 20.78 6' 18.97' - 28.57 8* 28.55 43.39 10' 40.43 54.74 M2* 53.6 '. 88.6 14' 63 . 107. 16' 83. 137.- 18' . 105. 171. 20' 123.- 209. 24' 171. 297. 2.85 3.76 4.86 7.45 10.01 14_.32 22.60 32.96 ' 45.30 74.70 116. 161. 190. 245. 309. 379. ' 542. ' 3.66 5.21 6.41 9.03 13.69 18.58 22.85 27.54 38.55 53.16 72.42 Table C-26. ORIFICE CAPAC5TJES AT LOW PRESSURES. Use only for sizing traps for automatic warm-up. Pressure psig- .5 10 2.0 Orifice No. 38 . 16* SM"- %' ' %' 'A' V!W : W W 9fe' J4' X" lMs" 37 ' 49 73 94 148 214 291 379 - 482 595 715 851 1,160 1,515 1,875 2,375 3,100 4,225 6,240 Pounds per hour 52 69 103 - 134 209 302 411 535 680 841 1,010 1,205 1,640 2,140 2,650 3,350 4,160 5,700 8,400 71 121 140 182 284 410 559 728 925 1,145 .1,370 1,640 2,230 2,910 3,600 4,550 5,400 7,250 10,700 Note: For higher minimum pressure use ca pacity ratings in chart on page 26. Se sure Orifice selected will open at the maximum working pressure. . Fig. 26-1. Trap draining drip leg at riser. Distance "H" in inches -f- 28 = psi static head for forcing water through trap. Fig. 26-2. Trap draining strainer ahead of P.R.V. "H" in inches4- 28=psi foroperat ing trap during automatic warm-up. Fig. 26-3. Forged steel trap-draining drip. leg on main under supervised warm-up. ] NA-TEX 004135 1 WA-TEX004135 AMS ITEM NO. B-35 TRAINING DETAILS PAGE 208 1. Provide storage of condensate until there is positive pressure. 2. Provide static pressure head so trap can discharge condensate before a positive pressure exists in the main. See dimension "H" in piping draw- ings. Trap Sizing ' Step 1. Use table A-26 to determine con densate produced in warming Schedule 40 pipe to 219F or 2 psig. This is the warming-up load for steam trap sizing. For steam pressures and pipe sched ules not covered by the table, the warm ing-up Joad can be calculated using the following formula: c_ ---W-----X-- -j-t-r^X .114 C = Amount of condensate W = Total weight of pipe (See -Table B-26 for pipe weights) tx = Final temperature of pipe t2 = Initial temperature of pipe L = Latent heat of steam at final temperature--See Steam Table on inside front cover. .114 = Specific heat of wrought or " ' steel pipe Step 2, Divide warming-up load by num ber of minutes required to reach 219F or 2 psig to get pounds per minute. Mul tiply by 60 to get pounds per hour. Step 3, Pressure differential for trap siz ing will be 1 psig for every 28" of head between bottom of main and top of trap --See Fig. 26-1. Step 4. Pick orifice size from Table C-26 and select trap size from the chart on page 26. Example: "Automatic" warm-up load is 750 Ibs/hr at warm-up pressure of 1 . psig. Final pressure is 125 psig. Refer to the 1 psig column of Table C-26 where you find a %o" orifice will handle 841 lbs/hr. Going up the 125 psig pressure line of the chart on page 26, you find that the No. 214 or No. 814 trap can open a %o" orifice. This is the size to use, ' The actual 841 750 or 1.12 to 1 safety factor in the preceding example will result in a xeallygenerous safety fac tor because: . 1. Pressure can not drop below the minimum or static head in drip leg. 2. As pressure rises in the main, trap capacity increases, . 3. As pressure rises, warming-up load decreases faster than increase in ra diation loss from insulated main. Trap Selection for Supervised Warm-Up Trap Spacing. Drip legs and traps should be located at all natural drip points or at intervals not to exceed about 500 feet. Drip Legs for a supervised warm-up main need not be as large as for an auto matic system. Here the emphasis is on removing condensate from the fast mov ing steam rather than on storage capacity. Eyen so, it is good practice to use pipe diameter drip legs up to 4" pipe size and at least 4" diameter legs for the larger pipe sizes. Trap Sizing. If the warm-up is 100% su pervised, traps will be selected merely to discharge condensate produced by ra diation losses. Table B-27 shows conden sate per lineal foot of insulated pipe. In sulation was assumed to be 75% efficient. For pressures or pipe sizes not in cluded in the Tables, use the following formula: * c,, _ AX,UX-fti-yE C = Condensate in lbs per hour A = External area of pipe in square feet (see table on page 4,8) = Steam temperature, degrees F t2 = Air temperature in degrees F L = Latent neat of steam U = Btuper sq. ft. per degree tem perature difference per hour from Chart A-27 E = 1 minus efficiency of insulation (Example, 81% efficient insola tion: 1--.81 = .19 or E = .19 Safety Factors. Traps installed between the boiler and the end of the steam main: 2 to 1. Traps installed at the end of the main or ahead of reducing and shut-off valves that are closed part of'the time: 3 to I. Replacing Existing Traps If the .trap to be replaced has never lacked capacity, you are perfectly safe'in using an Armstrong that has an orifice size at least as large as in the trap re placed. But if main drainage has not been satisfactory,, follow the selection proce dure given on these pages. Install a drip leg if needed. Chart A-27. Btu HEAT LOSS CURVES. Unit heat loss per sq. . ft. of surface uninsulated pipe of various diameters (also flat . surface) in quiet air at 75F far various saturated steam pressures or temperature differences. Table B-27. CONDENSATION IN INSULATED PIPES carrying saturated steam in quiet air at 70F. Insulation assumed to be 75% efficient. Pressure psig Pipe Sq. Ft par Size Lineal Ft 15 | 3D 60 125 130 250 Pounds ot Condensate per hr. per lineal ft 1* . 114' Hf' \2' 254' 3' 354' 4'. ' 5' 6' -8' !Q' 12' 14' 16' 18' 20' 24' | : 344 ! .434 ' .497 ' .622 .753' : .916 ' 1.047 1,178 1.456 1.735 2.26 . 2.81 . 3.34 3.67 4.20 4.71 . 515028 115 .06 .07; .08 .10 .12 .13 .15 .18. .20 21 J32 .38 .42 .47 .53 .58 .79 .06 .07 .08 .10 .12 . .14 .16 .18 .22 .25. .32 .39 .46 .51 .57 .64 .71 .84 .07 .09 .10 .13 .15 .18 .20 .22 .27 .32 .41 .51 .58 .65 .74 .85 .91 1.90 .30 .12 .14 .37 SO .24 .27 .30 .37 .44 .55 .68 .80 .87 .99 Ui 123 1.45 .12 .14 .16 .20 .24 .28 .32 .36 .44 .51 .53 .80 .92 1.03 1.27 1.31 1.45 1.71 J4 .17 .39 23 .28 .33 .38 .43 .51 .59 .76 .94 1.11 1.21 1.38 1.53 1,70 2.03 IStf WO* TEMPERATURE DIFFERENCE too* 200* 240* 300* 400* 500* 700* 000* 1OS0* ; WA-TEX 004136 WA-TEX004136 ITEM NO. B-35 TRAINING DETAILS PAGE 209 SIZING TRAPS POP SUBMERGED EMBOSSEB COILS ^~r>'c~*rrmfTKzrttT^Bzasrv.-trsms^mssmgpr* *s- <mc i In general the drainage of embossed coils is similar to the drainage of pipe coils of &e same configuration. Embossed coils can be of the multiple header type or serpentine type. They are either double or single embossed. . For maximum coil output, trap each coil independently. This is a "must when coils are syphon drained. Syphon Drainage. Embossed coils fre quently are used for heating open tanks Uirougn which it is not practical to make a gravity condensate drain Connection. Condensate must be syphoned from the bottom of the coil over the tank wall to the trap (See Fig. 35-3). To keep the coil drained, the minimum steam pressure in pounds should never be less than the syphon lift in feet Use "LV" (enlarged vent) traps installed below the high point of the syphon. Short Circuiting. When the embossed coil in Fig. 35-2 is suspended vertically in a tank, short circuiting complicates syphon drainage. Schematic drawing Fig. 35-4 shows channels 1, 2 and 3 replacing the multiple channels of Fig. 35-2. At start-up, condensate will fill the lower sections of channels 1 and 2 because steam can short circuit through channel 3 to close the trap. Condensate formed in channels 1 and 2 will rise to the drain point of channel 3 and be syphoned to the trap. Air accumulation in channels 1 and 2 reduces the heat transfer rate and, therefore, the pressure drop. Thus, in . creased pressure in channels 1 and 2 will forpe out condensate and vent the air. Once purged the process will be re peated. Thermostatic pontrol. When tank tem perature is regulated automatically, the temperature control valve frequently will close to the point where a vacuum will be formed in the coil. Drainage becomes impossible with negative coil pressure. A vacuum breaker check valve should be installed between the control valve and the coil to admit air to the coil when the vacuum forms. See Fig. 35-3. As the control valvp starts to reopen, incoming steam heats the air in the coil, causing the air to expand and build up enough pressure to force the water up the syphon and into the trap. Air quickly escapes through the "LV* trap bringing the coil to steam temperature. Determining Load. The amount of con densate on which trap selection is based must be determined for each individual application. The consulting engineer or coil manufacturer should know the Btu per hour design heat.transfer rate for the particular coil installations. Dividing this Btu figure by the latent heat of steam at the operating steam pressure will give a condensate load in pounds per hour. To size traps, use the recommended trap selection safety factors given in the cap tions with the drawings. NOTE: "LV" trap has enlarged bucketvent (seeexplanation under Syphon Drainage, page 39). "CV" indicates trap equipped with internal check valve. WA-TEX 004137 WA-TEX004137 ITEM NO, B-35 TRAINING DETAILS PAGE 210 SYPHON DRAINAGE AND HOW TO TRAP REVOLVING DRYERS rt ,-tj-v-<ttxj rt.t. efloryg-waflEwgiy cftAwawag'^>"V~t When condensate must he lifted above the gravity drain point to reach the trap, a syphon exists. Fig. 37-1 shows an ex ternal syphon --one surrounded by air. Fig. 37-2 depicts an internal sypnon -- . one surrounded by steam. External Syphon (Fig. 37-1). As soon as condensate fills the water seal, no more steam can flow to the syphon pipe. Radi ation loss from the syphon causes con densation and a pressure drop. This allows full steam pressure in the unit to force condensate up the syphon pipe. The water seal may break and reform more than once before enough conden sate has accumulated to fill the syphon and reach the trap. Height Limitation. Theoretically, con densate will rise 28" in the syphon for every pound of pressure differential. To use all of the differential for elevating condensate would leave none for forcing condensate through the trap orifice. A safe rule is one foot of lift for every pound of pressure differential. Flash Steam In External Syphon. As the ,rssure drops above the condensate in " yphon pipe, flashing is likely to occur, isvery 28" rise in condensate level re quires a pressure drop of 1 psi. With .condensate entering the syphon at, say, 15.3 psi a lift of 7 feet requires the syphon steam pressure to drop to 12.3 psi. Ignoring heat loss from the syphon SYPHON. After water seal fills with con densate, radiation loss will lower the steam pressure in the syphon. some 0.64% of the condensate would flash into steam. (See discussion of flash stearn'Toriffation- -on .t.he inside front cover.) With a condensing rate of ]000 Jbs/hr there would be 6.4 lbs or 97 cu, ft. of flash per hour. This flash steam must be vented to keep it from closing the trap while condensate is waiting to be dis charged. Armstrong traps with enlarged bucket vents (LV suffix to Trap No.) are re quired to vent the flash steam that forms in syphon pipes. When ordering traps for syphon drainagemdirSite the condensate load, the maximum and minimum pres sures and the amount of lift. With this information vent size can be determined accurately. Where the trap is installed as in Fig. 37-1 it should be equipped with an in ternal check valve. Provide a loop ahead of 200 series traps as shown. Internal Syphon (Fig. 37-2). Here there is no radiation loss from the syphon pipe surrounded by steam. Condensate rising in the syphon flashes readily aided by the small heat flow to the syphon. Vent ing of flash becomes imperative if slug gish drainage is to be avoided. EFFECT OF SYPHON PIPE SIZE Fig. 37-3. Oversizesyphon. Steam can bubble up through the condensate without changing its density. Conden sate cannot reach trap until pipe is filled with condensate. Fig. 37,4. In correctly sized syphon (one pipe size smaller than nominal trap size but not smaller than Vf) steam bubbles, in effect, reduce the density of the condensate and help carry condensate along to the trap. Fig. 37-2. A revolving cylinder drained with a syphon-an INTERNAL SYPHON sur rounded by steam. No radiation loss from syphon--only from the external piping be tween cylinder and trap. How to Trap Revolving Dryers Traps {or draining revolving dryers need enlarged bucket vents. When steam is first turned on the enlarged vents pass entrained air rapidly. When all air has been discharged the dryer reaches steam temperature and the capacity of the large vent is then needed to prevent flash steam from impeding trap operation. Trap Sizing. Table' A-37 shows experi ence-proven size recommendations by size and type of dryer. The order for traps should specify "For syphon-drained cylinder service." Also give tire diameter and length of the dryer, condensate load, if known, as well as the maximum and minimum steam pressures. . ' Table A-37. TRAP SIZES RECOM MENCED FfrR SYPHON DRAINED CYLINDERS Type of Dryer Pressure Range Psi Trap Size Dry Cans: 23 x SO' 23'x 60" and up Drum Dryers: 24"x 40" 28"x 72" 36"x 84" 42"x 120" Laundry1 toners-- Cylinder Type: 12"x 72" 14"x 8i* . 30" x 100" or 123' 36" x 100" or 120" Paper Machine Dryers: 36* x 72" and 42"x120" - 5--20 21--70 5-20 21-70 20-100 20-100 20-100 20-100 100 100 100 100 0-15 16-35 36-50 51-70 800 LV BOO LV 811 LV 811 LV 812 LV 813 LV 814 LV 215 LV 811 LV 812 LV 813 LV 814 LV 813 LV 813 LV 813 LV 813 LV 48" X180" 0-1516-35 36-50 51-75 814 LV 814 LV 814 LV 814 LV 60"x240" 0-15 16-35 36-50 51-70 215 LV 215 LV 215 LV 215 LV WA--TEX 004138 WA-TEX004138 ITEM NO* B-35 TRAINING DETAILS PAGE 211 PIPE SIZING STEAM SUPPLYAND CONDENSATE RETURN LINES WBjf* Definitions: Steam Mains or mains which cany steam from the boiler to,an area m which mul tiple steam-using units are installed. Steam Supply Pipes which take steam from steam main to steam-heated unit. Trap Discharge Lines which move con densate and flash steam from the trap to a return line. . . Condensate Return Lines which receive condensate from many trap discharge Imps and carry the condensate back to the boiler room. Pipe Sizing Select pipe sizes large enough to take care,of reasonable future expansion. Steam Mains. The sizing and design of high capacity steam mains is a complex problem thatshould be assigned to a com petent engineer. Tables A-40 through F-41 will prove helpful in checking steam main sizes or in determining main size for small plants. Example: An existing 3" steam main may ..--supplying one department of a large : _ it with 3800 Ib/hr at 180 psi. Ques tion: Could the steam use of this departmen be increased to 8500 Ibs/hr without a new supply line? ' Table E-41 shows that 1 psi pressure drop is produced in 100 feet of 3" pipe when supplying 3800 Ib/hr. To increase the flow to 8500 Ib/hr would produce a pressure drop of 5 psi per hundred feet. If the pressure drop and corresponding decrease in steam temperature is not ob jectionable, the existing 3" pipe can be used, However, if this much pressure drop is not permissible, an additional 3" main will have to be installed, or .the existing 3" main will have to be replaced with a 4" main which can handle 8500 lb/hr with a pressure drop of only 1 psi per 100 feet. Steam Supply Pipes. When a new heat ing or process unit is installed in an exist ing plant, Tables A-40-F-41 are entirely (practical for checking the size of pipe to run from the steam main to the new unit. The use of the tables is best described by solving a typical problem: Assume a steam main pressure of 101 to 105 psig. Unit is rated to condense 600 3b/hr, and 100 psig minimum is re quired at unit for quality production. Measurements show 75 feet of pipe re quired, involving three standard elbows plus a globe valve. Allowable pressure drop not to exceed 1 psi. Assuming that a 2" pipe will be required, use Table H-41 to determine equivalent length of pipe to be added to compensate for fittings. 3--2" standard elbows at 4.3 =12.9 ft. 1--2" Globe valve = 46.0 ft. . Total for valve and fittings 58.9 ft. Adding this to the length of the supply pipe gives a .total effective length of 133.9 feet--call it 1.34 hundred feet. Dividing our maximum allowable pressure drop of 1 psi by 1.34 gives us an allowable pres sure drop of psi per 100 feet. Refer to Table C-41 for 100 psi steam. With a pressure drop of % psi per 100 feet, a 2" pipe will give a flow of 850 lb/hr. In fact, with a pressure drop of only Ja psi per 100 feet the flow would be 690 Ib/hr. However,'a Ifi" pipe would require a pressure drop of 2 psi per 100 feet .for a flow of 680 Ib/hr. 1%" pipe is too small and the 2" is the size to use. In the example just cited, if the steam pressure in the unit is not critical, a 1U" pipe could-be used which would give a pressure drop of about 5 psi per 100 feet, or about 611 psi for the effective length of 133.9 feet Trap Discharge Lines. Trap discharge lines usually are short Assuming the trap is properly sized for the job, use a trap discharge line the same size as the trap connections. At very low pressure differ entials between trap and condensate re turn pipe, trap discharge lines can be increased one pipe size advantageously. Condensate Return Lines. Here again, for medium and large-sized plants, the services of a consultant should be em ployed to engineer the condensate return pipe or pipes. Table G-41 shows conden sate return pipe capacities when pipe is new and with the pressure drops per 100 feet specified. Usual}/ it is considered good practice to select return pipe one or two sizes larger to allow for (1) increase in plant capacity and (2) fouling of pipe with rust and scale. Traps and High Back Pressure. Back pressures excessive by normal standards may he carried by design, or back pres sures may increase due to fouling of re turn lines, increase in condensate load, or faulty trap operation. Back pressure, high or low, has no ad verse effect on the operation of an Arm strong trap. As back pressure goes up, discharges become shorter but are more frequent. However, the trap continues to perform its primary function of discharg ing condensate with no loss of steam. See explanation on page 3. Back pressure does lower the pressure differential and, hence, the capacity of the trap is decreased. In severe cases, the reduction in capaeity.could make it neces sary to use traps one size larger to com pensate for the decrease in operating pressure differential. .--ri...; STEAM SUPPLY AND CONDENSATE RETURN PIPE CAPACITIES All capacities are shown in pounds per hour and are based on steam and condensate flowing in the same direction. - Pipe Size 7n. . - Table A-40. STEAM PIPE CAPACITY AT 5 PSI dropPressure par TOO ft.atpipe length f:X X - % X Yi - 4, 10.. 6'. 15 ' ' 1 ,, * ' 24 . 31 . m: :v 52 68 IX/ 81 100 160 - - 210 . m : 270 ' 350 -3- 490 650 . 3% . .? -730 970 4 ." - im - =- 1,370 ' 5 v/ ' 1,930 -2,540 6 .= 3,160, 4,170 8 6,590 8,680 10 / 12,020 15,840 12 19,290 25,420' 9 21 44 /. 97 * 150 ' 300 ' 500 920 -1,370 1,940 3,600 5,910 12,310 22,460 36,050 11 26 . 54 120 180 370 610 1,130 1,680 2,380 - 4,410 7,250 15,090 27,530 44,190 ' .1 13 - 30 ' 62. .211400 430 710 1,300 1,940 - 2,750 5,090 8,360 17,400 31,760 50,970 Table B-40. STEAM PIPE CAPACITY AT 15 PSI. Pipe Size in. X Pressure drop per 100 ft of pipe length X X X .1 X5 X 1 13 27 1!4 59 m 91 2 180 m 300 3 560 3X 830 4 1,180 5 2,180 6 3,580 8 7,450 10 13,600 12 121,830 8 18 38 83 130 260' 430 790 1,180 1,660 3,080 5,060 10,530 19,220 j 30,840 | 11 26 53 120 18Q 370 600 1,110 1,660 2,350 4,350 7,150 14,880 27,150 43,570 14 32 65 140 220 450 740 1,360 2,040 2,880 5,330 8,750 18,220 33,250 53,370 16 37 76` 160 260 520 860 1,570 2,350 3,330 6,160 10,120 21,060 38,430 61,690 2 23 52 110 230 360 740 1,210 2,220 3,320 4,700 8,700 14,290 29,740 54,270 87,100 ! WA-TEX 004139 WA-TEX004139 . ITEM NO. M5 TRAINING DETAILS PAGE" 212 v:. TableW-W.STEAM PIPE CAPACITY AT30 PSI. > In. Vi; y< i. M W4" 2- . . '314 4 5 6: 8 10 12 Vi 7 . 16 32 ' 70 .110 223 . 368 675 990 ' 1,420 2,625 4,315 9,000 16,400 26,350 Pressure drop per MO ft. of pipe length Vi Vi Vi 1 10 ' 22 ' 45 99 156 316 . 520 953 1,405 2,020 3,720 6,100 12,700 23,200 37,250 14 ' 32 . ' 64 . 142 : 220 ; 446 735 1,340 2,010 2,850 5,260 . 8,650 18,000 33,300 52,500 17 39 79 174 270 546 m 1,652 2,470 ' 3,490 6,450 10,600 22,000 40,250 64,500 19 45 . 91 202 312 . 630 1,040 1,905 2,850 4,025 7,450 12,200 25,420 46.500 74.500 Z 28 64 129 283 440 892 1,472 2.690 4,020 5,700 10,550 17,300 36,000 65,750 105,500 Table B-41. STEAM PIPE CAPACITY At 60 PSI. ,. In. % vi i* 154 114 2 2Vi 3 35i 4 5 6 8 . 10 12 .8 20 40 .89 139 282 . 465 853 I,275 1,800 3,320 5,475 II,360 20,800 33,300 Pressure drop par 100 ft of pipe length V4 Vi Vi 1 2 12 28 57 127 197 400 660 1,205 1,800 2,550 4,710 7,725 16,100 29,400 47,100 17. . . 40 81 179 279 565 930 1,690 2,550 3,610 .6,660 10,950 22.800 41,500 66,700 21 49 - 100 ' 239 342 691 1,140 2,090 3,120 4,462 8,150 13,420 27,900 51,000 81,750 .25 57 115 253 395 800 1,318 2,410 3,605 5,100 9,440 15,450 32,200 58,900 94,500 35 81 163 358 558 1,130 1,860 3,410 5,090 7,220 13,300 21,900 45,550 83,250 133,200 5 55 128 258 .567 882 I,790 2,940 5,400 8,060 II,400 21,100 34,600 72,100 131,200 210,600 . , - Table C-41. STEAM PIPE CAPACITY AT 100 PSI. Pressure drop per 10D ft. of pipe length in* Vi w Ya -1 . m IA . 2 m 3 3V4 -4 5. 6 8 10 12 21 50 100 . 220 - 340 . 690 3,140 2,090 3,120 4,420 8,170 ' 13,420 27,930 50,970 81,810 Ya 1 26 30 61 . 70 120 : 140 270 . 310 420' 480 850 980 1,400 - 1,620 2,560 2,960 3,830 4,420 5,420 6,260 10,020 11.580 16,450 19,020 34,250 39.580 62,500 72,230 100,300 115,900 2 43 ' 99 200 440 680 1,390 2,280 4,180 6,250 8,840 16,350 26,840 55,870 101,900 163,600 . . 5 68 160 320 690 1,080 2,190 3.610 6.610 9,870 13,960 25,840 42,410 88,280 161,100 258,500 Pipe Size In. * yz ' iV"s. 154 lk *2 * 254 3' 354 4 5 6' 8 10 . 12 . Table D-41. STEAM PIPE CAPACITY AT 125 PSI. . .. Pressure drop per 100 ft of pipe lenglh Vi Ya 1. 2 23 54 ` 109 - 241 375 760 1,250 2,280 ' 3,430 4,850 8,950 14,710 30;650 56,000 89,900 29 . 66 .134 ' 296 460. 930 1,535 2,815 4,200 5,930 11,000 18,070 37,550 68,500 110,200 33 IT 155 341 532 1,075 1,775 3,245 4,850 6,850 12,700 20,800 43,400 79,200 127,100 47 109 220 483 751 1,520 2,550 4,590 6,850 9,700 17,950 29,500 61,400 212,000 179,600 5 75 172 347 /64 1,185 2,410 3,960 7,260 10,880 15,350 28,400 . 46,500 97,100 177,000 284,100 - Table E-Al. STEAM PIPE CAPACITY AT 180 PSI. Pipe Size In. Pressure drop perlOO ft. of pipe length a Ya A 28 34 39 56 1Ya 64 78. 90 128 129 158 182 258 I`/ 283 347 400 566 tVi 2 441 540 624 ` 882 895 1,092 1,260 I,785 m 1,470 1,800 2,080 2,940 3 3/2 2,675 4,040 3,300 4.930 3,805 5,695 5,390 8,050 4 5,700 6,980 8,500 II,400 65 10,500 17,300 12,900 22,200 14,900 24,420 21,080 34,600 S 36,000 44,100 50,850 72,000 10 65,800 80,500 93,000 131,300 88 202 407 895 1,394 2,820 4,650 8,550 12,740 18,000 33,300 54,600 113,900 207,000 Table F-41. STEAM PIPE CAPACITY AT 250 PSI. Pressure drop per MO ft of pipe length fit. !4 Ya ' 1 2 5 v. 32 39 45 64 102 3A l 74 91 105 150 230 150 180 210 300 470 VA U6 2 330 510 1,040 400 620 1,270 470 720 1,470 660 1,020 2,070 1,160 1,620 3,280 ?Vi 3 1,710 3,130 2,090 3,820 2,410 4,420 3,410 6,250 5,400 9,880 31/2 4,670 5,710 6,610 9,340 '24,770 4" 6,600 8,080 . 9,340 13,210 20,890 5 12220 14,950 17,290 24,440 38,650 0 20 060 24,540 28,380 40,100 63,400 8 41,750 51,100 59,100 83,500 132,000 Table G-41. CONDENSATE RETURN PIPE CAPACITY IN IBS. PER HR. tow pressure High pressure return, steam pressure In pst size, In* Gravity Vacuum return return 25 50 100 150 ZOO 250 Ya 1 m 154 2 254 3 200 400 700 1,200 1,650 2,600 350 600 950 2,000 3.350 5.350 236 474 989 1,610 3,280 5,400 9,890 312 419 617' - 823 1,306 1,755 2,126 2,850 4,325 5,785 7,160 9,640 13,070 17.550 560 1,120 2,330 3.800 7,700 12.800 23,300 682 1,385 2,880 4,710 9,550 15.850 28.850 1,074 2,150 4,450 7,350 14,875 24.600 34,750 354 4 5 .3,800 8,000 14,700 19,400 6,500 11,000 20,800 27,360 10,400 19,400 38,850 52,925 25900 36.550 70,000 34.500 42,700 51.350 49,200 60,900 73.350 91.500 114.500 127.600 6 18,000 31,000 61,200 83,700 112,700 150,000 185.500 223,100 Press. Drop* / V4 % Ya 1 1Ya m "Pressure drop in psi per 100 ft. of equivalent length used in deter mining capacities given. Table H-4I. EQUIVALENT LENGTH OF PIPE TO BE ADDED FOR FITTINGS Size of pipe, m. Standard elbow Length in feet to he pdded to run Side Gate outlet tee valve (*> Globe valve (*) Vi Ya 1 Wa 114 2 2!4 3 314 4 5 6 8 10 12 1.3 1.8 2.2 3.0 3.5 4.3 5.0 6.5 8.0 9.0 11.0 13.0 17.0 21.0 27.0 3 03 4 0.4 5 0.5 6 0.6 7 . 0.8 8 2.0 11 1.1 13 1.4 15 1.6. 18 1.9 22 2.2 27 2.8 35 3.7 45 4.6 53 5.5 14 18 23 29 34 46 54 66 80 92 . 112 136 180 230 270' "Valve in full open position Angle valve (*) - "7 10 12 25 18 . 22 27 34 40 - 45 56 67 92 112 132 ! WA-TBX 004140 WA-TEX004140 ITEM NO. Br35 TRAINING DETAILS PAGE 213 INSTALLATION OF ARMSTRONG INVERTED BUCKET TRAPS : stjt" p-isrT*,n :sr* j'k i Ifore Installing Run pipe to trap. Before installing the . trap; clean the line by blowing down at full steam pressure. (Clean any strainer screens after this blow-down.) Trap location ABC's . Accessible for inspection and repair . Below drip point whenever possible . Close to drip point Trap Hook-Ups. For low and medium pressure service, see Figs. 42-1 through 42-8. Follow the Power Piping Code for Drips and Drains when installing high pressure traps. Shut-Off Valves ahead of traps are needed ` when traps drain steam mains, large wa ter heaters, ete., where system cannot be shut down for trap maintenance. They are not needed for small steam heated machines--a laundry press, for example. Shut-off valve in steam supply to ma chine is sufficient. ' ' Shut-off valve in trap discharge line is needed when trap has a bypass. It is a . good idea when there is high pressure in discharge header. See also Check Valves. ^By-passes (Figs. 42-8 and 42-7). Use . 'ly when continuous service is a must. *.eep by-passes above traps as shown. Unions. If only one is used, it should be on discharge side of trap. With two unions, avoid horizontal or vertical in-line installations. The best practice is to in stall at right angles as in Figs. 42-1 and 42-6 or parallel as in Fig. 42-7.- ' Standard Connections. Servicing is sim plified by keeping lengths of inlet and ' outlet nipples identical for traps of a given size and type. A spare trap with identical fittings and half unions can be kept in the storeroom. In the event a trap needs repair it is a simple matter to break the two unions slip out the ailing trap, put in the spare :and tighten the unions. Repairs can then be made in the shop and the repaired trap, .with fittings and half unions, pfrt back in stock. Test Valves (Fig. 42-1) provide best means of checking trap operation. Use a pet cock or a small globe valve. Provide a check valve or snut-off valve in the discharge line to isolate trap while testing. Strainers. Install strainers ahead of small traps when dirt conditions are bad or where specified, -They are seldom needed with larger size of traps. Traps No. 880;883 have built-in strain ers. When strainer blow down valve is used, shut off steam supply valve before opening strainer blow-down valve. Con densate in trap body will flash back through strainer screen for thorough cleaning. Open steam valve slowly to be sure trap regains its seal. Dirt Pockets (Figs. 42-1 and 42-7) are excellent for stoppingscale and core sand. Clean periodically. Syphon Installations require a water seal and a check w-ilve in the trap. Syphon - pipe should he one size smaller than - nominal size of trap used but not less than is" pipe size. . .. Elevating Condensate/ Do .not oversize the vertical riser. In fact, one pipe size smaller than normal for the Job. will give excellent results. ' Check Valves .are frequently needed. They are a must if no discharge line shut off valve is used. Fig. 42-9 shows three possible locations for external checkvalves --also an Armstrong Internal Check Valve (See page 4). Recommended locations given below. ' Discharge Line Check Valves prevent back flow nnd isolate trap when test valve is opened. Normally installed at location B. When return line is elevated and trap is exposed to freezing conditions, install ' check valve at location A, Fig. 42-9. Inlet Line Check Valves prevent loss-of seal if pressure should drop suddenly or if trap is above drip point. Armstrong Stain- less Steel Check Valve in trap body, loca tion D, is recommended. If swing check is used, install at location C. '' . ' Protection Against Freezing. In general, a properly selected and installed Arm- - ` strong Trap will not freeze as long as steam is coming to the trap. If the steam supply should be shut off, the trap should be drained manually or automatically by means of a thermo drain or pop drain. Fig. 42-1. Standard hookup No. 800-814, - 880-883 traps, with shut-off valves to iso . late trap during testing, inspection or re pair. Unions should be at right angles--not in-line--to facilitate trap removal. Fig.42-4. Hookup No. 801 trap (shows how shut-off valve ahead of unit can serve as shut-off for a trap). FUIS Fig. 42-2. Hookup No. 211-216 traps. Fig. 42-5. Alternate hookup for No. 800 .814 with .inlet at bot tom. -- f /-- UUT-IN, SWAINI* --` SSlTOBWAI-NOSfKP VALVE : Fig. 42-3. No. 880-883 with strainer blow down valve. . l Fig. 42-6. Bypass hookups for No. 800-814 and 880-883 traps. Fig. 42-8. Trap draining syphon. A- Fig. 42-9. Possible check valve locations. WA-TEX 004141 WA-TEX004141 ITEM NO.' B-35 ' ' TRAINING. DETAILS . PAGE 214. TROUBLE SHOOTINQ INVERTED BUCKET STEAM -TRAPS']' The following summary will prove help- F. Bucket'vent filled with dirt. ful-in locating and correcting nearly alt . Prevent by: _ steam .trap troubles. Many ofthese trou' hies are in reality system troubles rather . than trap troubles. ' 3. Installing strainer, 2. Enlarging vent slightly. . Whenever a trap fails to operate and 3. Using bucket vent scrubbing wire. die reason is not readily apparent, the discharge from the trap should be ob-' served. If the trap is installed-with a test outlet, this will be a simple mntter-other.wise, it will be necessary to break the discharge connection. Vent Scrubber. If the bucket vent should be closed by an oil film, either enlarge the vent or install a scrubbing wire. For vent enlargement, first by a No. 46 drill. If this is not enough, then use a No. 42 drill. Make scrubbing wire as shown in Fig. 44-1 to the length shown in Table Cold Trap--No Discharge. If trap fails A-44. The hole in the center rib of the to discharge condensate, then: trap should be. %>". Enlarge vent with No. 37 drill. A. Pressure may be too high. 1. Wrong pressure originally specified. . 2. Pressure raised without installing new pressure change assembly. Table A-44. SCRUBBING WIRE DIMENSION Trap Number Length "A" 3. E R.V. out of order. 4. Pressure gage in boiler reads low, ' 5. Orifice enlarged by normal wear. 800,880,801,811,881,211 812, 212,882 813,213,883,814,214.215 2Vt" 3" 5" B. No water or steam coming to trap. 1. Stopped by plugged strainer ahead ` of trap--or plugged strainer in Nos. 880-883 and 983 traps. 2. Broken valve in line to trap. - 3. Pipe line or elbows plugged. C. Worn or defective mechanism. Repair or replace as required. . 216 614' Hot Trap--No Discharge A. No water coming to trap. 1. Trap installed above leaky by-pass valve. 2. Broken or. damaged syphon pipe in syphon drained cylinder. D. High Vacuum in return line. Increases pressure differential beyond which trap may operate. Install correct pres sure change assembly for pressure dif ferential encountered. ' 3. Vacuum in water heater coils may prevent drainage. Install a Y" check valve as vacuum breaker between steam admission valve and coil. E. Trap body filled with dirt. Install strainer or remove dirt at source. 7j'.r v t.-'-i.' .r.t Steam Loss. If the trap blows live steam, trouble may be due to any of the follow ing causes: A. Valve may fail to seat. 1. Piece of scale lodged in orifice. 2. Worn valve parts. Fig. 44-1. Vent scrubbing wire for use when pit plugs vent" Trap inlet tube must be removed. B. Trap may lose its prime. 1. If the trap is blowing .live steam, close the inlet valve for a few min utes. Then gradually open. If the trap catches its prime, the chances are that the trap is all right. 2. Prime loss is usually due to sudden or frequent drops in steam pressure. On such jobs, the installation oF a check valve is called for--location D or C in Fig. 42-9. If possible lo cate trap well below drip point. Continuous Flow. If the trap discharges continuously, check the following: A. Trap too small. ', 3. A larger trap, or'.additional-traps should be installed in parallel. 2. High pressure traps may have been used for a low pressure job. Install right size of pressure change as-' sembly, - B. Abnormal water conditions. " 3. Boiler may foam or prime, throwing . large quantities of water into steam lines. A separator should be installed or else the feed water conditions remedied. ' Sluggish Heating. When trap operates satisfactorily but units fail to heat prop erly; . A. One or more units may be short-cir cuiting and the remedy is to install a trap on each unit. See - page 24. B. Traps may be too small for job' even ' though they .may discharge .intermit tently. Try next-size-larger trap. C. Trap may have insufficient'air-han dling capacity. Use of thermic buckets may help. See page 4. Where thermic bucket is not recommended, larger- than-standard bucket vents will speed up heating. . Mysterious Trouble. If trap operates sat isfactorily when discharging to atmos phere, but trouble is encountered when connected with return line, check the fol lowing: . ' A. Back Pressure may reduce capacity of trap. 1. Return line too small (Trap hot). 2. Other traps may be blowing steam (Trap hot). 3. Atmospheric vent in condensate re ceiver may be plugged (Trap hot or cold). 4. Obstruction in return line (Trap hot or cold). 5. Excess vacuum in return line (Trap cold). Imaginary Troubles. If it appears that steam escapes every time trap discharges, remember: Hot condensate forms flash steam when released to lower pressure, but flash steam usually condenses quickly in the return line. How to Order Repair Parts. For all operating mechanism parts, specify trap size and maximum operating pressure or orifice size. For gaskets, specify trap size. . For body and cap, specify trap size and pipe connections. . ; WA-TEX 004142 ' . WA-T EX004142 ITEM NO. B-35 TRAINING DETAILS PAGE 215 INSPECTION AND REPAIR OF INVERTED BUCKET TRAPS fequency. All traps should be opened at least once a year to check operating .mechanism. Valves and Seats. If the valve seat has a sharp smooth edge, and if there is a frar- row bright ring all the way around the hall valve, chances tire that the valve is tight. Valves and Seats which have be ' come wire drawn or badly grooved from wear'.should be replaced. Do not use a new seat with an old valve or vice-versa. Valves and seats are factory-lapped to gether in matched sets for perfect fit. ` Yt-.u i or experience have proved il-at when valves and seats have worn enough to require renewal, a new lever and guide . pin assembly should also be installed in get maximum mileage from-the now valve parts. - Valve Seat' installation. When installing valve seats in Armstrong traps,' do' NOT , use any pipe dope or lubricant of any kind on the seat threads. The joint is made, not by the threads, but rather by the contact between the ground end of ' the valve- seat and the beveled seating area af-the bottom of the tapped-hole. See Fig. 45-1. Make sure- that this sent- >g area is perfectly clean. metal to . metal Fig. 45-1. Important! Valve seat seal is made at point of contact in dicated, not by threads. Be sure to read para graph above. Replace Lever and Guide Pin Assembly. When new valve parts-am used .---Iti* an ok! i:v-?r, bucket travel, valve upeniv!' and trap capacity are reduced. Willi "jred and won) guide pins, the valve is not guiib-d as closely to its seat. Poor gmd* an'r-c develops leaks quickly because valve can strike side of seat instead o? centc*. When yen install a now hiechamv.o less bueke! > a pressure change asseMNv, ycat make the 'rap ns gonri n-'v Guide Pin Assembly installation. Install with hooks pointing away from adjoin ing gasket surfaces as shown in Fig. 45-7. Alignment of Guide Pins, To check the alignment-of the guide pins, hold the lever assembly against the valve seat with the valve contacting's seat, and the two fulcrum points resting on the face of the seat. When the lever is held in this posi tion, the guide pins should be central in the guide pin holes. See Fig. 45-2. There should be equal side-to-side movement of lever as shown in Fig. 45-3 and Fig. 45-4. It is a very simple matter to bend the pins until they are centrally located. Care should be taken so that the pins will' remain perpendicular to the guide pin plate so that the lever can drop until it rests on the guide pin hooks. The Lever Assembly Is hooked over the guide pins. In a few sizes of traps, par . ticularly at low pressures, the valve lever assembly must be-slipped on the guide pins before the guide pin assembly is fastened into position. ' Buckets. Cracked or corroded buckets- should be replaced. Bucket Hooks. Since July 1, 1940, all free-floating lever Armstrong Traps have been furnished with stainless steel buckets. Normally wear is limited to the bncket book. In the Nos. 212-812 and larger sizes, these hooks are now riveted to the bucket .cap, so that the hooks can be.renewed. Thermic Buckets. Hold over steam jet or . lighted match to see that disc seats prop erly when bi-metal strip is heated. Dirt in Trap. Remove all sediment and other dirt from the trap body. The mech.-. anism may require cleaning by immers ing in gasoline or kerosene. .If there is nn exceptional amount of dirt, install astrainer ahead of the trap.- The- strainer ' will have to be blown down or cleaned at periodic intervals. . By-Pass Valve Inspection. If traps are installed with a by-pass, it is highly im-' portant that the by-pass valve be checked to make sure it is perfectly steam tight. If the trap can be operated without the by-pass by all means remove it. Avoid the practice of opening by-pass valves and leaving them open. . Internal Check Valve Installation. Since - . November, 1946, all Armstrong Trap bodies have been tapped on the. inside to take Armstrong spring-loaded check valves. To install one of these check valves after a trap has been installed in the line,. simply remove the trap cap-and extended inlet tube from the body and screw the check valve in position, or replace tube with checkvalve, coupling and tube com bination. . Check Valve-Inspection. Make sure that check valves ahead of trap, in trap, or in return line, are tight and in good condi tion. . .. .. _ Pressure Changes. An Armstrong Trap will operate at any pressure lower than the maximum for which it is furnished. The maximum pressure depends upon the diameter of the discharge orifice used . in each size of trap. - If it isnecessary to change the working pressure of the trap to obtain greater capacity at lower pressures, or to enable the trap to work at higher pressures, a complete `pressure change assembly is re quired. This comprises a valve seat, a valve, valve retainer, valve lever and guide pin assembly. Fig. 45.2shows CORRECT ALIGNMENTofguide pins. When correctly aligned, lever can be moved sideways the same distance to the right (Fig. 45-3) as to the left (Fig. 45-4). Two examples of INCORRECT ALIGN MENT. Guide pins should be bent in direction of arrows until they center in holes as shown in Fig. 45-2. Nos. 310,312,313 Nos. 314, and larger Nos. 800, 811,812,813 No. 814 - Nos. 880, 881, 882,883 No. 864T Nos. 860T, 861T. 862T, 863T - Fig. 45-7. Guide Pin Plate Locations.- Pins always point away from adjoining Gasket Surfaces. | WA-TEX 004143 WA-TEX004143 ITEM NO. B-35 '* ' -TRAINING DETAILS - :` ;r ... -f.. '"'Vis' r. fi-A.............. vry-. \^ j?vs.y.*a >*'0u?!r'ff y-^ **>"*%&r* s>*ft ^ fqAT;M .'TRAPS:S&cf:*11- &&**& IT - -- ' 'iiiiiMSsi PAGE 216 These traps, dne to their large orifices, can be sized to handle unusual dirt conditions * not possible with ordinary float traps but frequent blowdown or cleaning is advisable. . float traps may be damaged by surges of liquid which can cause float failure through col- . ' - lapsing offloat. In cases of this type the trap fails in the closed position and the trap does not blow through. -- Safety factor: A safety factor of VAtoZ times the maximum load is recommended for the nornial operation. Greater safety factors may be desirable to get the benefits of oversized orifices. " Oversizing float traps does not affect their operation as it does in other types of traps. See the capacity tables on the back of this folder. *=t dual Gravity . APPLICATIONS The ball float in the Clark duo-gravity drainers is weighted to sink in the lighter of the two liquids and to float in the heavier liquid. When the jbeavy liquid enters the drainer, the float be comes buoyant and.opens the discharge valve allowing the heavy liquid to be discharged from the unit. Typical installations in clude: removal of water from gasoline ' accumulators. Settling tanks, evap orators and Pipe lines carry ing 'light liquids with water present. When the float trap is placed below the level of the tank or fluid line, die liquid flows con tinuously .into the trap and the float -will reach a point of equilibrium, holding die discharge valve open sufficiently to discharge the liquid at the same rate it enters. ` MAINTAINING CONSTANT LEVELS ^ KK... > -r i f %vs -Xr.vt'v Clark FloatTraps may be used to maintain constant levels in tanks and reservoirs. As liquid level rises, tbe float buoyancy increases-. When the buoyancy is sufficient to overcome the force exerted hy the gas pressure against the -valve, the float mechanism will open the discharge valve, \. ressure then forces the liquid out of the . trap, lowering the liquid leveL As the drops the float loses buoyancy .. and sjnks to close the dis charge valve. \?,v m$rJ0 it:.''.-*:-. . Wa-TEX 004144 .. :&r- WA-TEX004144 ITEM MO. B-35 TRAINING DETAILS PAGE 217 CLARK FLOAT TRAPS discharge as accumulated liquid flows by gravity into the trap body, causing \e ball float to rise and open the discharge valve. " There is always a liquid level present at discharge over die discharge orifice, which creates a liquid seal and permits drainage without loss of air or gas. The float tends to reach a point of equilibrium to dis charge continuously at the same rate the liquid enters the trap. With these operating characteristics, the traps are used to advantage-- ' ' . to drain accumulated liquids from air or gas lines.. . for systems where there are wide variations in condensate load. Extreme light loads or no-load conditions do not affect the efficiency of these traps. . . for superheated steam systems where no-load or even re-evaporation conditions exist to prevent any loss of steam. . for maintaining constant levels. . for discharging liquids of low or varying specific gravities. . for dual-gravity service to maintain an interface by draining a heavy liquid from a lighter liquid. TRAPS No. 60F, 271G, 540. 542 are of high pressure cast iron (ASTM Class 35) for pressures to 250 psi--450F. or 300 psi-- 150F. Trap No. 701DF is of forged steel construction for pressures to 300 psi -- 500F. Working parts are of stainless steel with Clark-foy (heat-treated stainless steel) seats and discs. Floats are copper-plated steel or optional stainless steel. Trop No. In and Out Conn Equal Conn. DinlensiotIS Continuous discharge capacities In G.P.M. at in dicated pressures. Orifice diameters ore shown at the maximum operating pressure for each trap. HT. DIA. WT. 15 30 50 75 80 100 125 150 200 250 300 60F %"or%" 14" 5%" *5'/s" 5 Vs 7. Vu Va % Va 35. .9 1.3 1.3 1.1 1.1 .9 1.0 540 Vz" <%" 47," 9 % %4 1.2 1.6 Va 1.3 7m 1.5 #, .8 5k & .9 1.0 7,4 .6 7,4 .7 542 %"or%" Vi" 4"/u" 5%" 11 7m %4 7m 7m y 1.2 1.5 2.0 2.5 2.5 1.7 %* 7m 1.9 2.0 7m 1.2 %4 1.2 7,4 .9 271G %"or%" 'k" 834" *5%" 12 %, %2 2.9 4.0 % 2.7 Va 3.1 % 3.1 / 1.7 7 1.9 35z. %4 1.4 1.2 45, 1.2 1.3 701DF 54"or%" V5t"r?4" <%" 47." 9 7n Va % Va Va 7m 7m %t 2.9 4.0 2.7 3.1 3.1 1.7 1.9 1.4 1.2 7m 7m 1.2 1.3 pace to Face Dimension 280G SERIES 80G -- 280G CLARK TRAPS are of high-pressure cast iron (ASTM Class 35) construction for pressures to 250 psi --450F. or 300 psi-- 150F. Available for pipe sizes Yz" --2" in 80G Series and V2"--VA" in 280G series. Equipped with stainless steel working parts and Clark-loy (heattreated stainless steel) seats and discs. Duo-Step Leverage standard for greater capacities at lower cost Copper-plated steel floats for pressures to 200 psi or optional stainless steel floats for pressures to 300 psi. 80-G Six* 7".34` Equalizer Connection 'A" Height Diameter 834" WotgM 16 280-G Vi" JT/r" *77." 21 Vi 81-G V'/t" 77." 28 281-G 82-G 84-G Vi" 13" *9%" 40'/, 1154" 8'A" 41 I'A" 14'/," H14" 80 See back of this folder jfor complete charts of con tinuous discharge capacities in G.P.M. at indicated pressures and various specific gravities. Orifice diam eters shown on the chart are indicated at the maxi mum operating pressure for each trap. For sizing dual-gravity applications, forward requirements to your local representative or the factory. WA-TEX 004145 WA-TEX004145 ' ITEM NO. B-35 . TRAINING DETAIL PAGE 218 -. SERIES 640, 740 AND 4200 CLARK FLOAT TRAPS 640 740 SERIES 640 and 740 CLARK FLOAT TRAPS aie of fabricated steel foe maximum pressure of (500 psi at 750F. or 1000 psi at 150F. Equipped with stainless steel working parts, Clark-loy (heat-treated stainless steel) seat and valve disc for long wear and low maintenance. Duo-Step leverage for greater capacities at lower cost. Chrome-plated steel or optional stainless steel floats. . The 641 and 644 can also he furnished in all cast stainless steel construction. rr "ml ' V* o. 4400-- CLARK FLOAT TRAPS are of fabricated steel for maximum pressure of 600 psi--750F. or 1000 psi at 150F. Stainless steel working parts and Ciark-loy seats and valve disc--chrome-plated or optional stainless steel floats. Operating mechanism includes spring assist for greater capacities at higher pressures and low specific gravities. The 4201 is the same as above but is equipped with a side inlet similar to the 740 series. 4200 Pipe Size 60Q 740 Vs". 3A",1" 641 741 y4",i",iy4" 642 742 i",iy4"iy2" 643 743 644 744 iy*".2" 4200 4201 1",1 Equalizer Connection Vs" Vz" %" 1" %" Height 8%" ii'A" 12%" 14" 15%" 12%" Diameter 6'A" 7=AU 9'/." 10J&" 11 %" 9>/" Weight 23 46 75 106 .147 76 Note: Above traps can be furnished with socketweld connection. 740 series and 4201 can be furnished With 600 lb. ASA.flanged .connection. See back of this folder for complete charts on continuous discharge capacities in G.PM. at indicated pressures and various specific gravities. Orifice .diameters shown on the chart are indicated at the maxi mum operating pressure for each trap. For siring dual-gravity applications, forward your requirements to your local representative or the factory. WA-TEX 004146 WA-TEX004146 TEXACO INC. PUOSr^0Cl?FTONT TRAINING DETAILS PAGE 219 DEPARTMENTS PIPE CLASSIFICATIONS PIPEFITTER (TRAINEE) DATES JULY 1, 1970 "~ TTEM NO. B-36 --^ SUBJECT; INSTALLATION AND REPAIR ^-pnmuiNG" Installation of plumbing includes toilets, sinks, showers, hot water tanks, water coolers, septic tanks, sewer lines, water lines, etc. In this line of work extreme care must be used because of the type of material with which you are working. Toilets and sinks must be secured properly. Septic tanks and sewer lines must be laid one-eigith inch drop to two feet of pipe to get proper gravity flow and still float the material away. Repair of plumbing consists of plugged sewer lines, valve gaskets and corrosion to water lines. To unplug a toilet, use a plunger or plumber's friend. If this doesn't clear the line, use a plumber's snakej this will unplug the line. To replace valve gaskets, remove valve bonnet and put in new gasket. /--S | WA-*EX 004147 WA-TEX004147 TEXACO INC PAGE 220 --T----R--AININGm DETAIL^ -----~r^m DEPARTMENTS PIPE CLASSIFICATIQgrr^PIPEPITTER (TRAINEE) DATE; JULY 1, 1970 ITEM NO. B37 SUBJECTS INSTALL TUBING Tubing should be installed in tubing channel whenever possible. If not possible, it should be run on or in some type of hanger that runs the entire length of the job. Tubing must be cut square and reamed out on the end after each cut. Care should be taken when making tubing eonnee= tions that tubing is sufficiently in connection. When tightening connection, use backup wrench because tubing will twist or crimp. Also, it will' do this when putting tubing in hangers, so handle very carefully. W&-TEX 004148 WA-TEX004148 TEXACO INC. PUGEf^SOO!TO~PLANT TRAINING DETAILS . PAGE 221 DEPARTMENTS PIPE CLASSIFICATIONS PIPEFITTER (TRAINEE) DATES JULY 1* 1970 ITEM NO. B-38 SUBJECTS STEAM RADIATORS ` A. REMOVE When removing a radiator, secure a scaffold and rigging before disconnecting. There is a flange at the top of the radiator, from which the bolts must be removed, and a union at the bottom of the radiator. There are two hanger bolts that hold radiators in place. After the rigging is in place, the hanger bolts may be re~ moved and the radiator taken out. B. INSTALL When installing a radiator, clean flange and union surfaces, use the proper gasket and reverse the procedure above. C. REPAIR Radiators usually leak in the soldered fittings on the coil inside the radiator housing. If so, it will be necessary to completely take the raditor apart to repair the leak. Put a test cm the radiator to locate the leak. Then clean the ares thoroughly and resolder. . Sometimes radiator headers develop holes. If this happens, cut a patch to cover the hoxe and have it welded on. ; WA-TBX 004149 WA-TEX004149 TEXACO INC, PUGET SOUND PLANT TRAINING DETAILS PAGE 222 DEPARTMENTS PIPE CLASSIFICATION; PIPEFITTER (TRAINEE) * ' DATE; JULY 1, 1970 ' ITEM NO. B-39 ' SUBJECTS INSTALL PIPE HANGERS AND SUPPORT ' ' Pipe hangers are installed to hold pipe securely in place. The majority of the pipe hangers are made by the pipe fitter as he installs his fabrications to help hold the pipe as he proceeds. He makes the hangers out of whatever he feels necessary to do the job. Attached is information and illustrated drawings of various pipe hangers and supports. I WA-TEX 004150 WA-TEX004150 ITEM NO. B-39 t$ adjustable ring lig. 263 TRAINING DETAILS . . PAGE 223 ,wMill ring clevis adjustable clevis, light weight lig. 65 idze range: Vi through 8 inch, material: Carbon steeL , finish: Black or galvanized; furnished black unless otherwise specified. sorvice: Recommended .for suspension of non-insu- Inted, stationary pipe lines or conduit. ' maximum temperature: 65DF. approvals: Underwriters' Laboratories listed and factory Mutual approved for % to 8 inch pipe only when galvanized. Complies with Federal Specifica tion WW-H-171c (Type 7) and Manufacturers Stan dardization Society SP-69 (Type 7). features: Provides for vertical adjustment, 1 to 2 inches. ordering: Specify pipe size, figure number, name. loads weights packaging pip* III* max recom load, lb* wgt (approx) lb per 100 cation 610 J4 610 1 610 l'i ` 810 IS 610 2 610 2.'. 970 3 070 3'> 970 1 1250 fi 1250 6 1600 .8 1900 * Wnh minimum safety factor ol 5. dimensions (inches) 10 14 15 17 25 28 37 43 47 90 110 154 270 pip* ll* J t l!i l'i 2 l'i 3 .?' 4 5 6 a A X a a 34 34 X X X X X H X X B 1% 2% 2% 2% 2X 3 354 t'4 *X iX 5% 6X 7% c 2% W 2% 3% 3% 4% SXs e ex 734 - 8% 9% UX 2X 2X 2X 2X 2X 2X 3X 334 3X 3X 4 AX AX 25 25 25 25 25 . 25 . 25 25 25 ..1....0.*' .... rod takeout E IX 1% 1% 1% 1% 2% 3 3% 3% 3% m 5% . 6% adjust. men! F 1 1 1 iy* 1X U4 IX IX m 2 2 2 size range: % through 4 inch, material: Carbon steel, finish: Black. service: Recommended for suspension of light loads, pipe or conduit. maximum temperature: G50F. approval: Complies with Federal Specification WW-H-171c (Type 12). installation: Hanger load nut above the clevis must be tightened securely to assure proper hanger per formance. . adjustment: Vertical adjustment is provided, varymg with the size of clevis. Tighten upper nut after adjustment. features: An economical attachment for light duty service. ordering: Specify pipe size, figure number, name. loads weights packaging pipe SlZO X X X- 1 134 IX 2 2X 3 3'A 4 inaidnuim recommended load, lb" ISO 150 250 250 250 250 250 350 350 350 . 400 weight (approx) lb per 100 12 13 27 28 . 32 34 40 SI 90 99 139 pieces per carton 100 100 100 100 100 100 100 50 50 25 25 * With minimum safely factor of S. dimensions (inches) : WA-TEX 004151 , pipe size ofsteel size upper lower A B cD E adjust* mentF X X %Xixx %X X %%Xx X34 34 1% iX X 134 2& % 2% 334 234 234 234 34 % 2%% X 1% 1 134 #13 U.S. Gauge x X 134 X 3%, 334 X X 333%4 4% .434 234 234 234 234 234 2% 154 1% 154 2 234 3 3344xx115344 34xlJ4 Kxi54 X 34 354 4% 34 454 46 % 634 234 3334 235%4 1% 234 3% 154 3X 4 34x134 %x!J4 34x134 34*134 34 4% 6% 2% 4 34 eX 734 334 454 213%fs ..... '" WA-TEX004151 ITEM NO. B-39 TRAINING DETAILS PAGE 224 /"^dpe hangers and supports clevis adjustable clevis fig, 260 size range: through 24 inch, material: Carbon steel. . finish: Black or galvanized; furnished black unless otherwise ordered. service: Recommended for the suspension of non* insulated, stationary pipe lines. maximum temperature: 650F. approvals: Underwriters' Laboratories listed and Factory Mutual approved for % through 8 inch pipe. Complies with Federal Specification WW-H-171c (Type 1) and Manufacturers Standardization Society SP-69 (Type 1). installation: Hanger load nut above clevis must be tightened securely to assure proper hanger per formance. .When an oversized clevis is used, a nipple should be. placed over the clevis bolt as a spacer to assure that the lower U-strap will not move in on the bolt. adjustment: Vertical adjustment without removing pipe may be made from 1% to 4% inches, varying with the size of clevis. Tighten upper nut after ad justment. . features: New design has yoke on outside of lower U-strap so yoke cannot slide toward center of bolt, thus bending of bolt is minimized, New design provides increased- strength even with lighter stock size. . o Sizes 5-inch and up have rod and two nuts instead ' of bolt and nut; thread length on clevis rod is such that the thread locks the nuts in place. ordering: Specify pipe size, figure number, name. loads weights packaging e dimensions (inches) pipe size 'A A l m i'A 2 2'A 3 3% 4 5 6 8 V 10 712 14 16 18 20 24 30 maximum recommended load, lb" 610 610 610 610 610 .610 1130 1130 1130 1430 1430 1940 2000 3600 3800 4200 4800 4800 4800 4800 8000 weight (approx) lb per 100 . 34 39 44 45 55 .61 140 152 170 213 244 357 496 878 1140 1481 2100 2437 4256 4843 6950 pieces per cation 100 100 100 100 100 100 50 50 25 25 size of steel .upper lower Axl Axl Axl Ax 1 #9 U.S.Ga.X l j|f9 UlS.Ga.x 1 %x 1/4 %*1% Atxl'A AxlA AxlA Axi'A AxlA AxlA %xZ 'Ax 2 'AxZ'A 'AxZ'A %x3 %x3 AxZ %xl 'Ax l 'Ax l 'Axl Axi Axl Atxi'A %*i% %xl% HfXi'A Xtxi'A Asxi'A %xlVi. AxlA 'Ax 2 'Ax 2 AxZ'A AxZ'A Ax3 %X3 %X3 With minimum safety factor of 5 AB C DE adjustment F G % 2% A 2% A 3% % 3% A 3% A 3% 'A 4% 'A 4% 'A 4% A 5% A 6% A s% A 8% A 9% A 11% i 12% i 15 iA ISA iA 17A lA 19% iA 24A z% 3% 3% 4% 4% iA 6A 6% 6% 7% 9 io% 12% ISA 17% 19% 23 24% . 27% 31% 39% 2% 2% 2% 2% 2% 2% 3 3 3 3% 3% 4 4% i'A m 5A 6 B'A 7 7% 8% iA 23j* 2% 2% 2% 2% 3% 3% 4% i'A 5A 5% 7 8% 9% 10'% 12% 13'% 14% 17% 21% IA I'A IA 1A 1% m. 2 1% iA i'% i% i% 2% 2% 2% 2'% 2% 3% . 4 iA 5 A A A A A A A A A A % % A A A A l i% iA iA iA , ; WA--TEX 004152 WA-TEX004152 ITEM NO. B-39 TRAINING DETAILS PAGE 225 adjustable clevis for insulated lines fig. 300 alloy: tig. 3000. clevis size range: % through 12 inch. material: fig. 300 -- carbon steeL fig. 300A-- carbon steel yoke and clevis bolt; chrome molybdenum steel U-strap. finish: Black. service: Recommended for suspension of insulated, stationary pipe lines. maximum temperature: fig. 300--650F fig. 300A-- 1050T approvals: Complies with Federal Specification WW-H-171c (Type 1) and Manufacturers Standardi zation Society SP-69 (Type 1). installation: Hanger load nut above clevis must be tightened securely to assure proper hanger perform ance, adjustment: Vertical adjustment is provided, vary ing with the size of the clevis. Tighten upper nut after adjustment. features: . Designed for 2 inches of insulation on % through 1Vi inch pipe and 4 inches of insulation on 2 inch and larger pipe. When properly installed, clevis bolt is outside the insulation. ordering: Specify pipe size, figure number, name. load* weights dimensions (inches) pip* ills H ii'i l'-i 2 2ij 3 3% * s 6 B 10 12 maximum recommended load, lb* 610 610 610 610 610 1130 1130 1130 1430 1430 1940 2000 3600 3800 weigh! (approx) !b per 100 sirs of steel upper lower 51 58 64 72 85 131 201 210 247 301 337 ' 673 1102 1382 Axi Axl Axl #9 U.S. Ga. x I #3 U.S. Ga.x 1 %5tl% fax 1% %xi% AxiA AxiA AxiA AxiA AxiA AxZ %xl Axl Axl Axl Ax 1 %xl% %xi% %xi A %*iA HtxiA HixVA %*i% AxiA AxZ * With minimum safety lacior of 5. A % A A 'A A Vi A A A A A A A A B 4% 5 5% 5% 7% 8% 8% 8% 9% 9% m 12% 13% 15% CDE adjust ment F 6 5% 5% 6 8% 8% 9% io% 10A n% 12% 14 16% 13% 21% 2% 2% 2% 2% 2% 3 3 3 3% 3% 4 4 4% 4% 4 4% 4% 4% 6% 7% 7% 7% 8% 8% 9% 11 12% 13% IA 1A 1A 1% 1% 2 1% 1% 1% 1% 1% 2 2% 2% % A A A A A A A A A A A A A - | WA--TEX 004153 H 2 2 2 2 4 4 4 4 4 4 4 4 4 4 WA-TEX004153 ITEM NO. B-39 TRAINING DETAILS PAGE 226 double ifeaSS pipe elsasrc&s? fig. 295 --I e I-- steei damps stze range: % through 24 inch, material: Carbon steel. finish: Black or galvanized; furnished black unless ' otherwise specified. service: Recommended 'for suspension of pipe re quiring up to 4 inches of insulation and where flexi bility of the clamp is desirable -- within the limita tion of temperature and loads shown below. maximum temperature: 750T-. approvals: Complies with Federal Specification WWH-i71c (Type 3) and Manufacturers Standardization Society SP-69 (Type 3). installation: Attachment to the clqmp may be made with a weldless eye rod fig. 278, page ph-59, or the weldless eye nut fig. 290, page ph-63. features: o load bolt and attachment will extend outside of 4-inch thick pipe covering. o Load ratings meet USAS code requirements and are substantiated by laboratoryjest. o Rounded comers on clamp ends provide greater safety for personnel. ordering: Specify pip size, figure number, name. loads weights dimensions (inches) pipe elz Va I 1% \U 2 2% 3 3% '4 5 6 8 10 12 14 16 18 20 24 max iBcom load, lb* for service temp B5DF 950 ` 950 950 1545 1545 1545 1545 1545 2500 2500 2865 2865 3240 3240 4300 4300 4300 5490 4500 750F 850 850 850 1380 1380 1380 1380 1380 2230 2230 2555 2555 2890 2890 3835 3835 3835 4900 4015 vrgl (approx) lb per 100 70 76 81 234 258 272 304 328 668 699 1145 1315 1981 2225 3768 4137 44B7 5725 6580 , 3 '% % I'A 1% 2% 2% 2% 3 3% 3% 4% 5% 6% . 7% 9% 10% 11% 12% 14% C % % % 1% !% 1% ' 1% .1% 1% 1% 1% 1% 1% 1% 2 2 2 2 2 D 2% 3 3% 4% s% B'A 6% 6% 7% 8% 9% 10>% 12 13 14% 15% 16% 17% 19% E 2% 2% 2% m 5% 5% 5% 6% fiK 7 8% 8% 10% 11% 12% 13% 14% 15% 17% F % % % % % % % % % % "% % 1 1 1% 1% 1% 1% G %*! %*1 %xl %xl% %xl% %xl% %xl% %xl% %X2 %*2 %x2% %x2% %x2% %x2% %x3 %*3 %*3 %*3 %*3 SCO i W&-TEX 004154 H 1% 1v% 1% m 2% 2% 3'% 3% 4% 5 6% 7% 8% 3% 10% 11% IE'J'fs 14 16 WA-TEX004154 ITEM NO. B-39 TRAINING DETAILS PAGE 227 sfeel elamps heavy duty deasbl bolt pipe clamp !!> 295H size range: 6 through 24 inch. ' materied: Carbon steel, finish: Black. service: Recommended for suspension of pipe re quiring up to 4 inches of insulation and where flexi bility of the clamp is desirable. ' 750T. approvals: Complies with Federal Specification WW- H-171c (Type 3) and-Manufacturers Standardization Society SP-69 (Type 3). features: Load bolt and attachment will extend outside of 4-inch thick pipe covering. Load ratings meet USAS code requirements and are substantiated by laboratory test, ordering: Specify pipe size, figure number, name." . load* weights dimensions (inches) maximum recommended load,lb* pl(> lor torrlce temperature ill* wgttapp'x) lit. BSO'F 750F lb per 100 B f. 3500 3125 1 4800 4285 ID 5500 4910 1200 1850 3025 4% 8 7'A 12 7000 M 3500 m 10000 8250 8485 8930 4200 8000 8000 BA sy 10% ID 13000 12325 30 15300 136B5 U 16300 14555 11500 14000 19000 12% 13% 15% C i% 2 2% 2% 2% 3 3% 3% 3% 0 10% 11% 13% 14% 15% 17% 18% 13% 22% * Buxixi on lhB allowable stresses shown in the USAS Code lor Pressure Piping. E 8*% 10% 11% 12% 13% 14% 16% 17% 19% FG 1 %x2% 1% %xH% 1% %x3% 1% %x3% 1% %x 4 1% %x4% 2 I x4 2 1 xS 2 1 x6 WA-TEX 004155 H 67% 9 10% 11% 13% 14% IB 18% WA-TEX004155 item no. B-39 TRAINING DETAILS PAGE 228 sSeel pip slumps medlm pip slesmp fig. 212 size range: Vi through 24 inch, material: Carbon steel. finish: Black or galvanized; furnished black unless otherwise specified. services Recommended for suspension of cold pipe lines or hot lines where little or no insulation is re quired. maximum temperature: 750'T. approvals: Underwriters' Laboratories listed and Factory Mutual approved for % through 8-inch pipe. Complies with Federal Specification WW-H-17.1c (Type 4) and Manufacturers Standardization Society SP-69 (Type 4). installation: Normally used with weldless eye nut fig. 290, page ph-63, or eye.rod. features: Load ratings meet USAS Code requirements and are substantiated by laboratory test. Clamps tightly to pipe. Wide range of sizes. o Rounded corners provide greater safety for per sonnel. ordering: Specify pipe size, figure number, name. loads e weights dimensions (inches) pipe size H K l . IK i'A 2 2K 3 3)4 4 5 S 8 10 12 ' 14 16 18 20 24 max rocom load, lb8 for service temperature 6B0F 750F 500 445 500 445 500 445 500 445 800 71S 1040 930 1040 1040 1040 1040 1040 IG1S 930 930 930 930 830 1440 1815 2430 2490 2490 2490 3060 3060 3080 1440 2220 2220 2220 2220 2730 2730 . 2730 lb per 100 29 33 35 38 88 , 113 124 139 153 229 260 542 654 1362 1518 2050 2225 3155 3581 5312 B 1 iK iK i% 2V. 2K 2% 3K 3% 4 4% 8 7% 8K 3 10 uA 12K 15 C Hi Hi Hi Hi jH A % % % % % % i i l iK IK IK IK iK ' * Based on the allowable stresses shown In the USAS Code for Pressure Piping. D m i% i% 2K 2K 3K 3% 3% 4K 4% 5K 7 9% 10% 11% 13 14% 10% EF G 1 Hi K*i iK Hi Kxi iK Hi Kxi i% %6 Kxl IK Hi Kxl 2K A K*i 2K % K.xl 2% % Kxl 3% K Kxl 3K K KxiK 4% K KxiK 5 K KxiK 6% K KxiK 7% K Kx2 8% K Kx2 8K % Kx2K I0K % Kx2K 11% l Kx2K 12M i% Kx2K 15K iK Kx3 '< WA-TEX 004156 H 1% 1% 1% 1% 2.% 2% 3K 3 4%t 4% $% e% BHi 9K 10K UK 12K 13K 16K WA-TEX004156 ITEM NO. B-39 heavy pipe damp fig. 216 -HPf' -hkJ*"* TRAINING DETAILS PAGE 229 pipe clamps size range: 3 .through 16 inch, material: Carbon steel, finish: Black. service: Recommended for suspension of heavy loads where little or no insulation is required. maximum temperature: 750F. approvals: Complies with Federal Specification WW-H-171c (Type 4) and Manufacturers Standardi zation Society SP-69 (Type 4). installation: Normally used with eye rod or with weldless eye nut fig. 290, page ph-63. features: d Additional line can be suspended below clamp by attachment to bottom bolt. a Load ratings meet USAS Code requirements and are substantiated by laboratory test, o Designed for heavy loads in temperature up to 750F. Rounded corners provide greater safety for per sonnel. ordering: Specify pipe size, figure number, name. loads weights dimensions finches) pipe sirs rooxrocom load. lb" for service temperature 850F 750F wgi (approx) lb per 100 B CD 3 .m 4 5 6 8 10 12 14 is . 3370 3370 3515 3515 4B5S 4855 6010 8B75 9120 9120 3005 3005 3135 3135 4340 4340 5360 7740 8135 8135 417 456 604 700 1340 1570 2450 4250 5187 5687 2% 3% 3% 4JT~ 5 6% 7% 9 3% 10% I 1 1 1 iX i% i% i$A iy. IV. 4 4% 4% 0% 6 V, 7% 9% m 11% 12% * Batad on the allowable stresses shown In the USAS Code for Pressure Piping. E 3% 3% i% iA 5% e% 7% 9% 10 11 F 6H % 3% % %2c2 4% % %x2 4% % %x2 s% 1 Kx2'A 6% 1 %*2% 7Vt 1% %*2'A 8% IK %x3 10% lK %x3% 11% iK %*3% . 12% WA-TEX 004157 Z % % % % % K % K % % WA-TEX004157 TEXACO INC. PUGET'SOUND PLANT TRAINING DETAILS PAGE 230 DEPARTMENT? PIPE CLASSIFICATION; PIPEFITTER (TRAINEE) DATE; JULY 1, 1970 ITEM NO, B-40 SUBJECT; PACK VALVES When you are packing valves you must he sure to have the right size packing for the size valve you are packing. Also, there are special types of packing for steam, gas, etc., service. When packing valves be sure to have sufficient packing Vtnder packing ring to stop product leak and still let valve open and close. It helps to lubricate the packing while installing. WA--TEX 004158 WA-TEX004158 TEXACO INC. PUGET SOUND PLANT' TRAINING DETAILS PAGE 231 DEPARTMENTS PIPE niASSIPICATIONl 'PIPEFITTER (TRAINEE) DATEs JULY 1, 1970 ITEM NO. B-4l SUBJECTS INSTALL AND REMOVE OHMART W^L~GONTROLLER ' ~ A. REMOYE The removal of Ohmart level controller is done right after crude unit is brought down for test and inspection. There are two bolts left in the manway, remove them and open manway as far as possible. The Ohmart level controller is bolted to the manway by a two-inch flange,. This requires two men. One man loosens bolts while the other holds the controller, which has handles. Be careful not to touch upper part of controller. Take the controller out and let it down to the slab by rope. Keep it at arms length. Put controller in container and take it to storage room. B. INSTALL Installation if done -fter the decarbonizing tower is ready to be put back in operation. Be sure gasket surface is clean and put a new gasket and bolts in. Then reverse procedure above. It is important that you read and understand Standing Instruction No. 8. ` I WA--TEX 004159 WA-TEX004159 WA-TEX004160 TEXACO INC PAGE 233 TRAINING DETAILS DEPARTMENTS PIPE . CLASSIFICATIONs PIPEFITTER (TRAINEE) DATES JULY 1, 1970 ITEM NO. B-42 SUBJECTS REPAIR HYDRANTS A. SERVICE WATER Disconnect piping to hydrant, turn hydrant to open position, then take the top of the hydrant head off, with it will come hydrant shaft and hydrant disc, which is made of rubber. Put new rubber disc on shaft and it is ready to put back together. Before putting together, clean out bottom of hydrant and be sure all hydrant parts operate properly. B. FIRE WATER To repair this type of hydrant you must have the hydrant dug out and completely removed. These hydrants have a rubber disc in them which can be replaced. Before installing, clean hydrant and make sure all parts work properly. j WA-TEX 004161 WA-TEX004161 ITEM NO B~42 TRAINING DETAILS PAGE 234 Special ' VjOjf W.P. Self draining hydrant type valve, modified frosn manufacturer's standard fire hydrant to provide one 12l>jl flanged outlet nozr.ie on the barrel. Valve to open against line pressure, working parts to be removable from grade. Balance of parts to be manufacturer's stanLard fire hydrant construction with suitable corrosion resistant materials, seals and gaskets. Valve to be provided with hand.-neoi which is to ti. 11 counterclockwise to open. 1 frg 11 *| 3i c.e VALVE ITEM M9 = L~\08 -'otOajoh--Oaf THIS DW6. mb BE'CW ADAPTED VROM TEXAS CO. VALVE N^V-SSOBI 1 WA-TEX 004162 0,(4 fill 1IXAS COMPANY /3 l3;2 g *s * 4 .s 2, ' -V, PHIT SOUND WORKS A A A A :.REVfSfcfe> AS NOTTED tl-lI-57 5ftooEo oim's. a, e.c,T mfg. 5TO- penyewooR. 0owe. f.p.* z5- ah-e-aa * wirf. ISSUED FOR. COtOSTRUCriOM 1 ISSUED FOR. APPROVAt . 1 m. HYDRANT TfPE 'VAlvfe FOR WATER SERVICE Sjlh . H.6rii &. DR H&. OR. H-D CH'K. ENG. L CV CN'JC. DATE DR. SUJ>. CHIEF 6400--L. - APPROVED BY THE TEXAS CO. 4--/-S7 3WT" .... sup.vrtlk <ytZU Ml $f- 2job mo. 5-2 b DRAWING No. | REV. c / _ r* _io ol u WA-TEX004162 WA-TEX004163 n . >. "i . -a* P !? , "!J ' . $M ' Cu it - . 5 s ITEM NO. B-42 TRAINING. DETAILS , PAGE 236 Special " ' ! lyO# M.P. Seif draining hydrant type, valve, modi fled from manufacture: .standard ^`nominal valve opening firts hydrant, to provide one 2>0^ ASA Std. flanged pumper nozzle and one nose nov.eie on U;-.- barrel. Valve to opeh against line pressure, working parts to be . removable from grade. Balance of parts to be manufacturer's stanaar..' fire hydrant construction with suitable' corrosion reel:;Lent imtunair, seals and. gaskets. 7'ij.ve to ue provided with handwheat riiuer* Is lo'i counterclockwise to open, Similar to Danin?., ng Co. v-g. No. U-'.v. or equal. ` . -.. Km "i -2 n P ^2 . Ix 1" Js- ' * . v . ~E2S*-.2B ** s. .M" . ce. a.*.n . Ig oP U- J.S SJ -. <sj.tz u" Uj.g -I V . *1 - xa; V^ ** s. .-... ,8,5o , 8 MO .1a 3 !: m"22 |S Ilf a p. r' y{&tio 4" FLGD. PUMPER NOZZLE F.fcD. 250* ASA STD. GROUND OR. PAVING UNE 12" HANDWHEEL 2*/2 STD. HOSE NOZZLE-CAPPED. THREAD TO BE NAT. STD. HOSE THREADS ( N FPA) UNLESS OTHERWISE SPECIFIED. ~ MANUFACTURERS STD. "T " DIMENSION TO BS SPECIFIED WHEN ORDERING VALVE. DIM'S. A, B $ C TO BE FURNISHED BV VALVE SUPPLIER.. /$\ dim's b,c 4-" FL6D. INLET NOZZLE F- D. IZ5*ASA STD. VALVE -rr ITEM N9=L-I069 NOTE'- T*lS DRAWING HAS SEEN ADAPTED FROM TEXAS CO. VALVE DWG. WA-TBX 004164 NO V- 3.50 B 2 THE TEXAS COMPANY PUGET SOUND WORKS i 6400--k ' APPROVED BY THE TEXAS CO. rt*3gQ-L -n 4-1-57 A A A. A DATE 3-22-57 ADDED MlSC. OlHfS. PER VENDOR DHi6tF.P.frg2f.48-S-28-7-; issoeo pok. cou&TRocnoW ISSUED FOR APPROVAL % FIRE WATER MONITOR VALVE HYDRANT-TYPE ' 50-EL-I39 WA-TEX004164 TEXACO INC. PUGE,IrS0iaro PLANT PAGE 237 /""s TRAINING DETAILS DEPARTMENT; PIPE CLASS IFICATI ONTHPIFEFITTER (TRAINEE) DATE: JULY 1, 1970 ' "* ITEM NO. B-43 f' ' SUBJECTS INSTALL EXPANSION JOINTS 'J-1 * 'll'Wl III M III 1 I IHTIMW To install expansion Joints, be sure flanges are lined up properly and to have the right gasket for the job; tighten bolts up evenly. Expansion joints are used to prevent the transmission of vibration and to absorb the movement of piping due to thermal temperature changes. They are used on boilers, condensers, turbines, reactors and pumps. n i: WA-TEX .004165 WA-TEX004165 TEXACO INC. PUGET "SOUND PLANT PAGE 238 O- TRAINING DETAILS ' DEPARTMENTS PIPE olassificatiqnT~"pipefitter (TRAINEE ) DATES JULY I, 1970 ITEM N0,, B-44 """" SUBJECTS FLANGE AND UNFXANGE E9.UIPMfF~ ` To flange and unflange equipment, have the right tools for the job, know the right size bolt3 and nuts, have the right size gaskets for the flange and be sure that the surface of the flanges are clean and properly lined up. When working on flanged equipment, there are safety precautions to be taken. First, obtain a Safety Work Permit, Form R"24l-A. The permit will state the precautions that must be taken to disconnect the flanged equipment. When loosening the bolts on the flange, loosen the bolts on the opposite side of the flange from the one you are working! if there is product in the line. It will spray away from you. j WA-TEX 004166 WA-TEX004166 TEXACO INC. PUGET 'SOUND'FlAST TRAINING DETAILS PAGE 239 DEPARTMENT? PIPE ,x CLASSIFICATION; PIPEFITTER (TRAINEE). DATES JULY 1> 1970 ITEM N00 B-45 SUBJECTS INSTALL EDUCTORS A o INSTALL When installing eductors, be sure all flange and union surfaces are clean, proper gaskets are used and that flanges aye lined up properly. The above points are important because a leak may cause loss of suction. See the following examples of commonly used ejectors. : WA-TEX 004167 i ' WA-TEX004167 ITEM NO. B-45 TRAINING DETAILS PAGE 240 ppsrzrz**'s*'- In almost every Industry where liquid transfer, air or vapor removal, blending or agitating are a function of the production process, Penberthy Jet Pumps are a popular choice. Their acceptance is based on the effi cient, maintenance-free, quiet operation, minimum space requirements and ease of installation. In addition to the complete line of standard model jet pumps, Penberthy maintains, design and production facilities to produce special jet pumps to meet customer requirements and ^material specifications. Illustrated below are new bar stock ejector models and representa tive variety of.special design and special jet products built to-customer needs. . SPECIAL JE=T PUMPS'- This bar stock stainless steel ejector has butt-welding connections and is used where special corrosion resistance ,is desired. This special bar stack ejector Is constructed with an angled and. flanged suction connection required for a unique installation. ' Special stainless .steel jet pump with flanged connections for handling corrosive chemicals. Available in Hastelloy and carbon steel. Submerged type (open .suction) carbon steel ejector with screwed connections for use in tanks and having minimum resistance to flow. Special stainless steel all-flanged connections ejector with suction parallel to discharge to meet installation .limitations. Parallel flow design carbon steel ejector for use In liquid transfer. Suction connection is shown above Inlet. Special water-operated jet pump with flanged suction and discharge connections and screwed inlet. This small (H" x %" N.P.T. connections) bronze ejector has male discharge and ah infot mnnpntions. Large cast bronze hydraulic ejector with flanged connections for bilge water removal. Special stainlesssteel ejector with flanged discharge and screwed inlet and suction con nections for pumping corrosive chemicals. ' WA-TEX004168  . ' ITEM NO. B-45 ' TRAINING DETAILS PAGE 241 GRAHAM SINGLE STAGE NON CONDENSING AIR EJECTOR '? S steam Inlet STEAM LINE TO EJECTOR ; SHOULD BE A PROPER SIZE TO BE SURE STATED STEAM PRESSURE WILL BE PRO" VIDEO AT THE EJECTOR STEAM INLET. THE STEAM > LINE SHOULD BE PROPERLY INSULATED, AND IP NECESSARY TO INSURE DRY STEAM, A GOOD STEAM SEPARATOR SHOULD BE INSTALLED AS CLOSE TO THE EJECTOR.AS POSSIBLE. . : EXHAUST VAPOR OUTLET SHOULD BE PIPED WITHOUT RESTRICTION TO CARRY THE i VENTED CASES TO A POINT WHERE THESE GASES WILL NOT BE OBJECTION ABLE. ALL EJECTORS ARE SENSITIVE TO BACK PRESSURE, SO CARE SHOULD BE EXERCISED TO SEE THAT IT DOES NOT EXCEED. THAT FOR WHICH THE EJECTOR IS DESIGNED. NO NAME 1 STEAM NOZZLE 2 STEAM CHEST 3 AIR CHAMBER 4 DIFFUSER 5 AIR CHAMBER CASKET 6 DIFFUSER CASKET 7, STEAM VALVE 8 STEAM STRAINER . , .. .. GMC-194 GRAHAM MANUFACTURING CO., INC. 4lS LEXINGTON AVE ' A*--**.!_* KB ' '* ( WA-TEX 004169 l. . WA-TEX004169 TEXACU INC; pwBfsmnr'mm}- DRAINING DETAILS PAGE 242 DEPARTMENT! PIPE. CLASSIFICATION! PIPEFITTER (TRAINEE) DATE; JULY 1, 1970 ttom NO. B-46 --- SUBJECT? INSTALL TEMPORARY FIELD mm--- ------------------------- When installing field pumps, get the right pump fqr the job and the right equipment to haul the pump to the Job site. You can get piping and fittings for suction, discharge and steam supply . = from pipe storage area south of the airstrip. , ^ . It is best to hook up suctiori piping first and then. the.. v. discharge. The steam supply to operate the pump is the biggest Job because it is necessary to run from 50 to 500 feet of piping to get. to a steam supply sufficient to run the field pUmp. When running the steam supply, run a large enough pipe to steam whatever you, are hooking the pump to. A two-inch pipe Is usually sufficient. ; \, WA-TEX 004170 V WA-TEX004170 TEXACO INC. PUGET SOUtto HANT TRAINING DETAILS PACE 243 ; DEPARTMENTS PIPE .. fiTASSaICATIOfrr^PXPEgITTER (TRAINEE) ITEM NOo B-47 SUBJECT? DATES JULY 1* 1970 INSTALL STEAM-TRACING on nm m nmxiGr Steam treeing Is installed on piping or vessels to keep product in a liquid form. It is important that tracing is fit , properly to pipe so there will be no added heat loss. . Steam tracing should be trapped sufficiently to get maximum heat from ! WA-TEX U04171 WA-TEX004171 TEXACO INC, PAGE 244 TRAINING DETAILS DEPARTMENTS PIPE CLASSIFICATION? PIPEFITTER (TRAINEE) DATE? JULY lj.. 197Q ITEM NO. B~48 SUBJECTS MAKE PRESSURE TAPS A. REQUIREMENTS (1) WHEN PERMITTED - Where practical, operating line* , or equipmen'F ahilir*be emptied and freed Of combustible gases and liquids before performing hot work. However, pree^ure tapping may be performed in order to avoid loss of valuable operating time or expense for gag-freeing lines and equip- mertt when all Of the conditions for the operation have been met. "' (2) WHERE NOT PERMITTED aV . In vapor space of atmospheric, tankage, Sb) On alloys requiring stress relieving of welds, c) In hydrogen or hydrogen rich service (because of tendency to leak through the packing glands). (d) in systems with flanges rated over 300 # ASA. (e) No pressure tapping shall be authorized on wall thickness of less than 3/16". . (3) HOT WORK PERMIT FORM R-242 must be obtained from the operating^departmend The permit must be counter*} srne'd by the PLANT MANAGER or ASST.' PLANT MANAGE!' * MateHaT^o^e^ressure^appe"musl^BeTiamifler cea^ea- by Inspection Department. Inspector on Job must sign nermit and results of hammer test. Asst. Plant Manager should be notified one day in advance of pressure tap. Chief Engineer must initial permit indicating no alloy, is involved and meets engineering standards. . (4) SPECIAL PRECAUTIONS: (a) Close operating supervision shall be maintained during the entire operation. (b) A check of surrounding area for possible gas accumulation shall be made. Sewers shall be covered and surrounding area wet down. (c) A fire watch with adequate fire fighting facilities shall always be maintained. (d) The actual wall thickness shall be determined by the -Test and Inspection Department before starting work. ' |e) The pressure rating of the pressure tapping equipment shall be at least & great as the system being tapped. WA-TEX 004172 WA-TEX004172 ITEM NO. B~48 TRAILING X>TAIX*5 PAGE 245 (f) Welders shall be instructed to apply a light bead of weld to start frith, gradually building up to required weld to prevent excessive heat. B. LINE TAPPING (1) A continuous flow of product must be maintained at all times during the operation to carry off heat. C. PRESSURE TAPPING ON TANKS (1) Liquid in the tank shall be at least two. feet above the upper limit of the welding and tapping. No pumping shall be permitted in or out of the tank. . D. VESSEL TAPPING v (l) Liquid in the vessel shall be at least two feet above the upper limit of the welding and tapping. No pumping shall be permitted in or out of the vessel. In some cases when unit is down for T&I, a steam flow may be used in place of product. . E. WILLIAMS DRILLING MACHINES ," _ (l) These pressure tap machines-drill holes from 1" to 2" and 3" to l4" in any size or type of line or vessel. The drilling operation may fo? done under pressure by using a yalve between ' the machine and the line; The valve is not required when there . is no pressure. Line or vessel must be steamed and gas freed ' to drill without valve. This machine is hand operated' and tool must be fed by hand. ` F. WORKING PRESSURE AND TEMPERATURES (1) 1200 P.S.I. maximum working pressure at 100F. (2) 500F maximum temperature at 1000 P.S.I. The working pressure or temperature rating is reduced accordingly If any attachment, valve or fitting, subjected to pressure or tempera- . ture when using the machine, has a maximum working pressure or temperature rating less than that specified above. G. OPERATING INSTRUCTIONS . (1) Select the correct drill for the size tap to be made. CAUTIONS When drilling through schedule 120 or above nipples, a smaller size drill must be used. Examples When drilling through a 1" schedule 160 nipple a .3/4" drill should be used. Test drill to make sure the drill adapter end will go through adapter nipple. (2) Travel of boring bar is l'" - 2". WA-TEX 004X73 WA-TEX004173 ' .. ' r0o B-48 TRAINING DETAILS PAGE 246 , ) Assemble drill to holder, making certain that parts are" tightly assembled. Drill has flats for tightening with crescent wrench, (4) Be sure that length of nipple plus tapping valve is short enough to permit completion of tap in boring bar travel. (5) Attach combined drill and holder to boring bar, then attach machine adapter and gasket to drilling machine body. Tools are attached directly to boring bar by means of screw threads and . butt against the square shoulder of the boring bar. ' (6) After tools are attached, use the torque rod to retract the boring bar into the body of the machine. Make sure/drill Is Retracted far enough to attach machine adapter to closed valve ` op line to be tapped. (Screwed or flanged). . . (.7) Using special grease, lubricate drill bit and then attach drilling machine and adapter to closed gate valve (screwed or 'Hanged, whichever, the case may be). Make .sure all connections : are tight and bleeder valve is closed. (8)_ Open gate valve, after determining pipe thickness., advance tool-to the surface of metal to be cut. This can be done with ratchet handle. Set indicator rod to show travel required to .complete cut, . TAPPING OPERATION .- (1) Hand operation - automatic feed of tools when hand ' operating the machine is accomplished by positioning the torque rod into the gear case socket and also into the torque - rod socket. This prevents rotation of the feed gear case. Rotation of boring bar automatically feeds tools at a rate of l/80th of an Inch advance for each revolution of the ratchet handle or boring bar, ' (2) If a packing leakage should occur around boring bar after drill has penetrated the metal surface, operator can eorapj^fg drilling operation if leak is slight, or completely retrf|#~ boring bar and tighten packing. (3) To tighten the packing nut., position the feed tube to almost its upper limit. This permits alignment of the 3/8" hole to the feed tube with the corresponding holes in the packing nut. Insert wrench (found oh end of feed indicator rod) and pH ace it in packing nut hole. Thi3 permits packing nut to rotate clockwise for tightening by turning the feed tube. (4) If it is necessary to retract boring bar completely, mark location of feed Indicator rod oh feed tube before retracting. Leave indicato^r'rod location stationary which will locate position of tpdl in cut after packing is tightened and drilling r^p^med. Use "MARFAX" No. 2 ' ... WA-TEX 004174 \. . WA-TEX004174 ITEM HQ0 B-48 TRAINING DETAILS , PAGE 2^7 (-53 RETRACTING BORING BAR WHEN CUT IS COMPLETED - when feed indicator rod is aligned with feed tube groove j, the cut should he completed and boring bar may be retracted by using ratchet handle in counter-clockwise direct.!on 0 , (6) After boring bar is retracted into feed tube,, close gate valve. Use bleeder valve to bleed pressure from the machine before removing it from gate valve. i. | WA-TEX 004175 WA-TEX004175 ITEM NO. B-48 TRAILING DETAILS PAGE 248 Y::for mukkf '^ndIrnks withmt$i *" ' ...~ "........ 42" TRAVEL: LENGTH OF ^ BORING BAR permits ... ` i : / ' PIPE TAPS TO 14" SIZE Vtank taps.to u" size ^choice OF power: _ . .:! compact air motor r . '.. . hydraulic drive (ineSuding j.. . . . engine driven pump} provides fs' ' dependable lower cost power. _ Patent Nos.' 2,679*173 -2,097398 o a... K>K I '' - r -..I >'`V: .V i II Hr. 1 tf /? ft \fl * R 10 )/.tr. /?*V - ' .f.* '.-fy : ,... * U-Vw 'v . ... i s.a. <? x t* M WA-TBX .004176 WA-TEX004176 ' ITEM NO. B-48 TRAINING DETAILS PAGE 249 .j. THE WmSON-HILLCO MODEL.460 TAPPING ffaim, o. fiawsk. DIAGRAM ibj . SKID MOUNTED, ENGINE / , DRIVEN HYDRAULIC PUMP . WITH OIL RESERVOIR TANK . ' Relief vqlve protects system thru sepdrfate'circffit.r . Extra large reservoir provides ample cooling. , Mercury clutch between engine & pump With flexible coupling ` assures easy storting and long engine life (engine and, pump mounted on specially designed neoprene shock mounts). Hydraulic components assure constant torque regardless of speed. HYDRAULIC POWER UNIT HYDRAULIC MOTOR MOUNTED DIRECT INTO WORMSHAFT MOTOR MOUNT PRESSURE GAUGE CONTROL-VALVE HANDLE LOWER-IN CRANK .8 H,P. GASOLINE ENGINE WELDED STEEL SKID HYDRAULIC PUMP RETURN TO TANK PROM RELIEF VALVE DISCHARGE LINE TO TAPPING MACHINE hEi.IFF VALVE " ' (fij FILLER CAP @ RETURN LINE FROM TAPPING MACHINE SUCTION LINE Am MOTOR ATTACHMENT '7^'*'*****< . ' * - r* ` Sketch showing fiow of campressed air from air eomprestror to receiver to air motor through 50 ft. or less of suitable air hose. Min. Compressor size: 105 C0A @ 90 PS1. (Furnished by Customer). WITH NEW GEAR RATIO AND HIGH-SPEED POWER UNITS, (AIR OR' HYDRAULIC MOTOR) TAPPING TIME IS REDUCED WA-TBX 004177 WA-TEX004177 ITEM NO. B-48 TRAINING DETAILS PAGE 250 machine is rugged and dependable rs Weld side outlet to pipe line. Side outlet may be Pipe Nip ple or Weldolet with or with out reinforcement; or welded or bolted split fee. . 2. Mount tapping valve oh side' opening. Bound opening gate valves generally used. Plug valves may be used with special cotters. " 3. Mount adopter Fkinge- tap ping trscchi..-'e, i'bet, :-r.Aio`A proper cutie,. Attach tapping machine wbu adapter flange to tapping valve. 4. Valve open, lower-in crank is rotated to extend boring bar until pilot drill touches pipe. 5. Tapping under pressure through the wall without leakage. . Coupon is retained on pifoi drill by spring loaded balls. 6. Refract cutter with coupon, dose valve and remove ma chine. THE MEW LONGER BORING-BAR TRAVEL (42" USABLE TRAVEL) RESULTS IN A WIDER RANGE OF PIPS AND TANK TAPS . .. J WA-TBX 004178 l WA-TEX004178 ITEM NO. B-48 TRAINING DETAILS PAGE 251 MODEL 100 TAPS TO 2" ' Htmd'.OperatecT, . 800*F. @ 600 PSI or 1200 PSI @ IOg"F. MODEL 300 TAPS TO 4" Hand or Power Operated 400F. Of 200 PSI or 1000 PSI @ 10QF. TYPICAL DRILLS & CUTTERS NEEDED TO COMPLETE VARIOUS SIZE TAPS (Model 660 Machine) WmSon Insertootb . cutters for, Model 660 topping machine range in sizes 3" ' to 14" for pipe tops and up to .16" for tank tops; All cutters have tool steel cutting edges. insertip pilots ate equipped with spring loaded steel balls to hold cou pon in cutter. . SijmmkA. j^itadwft &, Sapping mmhimA. with. PV drills 0)nAbpmt $A, Mppmf kokA. ihhouqb FLUG IfALVES The PV drill is o spade type drill that passes through the rectangular open ing in a plug valve, threaded or flang ed, and drills a round hole in pipe. Other cutter shapes and sizes are available for use with special valves having restricted openings. STANDARD fV DRILL SIZES FOR MODEL 660 TAPPING MACHINE For Tapping Through 8" Plug Volvo CARRYING CASE FOR TAPPING MACHINE SPECIAL COMPARTMENT FOR PILOTS MACHINE IS.HELD IN PLACE MODEL 1200 PIPE TAPS TO 24" TANK iAPS TO 30" Power Operated 500PF, (n 500 P$l r 1900 Ml In' 10OP ( j rn-TEX 004179 TllE^DDCfollL^l5)eDG)aa WA-TEX004179 ITEM NO, B-48 TRAINING DETAILS Air motor w/2;t tf6ai* reducer Clutch Handle Minimum compressor requirements: 105 . CFM @ 90 psi. - (Furnished by customer) NOTE: Hydraulic power is recom- , mended for tips over 1 i" PAGE 252 TYPICAL TAPPING SET-UP /^-mplete self-contained . ,vver unit. No other source of power req'uired. Hydraulic Motor ' Weight 280 lbs. Hydraulic Power Unit 9 H.P. air cooled gasoline engine o 20 gal. hydraulic fluid reservoir (SAE 10 W oil normally used for-fluld.) Not furnished. . 9 Hydraulic hose -- 50 ft. Diameter: %" for pressure line %" for return line ' Hose connections equipped with best quality self sealing couplings to prevent ioss of hy draulic fluid and to keep system clean. Tapping Machine Mounted on Skid. WmSon Sandwich tapping valve. Conventional -gate valve may be used. 1 WA-TEX 004180 WA-TEX004180 ITEM NO; B-48 TRAINING DETAILS PAGE 253 Models 660 II 760 For making connections to pipelines and plant piping safely and without shut down. Models 660 and 760 Tapping Machines are identical with the ex ception of length and tapping capacity.. . MODEL 660 MODEL 760 Specifications Model 660: Boring bar travel 42"; taps 3" thru 12" Model 760: Boring bar travel 66"; taps 3" thru 16" Maximum operating pressure, both models: 1,440 psi @ 100 F. Maximum operating temp., both models: ' 7000 F, @ 700 psi Each machine factory tested to 2,175 psi Power: Hydraulic or air Feed: 660 standard .005 per rev. optional .003 per rev. 760- standard .003 per rev. Lower-in crank: Approx. 4% turns per in. Approximate Weights: 660 w/air motor 500 lbs. . . 760 w/alr motor 625 lbs. 660 w/hydraulic 535 lbs. 760 w/hydraulic 660 lbs. Lengths: 660,64%"without measuring rod 11014" with rod 760,88%" without measuring rod 158%" with rod* V V Cutters are available for standard pipe taps. Stopple Plugging Machine taps and Shortstoppl Plugging Machine taps. Special cutters can be furnished for tanks and flat plate taps. . . U. S. PATS. 2,679,173 -- 2,097,398 WA-TEX 004181 V. WA-TEX004181 ITEM NO* B-48 TRAINING DETAILS PAGE 254 For making connections to pipelines and plant piping safely qnd without shut down. Hand operated or air motor drive. Specifications; Boring b.ar travel; 24" Tank taps to 4", pipe Saps to 6" Maximum operating pressure; 1,440 psi @ 100 F. Maximum operating temperature; 700 F. @ 700 psi Each machine factory tested to 2,175 psi Power: Manual or air motor Feed: .005 per revolution Lower-in crank; 12 turns per inch Weights: Hand powered, 125 lbs. Air powered, 16314 lbs. . Length: 42%" without measuring rod 70" with rod n , U. S. PATS. 2,679,173-2,097,398 Cutters are available for standard pipe taps. Stopple Plugging Machine taps and Shortstopp^ . Plugging Machine taps. Speciaf cutters can be furnished for tanks and flat plate taps. .( . WA-TEX 004182 . . V, WA-TEX004182 ITEM NO. B-48 TRAINING DETAILS amsm shortcutt drilling machines T-8, T-12 & T-18 PAGE 255 A FEED ADJUSTMENT KNOB MAKE SHORTSTbPPPlUGGING MACHINE TAPS 9 make branch connections Feed tube * SPECIFICATIONS * (MODELS T-8, T-12, & T-18) MAXIMUM RECOMMENDED WORKING PRESSURE 1440 PSi @ IOOF. Each Machine Pressure Tested To 2173 psi OPERATIONAL TEMPERATURE-180F. MAX.* CALIBRATED BODV TUBE 1" NPT THREAD `For higher operating temp., consult factory n U.S. PATENT NO'S 3068725, 3068726 & PATENTS PENDING IN OTHER COUNTRIES WA-TEX 004183 WA-TEX004183 ITEM NO. B-48 TRAINING DETAILS PAGE 256 cf. '' ' ' ' " .. , ' Shown below is the proper cutler and drill, either of which may be used for drilling a hole for Pfg-Sig installation. The proper valve adapter is also shown..- Cutter HoMer-- Pilot -* 1%" dE Cotter holder -- Pilot . 5-206 Cotter Stock No. 5-181-01 fife Drilt I Drill Stock No. 5-193-01 - Valve Adapter for Cutter or Drill 706-16 For use on 2" tbrcacicd vcilvo. Notes: Cutter designed for wall thicknesses up to and including (For thicker wall pipe use drill:) '* Valve requirements: Min. thro bore . 2. " Thread-0-Rmgu Plug Holder A plug holder is used for setting Pig-Sig assembly with the 1-101. This holder is also used for setting T-O-R plugs which may hold gauge adapters, thermometer wells, corrosion test coupons and other instrument probes. - Stock No. 5-185-01 \ 'Tbrcod-O-Rin^ fe 3 T. O. WtUi-omson, Inc. tradeina.'k for an extern-ally, internally fhrcaoud p*pc nipp/e. ' ' ';f`V~* * t\ 'u 'S Hole sows ore used with the T-101 for size on size taps. ' Hole Saw 'IV Diameter Hole Saw Holder-Pilot Hole Saw -Nom.-f-Cutter \%\zq;Iojo. .] ~ `Cyf s % iVa"-' : Stock .' Ho. 5-204 1 , 5-204 Stock No. 5-179-02 5-179-03 A 'y.vt - : 5-205 5-179-04 Valve Dimensions*' Valve Size Min. Matt. Pais Thro to Face .'Bore Dimension 2" J / ft 14/2" 3" 3>t" MW7 4" 1-2" Valve Adapters (flanged) Size Series Stock No. 2" 150# 6-1305-15 3 " KJ 150# 6-1318-15 4" 150#. . ,6-1302-15 ''-"Vi., 3" 300# 6-1305-30 3" 300# 6-1318-30 4" 300# 6-1302-30 S>vt.;>.v ft: 'Size Stock No. : 706-15 . Size Stock Ho. .3" 6-1303-0? 1" 600# 3" 600# 4" 600# A Igftyfe:.-:. -: Minimum thru bore diameters and maximum face to face dimensions for making tops thro Shortstopp .. WA-TBX 0Q4X84 WA-TEX004184 ITEM NO. B-48 TRAINING DETAILS CHOICE OP FITTINGS THREAD-O-RING NIPPLE PAGE 257 THREAD-O-RI NG PLUG CAN BE SUPPLIED WELDED TO SCARFED NIPPLE OR WELDOLET FITTING. MADE FROM STANDARD WELDING FLANGE OF SPECIFIED SERIES AND FACING. SCABFED TO TIT SPECIFIED PIPE SIZE. MADE FROM SEAMLESS STEEL TUBING. PRESSURE RATING: Plugs are installed against line pressure up to 1,000 PS I using WmSON-HILLCO ' Tapping Machines* MADE FROM NAVAL BRASS WITH NEOPRENE O-RING INSTALLING TEST COUPON IN PIPELINE WITHOUT SHUTDOWN WmSON-HILLCO TAPPING MACHINE* VALVE CLOSED SPRING LOADED STEEL BALLS -\RETAIN PLUG \ON HOLDER 2. TAP COMPLETED, TAPPING MACHINE REMOVED. HOLDER PLUG .DRILL AND HOLDER 3. DRILL IS REPLACED BV PLUG HOLDER AND THREAD-O-RING PLUG. BUND FLANGE 1. TAPPING MACHINE 8EING MOUNTED ON FITTING IN PREPARATION FOR "HOT TAP", 5. TAPPING.MACHINE REMOVED, VALVE RECOVERED AND BLIND FLANGE IN PLACE. NOTE: COUPON IS RECOVERED.BV ABOVE PROCEDURE IN REVERSE. n * Threaded plugs are installed and removed with the following MnSON-HILLCO Tapping Machines only: Models 100, 1008, 100C, 300 and 36O. . P. 0.60X40 TULSA 2, OKLAHOMA WA-TBX 004185 V. . . . WA-TEX004185 with 600# ASA flanged outlet The Plidco Hot Tapping Saddle is an adaptation ofthe Plidco Split-Sleeve. It is used for hot taps where sur rounding conditions do not permit the immediate instaljation of a welded branch (including underwater tie-in to existing pipe.line.) With full branch connections, Plidco Hot. Tapping , Saddle can be utilized for tapping a hole large enough to permit plugging-off the main pipeline. A line break can thus, be isolated and bypassed, using two plugging taps: and'maintaining service through a bypass.. Available with full-size branches and in any range of sizes and pressures with threaded, welding or flanged, outlets. Buna-N packing standard. Silicone, Viton* and asbestos available, as well as neoprene. . After repairs are completed and oil-soaked earth is cleaned up. Hot Tapping Saddles may be permanently welded to pipeline if desired. . . DuPont Keg. i'. M. Write for Bulletin HT-700 PLIDCO HOT TAPPING SADDLE SPECIFICATIONS C~~~ Ham Pip* (Run) Nominal Size Branch Pipe Nomina! Size -- Body Dimensions length Dinm. Bdtwuen of 1.0. d,o. End Overall Pocking Studs Length Length of Branch Side Bora > Approx. Shipping Weight Inches `Inches */' B' `C* - `tr Ef Inches Inches Jnchos Jnchos Inched Inches Inches Pounds 1% 2 3 4 6 6 8 8 J0 10 12 12 i *12 3 14. I 14 I *14 3 16 I 16 M6 1 28 | 18 g *18 .20 20 *20 22 22 *22 24 24 l *24 i 26 1 26 [ *26 I 30 1 30 r *30 l thru 1*6 1 thru 2 1 thru 3 1 thru 4 1 thru 4 5 and 6 1 thru 4 5 thru 8 2 thru 4 S thru 10 1 thru 4 5 thru 10 12 1 thru 6 8 and 20 12 and 24 1 thru 6 8 pnd 10 12 thru 16 2 thru 5 8 and 10 12 thru IS 1 thru 6 8.and 10 12 thru 20 l,,thru 6 8 and 10 12 thro 22 1 thru 6 Sand 10 12 thru 24 1 thru 6 Sand 10 12 thru 26 1 thru 6 B and JO 12 thru.30 2 Vo 3% 2 54 A .5 3% -5 6 8% 7`/a 8% 9s 10% 9 Vo 10'/, m4 12% 11'A 12% 13 'A 14% 13% 14% 13% 14% 14% 16% 14 Vi 16% 14 Vi i6% 16% 18% 16l'j 18 Vi iev? !8V* is/2 21 18% 21 18% 21 20 Vi 23 20% 23 20% 23 22% 25 22% 25 22% 25 24*/* 2? 24*/* 27 24 V: 27 26% .30 26 VS 30 26 VS 30 30 Vs 34% 30 V2 34*/, 30 % 34*4 8% 8% 8% 8*4 9 18 10 18 10*4 18 10% 18 24 14 16 24 14 18 24 14 18 26 J4 18 28 14 18 30 14 18 32 .14 18 34 14 18 38 5% 5% 5% 5% 5% 12 5% 12 5% 12 .5% 12 18 8 IP. 18 B 12 13 8 12 20 8 12 22 S 12 24 8 12 26 8 12 28 8 12 32 -% % % % % % % Vo 1 1 1 .1 1 1% 1 Vo 1% 1% 1% 1% 1V* 1% IV, m i% IV. i% i% i% i% i% i% i% i% i% i% i% i% `'Not available from stock Z% 1 x 1 2% 1 xl% 2% L x 1% 3 l%xl% 3 l%xl% 3 J%xl% 18 20 28 35 48 120 3% 2 xl% 114 3% 2 xl% 4 2% x 2 4 2*6x2 180 143 225 4 2%x 2 4 2% x 2 4 2% x2 163 270 .360 4 3 X2% 264 4 3 x 2% 340 4 3 x2% 454 4 3 x2% 295 4 3 x.2% .380 4 3 x,2% 505 4 4 *2% 360 4 4 x2% 465 4 4 x2% 670 4 4 x2% 400 4 4 x2% 515 4 4 X 2% 80Q 4 4 x3 - 485 4 4 x3 4 4 x3 4 4 x3 4 4 *3 625 1038 .520 670 4 4 x3 1885 ' 4 5 x3 4 5 x3 618 795 4 5 x3 1500 4 5 x3 4 5 x3 940 2218 . J4 5 x 3 2550 Largersizes on application THE PIPE LIME DEVELOPMENT COMPACT 5350 West 130th Streei * Cleveland, Ohio 44143 Telephone. (Area Code 216)267-1640 Export Department: 17 Battery Place. New York, New York 1OO04 Caota: WELDENDS-New York \ V7A-TEX 004186 WA- TEXACO INC. PUGET SOUND PLANT PAGE 259 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION PIPEFITTER (TRAINEE) DATE? JULY 1, 1970 ITEM NO. B-49 ' SUBJECT: DISMANTLE, REPAIR AND REASSEMBLE OXYGEN LltfES AND EQUIPMENT "" 1 a.SAFETY: To avoid fire and explosion hazards due to !- presence of oil or other combustible materials. . In the oxygen piping system-, the following procedure shall ` be applied to the fabrication and installation of the oxygen ' piping systems - .' ' ' i b.ASSEMBLE: The system should be assembled without the use ' of any greased .joint compounds Gasket paste is nd't to be used on feaskgta, bolts or flanges. Spool pieces . Installed at connections to equipment such as pumps, vessels and exchangers should be blinded with clean grease free ' blinds, gaskets and bolts. Control valves, regulators and instruments are purchased-pre-cleaned and certified ' compatible for oxygen service$ these elements are not to .fee Installed until final equipment assembly. Valves should : be Installed, but without seats, gates, discs and other . removeable parts. ' ' ' e.HYDROSTATIC TESTING: Each section of the line should, be . subjected to a hydrostatic test, . ' using, clean, oil free water. The test pressure should be 1.5 timeB maximum operating pressure. The system .should ; be filled with city water or other oil free water, then '. pumped up to test pressure. This should keep pump grease ' . from Entering the system. ... After test is completed, the system should be " degreased by washing with trichlorethylene. d.NITROGEN TESTING:Nitrogen should be used in place of . water, if available. The test pressure shall be 1.1 times maximum operating pressure. When testing with nitrogeh, make sure proper fittings and gauges are checked out from main tool room. A ball . check valve shall be placed In line between- nitrogen supply and equipment being tested. \: e.DEGREASING OXYGEN LINES: The system should be .degreased -. by washing with trichlorethylene solvent followed by oil free hot water, then blown dry rS . using warm dry nitrogen. ' . ' The- valve parts which were removed should be individually degreased with trichlorethylene solvent. The - valve parts should be thoroughly dried, reassembled without ' ' ' - the use of oil, grease, or any lubricant, and valves / ` -- WR-TBX 004187 V WA-TEX004187 ITEM NO. B-49 frf TRAINING DETAILS PAGE 260 repacked with dry oil-free asbestos packing. 1 Screwed connections at control valves and solenoid valves should be made up with a thin paste of freshly ` mixed litharge and glycerine dag.dispersion #217, made by Achespn Colloids Company of Port Huron, Michigan, or equal applied to male threads only. (l) Valve stem packing shall be suitable for oxygen service at, 500P (Johns-Manville Chempac 2024.) : . (2) Low pressure nitrogen (app. 75 lbsO available . at H-2 Complex may be transferred through air ; hose.. (Use pipe if long distance from test). , (3) High pressure nitrogen bottle connections available in main tool room. (4) Box pump or field pressure pump may be used on hydrostatic test. Use high pressure test hoses or pipe If available. f.REASSEMBLE; When reassembling existing oxygen lines and ` . equipment after repairs are made, wash all parts with Trichlprethylene before replacing. Be sure no grease or pipe dopes of any kind get into these lines, nor should they be used as lubricant on gaskets, bolts or flanges. . CAUTION; Most oxygen fittings are Stainless Steel ' or Brass so be sure when dismantling and reassembling- that huts, bolts, flanges or other parts or fittings do not come In contact with oil or grease. It is recommended when disassembling that all fittings and parts be stored In a clean bucket. WA-TEX 004188 \ WA-TEX004188 TEXACO INC. PAGE 261 TRAINING DETAILS GEPAR^MENT; PIPE ; classification! pipefitter (trainee) DATEi JULY I, 1970 ~~ s--- ITEM NO, B"50 . ' SUBJECT INSTALL PIPE CLAMPS A. pipe elamp is used to repair a leak when the pipe line can't be blocked off or welding can't be done in the area. The pipe to be clamped must be cleaned as well as possible before putting the, clamp over the hole. It is important that the clamp is centered over the hold and tightened evenly. i W&-TBX 004189 V if* WA-TEX004189