Document zQZq1MbjokeGK6Qv1krzLVXEB

TEXACO INC. PUGET SOUND PLANT PAGE i TRAINING OUTLINE DEPARTMENT: PIPE CLASSIFICATION! "PIPEFITTER (TRAINEE) DATE: JULY 1, 1970 Subject *1, *2. A. BASIC TRAINING Departmental Organization Relationship of Department to Refinery Operations . Page No. 1 2 *3. Department Standards and Working Rules *4. Department Fire Protection 3 5 *5. Department and Plant Safety Practices *6. Departmental and Plant Housekeeping 8 12 *7. Departmental Lubrication *8. Care., Purpose and Use of Hand and Portable Power Tools 14 16 *9. Procedures for Obtaining and Transporting Tools, Materials and Equipment 19 *10. ' *11. *12. Location and Use of Utilities Departmental Standards of Craftsmanship Procedures for Obtaining Work Permits 20 21 22 *13. Identification, Purpose, Characteristics and Use of Materials 23 *l4. Read, Interpret and Work from Blueprints, Sketches, and Bills of Material and Requires a Knowledge of Shop Mathematics 39 *15. *16. Measuring and Layout Methods and Tools Care and Purpose of Shop Equipment 83 89 *17. Taking Field Measurements and Job Planning 90 WA-TEX 001203 TEXACO INC .It puoIt"sound vim's PAGE il TRAINING OUTLINE DEPARTMENT; ,% GLASSIFICATION! PIPEFITTER (TRAINEE) DATE; JULY 1, 1970 Subject *1. *2, B. dfcJ THE JOB TRAINING Assemble and Transfer Equipment and Tools Move Materials Page No. 99 100 *3. Load and Unload Materials '4. Dope and Wrap Pipe ' 101 102 *5. *6. .. String Out Pipe Dismantle Pipe and Fittings - 103 105 *7. Salvage Piping ' *8. Use Hand Dies 10$ . 109 *9. Operate Power Tools 10. Operate Pumps ^ 111 112 a. Sump Pumps 112 *b. Test Pumps 112 11. Operate Compressor^ 113 12. Operate Hoists *a. Air Hoist ll4 114 *b. Electric Hoist il4 *c. Air Tugger 114 *13. *l4. Cut Gaskets ' Use Hand Tools 116 118 *15. Sharpen Tools . 120 *16. Clean Up Shop and Work Areas 122 *17. Tie Knots and Hitches- 123 *18. Rigging and Hoisting of Material, Tools and Equipment 127 *19- Check Tools p 134 : WA-TEX 001204 ib.tect *20. *21. *22. *23. 24. *a. *25. *26 * *27. *28. 29. *a. *b. *c, 30. *a. *b. *e. *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 Tests Renew Tubes Burners - Gas and Oil Remove and Install Clean and Repair Coils Remove and Install Repair PAGE lii Page No 135 136 138 145 146 146 146 147 148 165 167 171 171 171 171 174 174 174 174 175 176 177 177 177 180 180 180 WA-TEX 001205 l Subject 35. *a. *b. *36. *37'38. *b. *43. *44. *45. *46. *47. *48, 49* *50. 51 52 B. ON THE JOB TRAINING Steam and Air Traps Remove and Install Repair and Inspect Installation and Repair of Plumbing Install Tubing Steam Radiators Remove Install Repair Install Pipe Hangers and Supports Pack Valves Install and Remove Ohmart Level Controller Repair Hydrants Service Water Fire Water Install Expansion Joints Flange and Unflange Equipment Install Eductors Install Temporary Field Pumps Install Steam Tracing on Pipe and Fittings Make Pressure Taps Dismantle, Repair and Reassemble Oxygen Lines and Equipment Install Pipe Clamps Conduct On-The-Job Training Conduct (Basic) Classroom Training PAGE iv Page No. 181 181 182 219 220 221 221 221 221 222 230 231 233 233 233 237 238 239 242 243 244 259 261 ; WA-TEX 001206 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 whlon cornea under the jurisdiction of the Assistant Plant Manager. N The Supervisor-Maintenance is in charge, of the planning, scheduling and execution of work -involving all the maintenance depart ments of the Plant ineluding 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 ff WA-TEX 001207 TEXACO INC, PUGET SOUND PLANT PAGE g DRAINING DETAILS DEPARTMENT: FIFE CLASSIFICATION: PIPEFITTER(TRAINEE) DATE: July I, 1970 ITEM NO, A^S 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, valveB 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 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 reaponslblity 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. <2 1 WA-TEX 00X208 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 bo 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 tp.ol 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. 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 001209 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 not 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. j WA-TEX 001210 TEXACO INC. PUGET SOUND PLANT PAGE 5 TRAINING DETAILS DEPARTMENT: PIPE classification! pipefitter (trainee) DATE: July 1, 1970 ITEM NO. A^i SUBJECT; DEPARTMENT FIRE PROTECTION . . Fire protection and fire fighting are the concern of each and every individual at Puget Sound Plant, 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, ` I. HOW 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' yotfcah hancfle 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. W&-TEX 001211 ITEM NO. A-4 TRAINING DETAILS PAGE 6 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 i.o 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 FIRE 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 l Wildcat (pause 10 sec.) 1 short blast : (pause 10 sec.) Repeat wildcat and zone 2 1 Wildcat (pause 10 sec.) 2 short blasts : (pause 10 sec.) Repeat wildcat and zone 3 1 Wildcat (pause 10 sec.) 3 short blasts :,(pause 10 sec.) Repeat wildcat and'zone 4 l wildcat (pause 10 sec.) 4 short blasts : (pause 10 sdc.) Repeat wildcat and zone 5 1 Wildcat (pause 10 sec.) 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 thf-ir 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 are 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 rangp from high pitch down to low pitch and back to high pitch again The high pitch is used for zone signals. 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. i m-TEX 001212 ITEM NO. iL4 TRAINING DETAILS PAGE 7 GENERAL ALARM: 10 continuous wildcat cycles (approximately two minutes.) "General Alarm" to be Bounded 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 this authority. Responsibility} When General Alarm is sounded, all available employes except women are re'in?ed to nenort as outlined Jp beoi-iwu 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 001213 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: (1) 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 for 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 woi'n 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 I WA-TEX 001214 ITEM NO. A-5 TRAINING DETAILS PAGE 9 blowing around, grinding, buffing, etc. Protective clothing (impervious suits) and other protective equipment musfbe worn when specified on HOT or SAFETY WORK PERMITS, when working on lines or equipment in aeld 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-24l (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 Ips^r-Elec Foreman must be consulted before ' the line is broken (disconnected) 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 caRp 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) When 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 f,t. deep, shoring should be installed to prevent cave-ins of dirt. (15) Before perafcing 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* , 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-TEX 001215 ITEM NO. A-5 TRAINING DETAILS PAGE 10 (e) When unbolting flanges be sure to looBen 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) Wooing 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) Deoking 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 as orecautionary 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 001216 ITEM NO. A-5 TRAINING DETAILS PAGE 11 (4) When lifting, make full use of the leg muscles, keep the back as nearly upright as possible and avoid twisting while lifting. Get help with heavy loads. (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 flashers- used at night. (7) Leather gloves should be worn while fabricating pipe and fittings with welder. (8) When using a eome-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 001217 TEXACO INC. PUGET SOUND PLANT PAGE 12 TRAINING DETAILS DEPARTMENT: PIPE ,% CLASSIFICATION PIPEFITTER (TRAINEE) DATE: July 1, 1970 . .ITEM NO. b-6 SUBJECT: DEPARTMENTAL AND PLANT HOUSEKEEPING DEFINITION: The terra "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. . TfflRFONSiBiLITY: 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 reflnerv, there is a number of "Housekeeping Practices" which are emphasized 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 be allowed to accumulate but should be cleaned up and av'ni>e,,jents mad^ ! it hauled away. Sal- vag'e'able. materials' sh'Or 'd be neatly piled until they can be hauled 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. WA-TEX 001218 ITEM NO. A-6 TRAINING DETAILS PAGE 13 (7) Area abound pipe machine should be kept free of pieces of pipe, , blocks, chips or shaving. 0.11 drippings Bhould 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 toolB should be tagged and sent to Main Tool Room for repair. WA-TEX 001219 TEXACO INC. PUGET SOUND PLANT PAGE l4 TRAINING DETAILS DEPARTMENT! PIPE ' DATE! July 1, 1970 CLASSIFICATION: PIPEFITTER (TRAINEE) ITEM NO. Ar-L 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 aw,-TM feint? 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 001220 ITEM AnX 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. (*) 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 Btiek 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 gi'aphlte 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. f WA-TEX 001221 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 topi 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 caseB, 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 so 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. I WA-TEX 001222 ITEM NO.' A-8 TRAINING DETAILS PAGE 17 (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 OP PORTABLE POWER TOOLS: (l) Pbrtable 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 MAIN TOOL ROOM FOR REPAIR AND INFORM TOOLKEEPER. . SAFETY? (1) Do not use defective tools. (2) "S" wrenches or light wrenches of any '-"'nd 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 wi'ench, be sure it fits properly and in applying force, push or pull evenly and steadily, otherwise, a sudden jerk or slip may cause Injury. (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 anyload greater than its safe working capacity. Inspect carefully befoi'e 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 laduer ... climbing 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 001223 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 thut 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. J WA-TEX 001224 TEXACO INC. PUGET SOUND^PLANT PAGE 19 TRAINING DETAILS DEPARTMENT:- PIPE CLASSIFICATION*: PIPEFITTER (TRAINEE DATE: July 1, 1970 ITEM NO, Az9 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 then] 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 be 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. WA-TEX 001225 TEXACO INC. PUGET SOUND PLANT PAGE 20 TRAINING DETAILS DEPARTMENTi- PIPE niARSIEICATIONT--PIPEFITTER (TRAINEE) DATE: July 1, 1970 ---------------------- 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 Pipefitter's duty to see that utilities are not wasted. - LOCATION: (1) 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 001226 TEXACO INC. PUGET ^MndHpLANT PAGE 21 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION PIPEFITTER TRAINEE DATE: July 1, 1970 ITEM NO. A-ll SUBJECT: DEPARTMENTAL STANDARDS ^"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 sa'fety 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 uraft. 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 which equip ment operates and plant locations of such equipment. WA-TEX 001227 TEXACO INC. PUQET SOUND PLANT PACE 22 TRAINING DETAILS DEPARTMENTJ * 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'bn during the unit down period and Operators will post the permits. All requirements noted on the permits should be carefully followed. o. OPERATING UNITS (1) 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 (1) 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 001228 TEXACO INC. PUGET FOlfigHF&ANT PAGE 23 TRAINING DETAILS DEPARTMENT: - PIPE CLASSIFICATION PIPEFITTER TRAINEE DATE: July 1, 19TO ITEM NO. A>-13 SUBJECT! IDENTIFICATION. PURPOSE ShSKKc^erIstics and use' OF `MATERIALS a. VALVE IDENTIFICATION (l) 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" represents valve and on blueprints will be prefixed by the nominal valve size. (2-V-100F1). 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 ido-299" - "Gates ' 300-499 - Globes 00-599 - Angle 600-699 - Checks 700-849 - Cocks 850 - Miscellaneous . Note: 250-209; 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 j WA-TEX 001229 ITEM NO. A-I3 TRAINING DETAILS (2) To Identify V-lOO-Fl PAGE 24 ' (a) The V always indicates a valve. (bj The number 100 indicates a gate valve. (c) The letter F shows the pressure rating to be 300# Steel." Note t Sub-claBsifieations 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. b. 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 n<w'i*tely 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 vslves 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 001230 ITEM NO. A-13 TRAINING DETAILS PAGE 25 (5) CAPTION; It la 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 down 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 erroslve effects in the disc. CAUTION; 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 (1) Fluids can flow through check valves in one direction only, preventing back-flow when desired. There are only two basic types of check VBlves, 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 check valve as compared to globe valves. In lift check valves, flow moves through the body in a changing course as in a globe valve. WA-TEX 001231 ITEM MO. A-13 mss TRAINING DETAILS HANDWHEEL PAGE 26 GLAND FLANGE GLAND PACKING , BONNET BUSHING BONNET ' PACKING NUT GLAND PACKING BONNET GASKET DISC ' . UNION BONNET RING DISC SEAT RINGS BODY SEAT RINGS DISC BODY'53' BODY SEAT RING *- BODY GATE VALVE GREASE PLUG GREASE CHECK VALVi COCK VALVI TYPES' 0P ' VALVES fat*' urnnr, *,+**/>! uuinirimin>i iiiunaiHm iwi.ii i.ih n WA-TEX 001232 ITEM NO. A-13 TRAINING DETAILS PAGE 27 t ! WA-TEX 001233 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 VALUES (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 selfprotecting 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, SLIDE VALVES (1) The mechanism of the slide vsIves at the PCCU is maintained by the machine department, (2) These valves are hydraulically operated but can he manually operated in case of emergency, WA-TEX 001234 ITEM NO. A-13 TRAINING DETAILS PAGE 29 t PMA/c/PLE j WA-TEX 001235 I 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 GLAND PACKING RING RETAINING RING VALVE E10DY /-/krx .VALVE 1. IDENTIFICATION OF PIPE AND TUBING (l) Piping classification is determined by three factors: size, xneight (or schedule) and material. (a) Size of piping has to do with the diameter. (b) Weight is determined by wall thick: ess. (c) Piping is made in a wide variety of materials for an equally wide variety of services. These materials range from clay soil pipe through various metals and allojrs to plastics and fiberglass. WA-TEX 001236 ITEM NO. A-I3 TRAINING DETAILS PAGE 31 () Pipe sizes up to and including 12" are known by the inside diamter (l.D.) which is referred to as the "nominal pipe size," Above 12" the pipe size is deter mined by the outside diamter (O.P.). (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 Seh. #40, Sch. #80,. or Sch. #160, Standard pipe up to 10" Inclusive, and Sch, #40 pipe have the Bame 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. () 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 (1) 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. j WA-TEX 001237 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 3-1/2" X 1/2" 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; SIZE ' OJL Pipe Tubing Pipe Tubing Pipe Tubing Pipe Tubing 1-1/2" 1-7/8" 3" 3-2/2" 4" 4-1/2" 6" 6-5/8" 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 1/10" above the surface of the flange. This is the type of flange most commonly used in the refinery. ! WA-TEX 001238 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 be purchased in pairB, 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 besting and ts king samples. (h) Screwed - Screwed flanges are drilled and tapped to pipe sizes. Used in low pressure service. (l) Weld Hub - Weld hubs k're 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 ate 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 flanger'^ut 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. | WA-TEX 001239 ITEM NO. A-13 TRAINING DETAILS PAGE 34 p. GASKET PURPOSE (1) The principal purpose of gaskets is to form a seal to prevent leaks into or out of vessels, pipeline, vacuum or pressure pumps, compressors, etcB q. GASKET USE . (1) Gaskets are used between'non-wo^tHg^parts"Such as the openings in vessels, betw.^i rianges 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 soft 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 Gariock 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. Full face composition gaskets are also used when required. (b) Ironclad Asbestos - These gaskets are used on joints ancTequipment with high temperature. This type of ironclad gasket is asbestos filled. These gaskets are used on some types of exchangers. (Flat 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) Flexitallic = 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 001240 ITEM NO. A-13 TRAINING DETAILS PAGE 35 (f) Aluminum - These gaskets are made of soft aluminum and 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. s. PIPE FITTINGS. PURPOSE (1) 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 (a) 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. . Note; Orifice flanges should always be drilled and tapped to proper size before installing. j WA-TEX 001241 i ITEM No. 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, sizeB 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 clamps; 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 bo 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 180 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 l8o bends on heaters are stamped with a number corresponding with the tube number. These numbers should be installed looking up. (T) Flanged sittings (a) Most of the flanged fittings (excluding valves) 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. ! WA-TEX 001242 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 injibp 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) Victaullc 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 victaulic 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. WA-TEX 001243 ITEM NO. A-13 TRAINING DETAILS PAGE 38 (2) Thread-Tex (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) Copaltlte (a) Copaltite is used on gaskets on flange or exchanger heads when leaks are very difficult to stop. (4) Permatex ' (a) Permatex #1 is used for forming a hard gasket. (b) 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 uni* 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. "* (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. ' r M.OcA ill e boi m ITJJ A/of WA-TEX 001244 I. *' TEXACO INO, PUGET"SOUND'PLANT PAGE 39 TRAINING DETAILS DEPARTMENTS ALL CLASSIFIC ATlMi aSE DATEs July 1, 1970 ITEM NO. A-14 SUBJECTS, Rs-fErgvAArDe^.Tsy..sINT.uE"'.R...vP.'sR-svEsT AND. ` cSes and^bTSlS'^qf MATERIAL AND REQUIRES A ' KNOWLEDGE OP SHOP ~ ' . MATHEMATICS a. INTRODUCTION; The following mater'IFT'Eas'been developed to give the craftsman a working knowledge of mechanical and construction drawings., elementary mathematics* Bills of Material and field sketching. The craftsman'in 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 part, of the craftsman's work. Practically everything that is c-. nstrue tv.-:l 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 TO-im'CHPrsi----------- ----------------------------- ---------- --- CD Blueprints - what they-ares A blueprint is the reproduction to scale of a draw:! ng which has been prepared by the engineer or draftsman to provide the work-' man with a description of the shape and r.iro of nn object, and other details essential to it.* const r-onv in such a form as to be easily recognizable by anyone familiar with a blueprint. Blueprint is actually a misnomer, as they may be black ar<X white, brown and white, or blue and -white. At Puget Sound Plant, the prints used are technically not blueprints. However, blueprint or print Ir. r. commonly accepted term for both types of reproduction!'. Blueprints are actually the language of .modern construction. They provide an excellent means whereby t.he 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 other1 country, or in some other section of this country, or in romo industry. I WA-TEX 001245 . ITEM NO. A-14 TRAINING DETAILS PAGE IfO 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 '.nstead 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 exaot 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 he held responsible for a drafting room error. (3) Drawing Paper and Sizes; To better understand prints and their 'origin, it la 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 drawing or where permanent records are unnecessary. For example, simple 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* proceeding the drawing number as well as by actual measurement. A 'D* size drawing is 22" x 38", a 'C* drawing is IT" x 22", a SB* size is ll" x 17" and an *A* drawing, is 8-1/2" x ll". Sketches are drawn on 8-1/2" x ll" 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 Blueprint; In making a blueprint the "working drawingswhether 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. i WA-TEX 001246 "ITEM Ha* jWdJ&h"'' r-E^AILS The blueprint is ma- e as f ci-iows; PAGE 41 (a) The-workir-' h'cv.i ng i placed over blue- print paper. ` ' ' (b) A strong electric arc light or sunlight is focused through the tracing paper.. (c) Th'e inked or pencilled lines keep the light from parts of the blueprint paper, whleh changes color everywhere except where there are markings-or lines on the original dravjdng. ()' 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 made 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 s 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 importance of taking proper care of the blueprints in his possession. There are several things to remember , -(a) If the-print is rolled'; re-roll it after use. Do not fold a rolled print. (b) If the print is folded, fold it as it was originally. Do not fold it opposite the orIg,lnal'~foTd or crease. > ' (c) Do n&t leave exposed to sunlight when. not in use, or for any great length of'time - sunlight will cause fading. ' (d) Do not get prints wet. . (e) Do not mark up prints with pencil, ink or crayon,'unless given permission to do so. ` Prom the foregoing it can be seen that blueprints are relatlvelv expensive to oroduce. therefore- the least that can be expected of each craftsman is that he take considerable care when using these prints. WA-TEX 001247 WA-TEX 001248 ITEM NO. A-l4 TRAINING DETAILS PAGE 43 (6) The Use of Titles and Margins on Drawingss '" . _ . TaehtiflcatIoh'Far5rawlng"makes it necessary- to "* provide some means of showing what 31 represents, the _ . Company name, initials or names of the persons making the drawing, cheeking 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. ' (T) Alterations or Revisions: Alterations or re.yis3.onc of drawings must frequently be made due to some 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 objecWare"drawn full size 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 sixes 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 property r-n to the actual size is the device used by the draftsman to provide a readable print and is known as 'drawing to scale*. (Fee Figure 3) , The foot is the most common means used as a basis for establishing the scale to be used 3n 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 001249 ' ITEM NO, A-14 TRAINING DETAILS PAGE 44 3* , J~ J-. FLANGES ,-:w - . .* . . mW** ft ret hui U m # OH * tt f<iui3*. v>u *f uf, It/M Knnmn mi b * ttr r> Ntt-n "TEXACO Us'C." niiZiV.Q fc&AAnCSKT VS/ fcaW YOnft N. T. \i V1 "* *, FLANGED4 PULLEY ^"`4 * flu lY DAie DtPCMPTiOK P.PYJ2IOH5 SfHtOl tuVuK Al-TE.RATtO.H5 OR RE.VISIONS, v*o* jS r. 1^11 ---- j li?gSe)tiTrTr M mmn t> i >n<iu uk m kl' Ik M ftti i (III M KH'MMk !* M M II*.U li ^Texaco inc." /J?S\ mm** KMarBwr HEW Y&fWtKY* N&y M<7 iJr-<*Sini!l2fi5&"mX.ft?* bY PA*fZ} DESC*PHON FLANQED PULLEY mrulf ,0r^Sr-tu]'' sxviot-L 1209-T FIGURE 2 WA--TEX 001250 ITEM-NO. A-14 '___ r X s*M Is TJTJTf' TTryr 2 TKA1N1NU DH.tr j.up SCAXB SI^ES ' ' livf ji. N Mr 7 rMta. 'M cn: v; f1 ' py p T | \h 2 DRAW)) FULL SIZE OR THE ACTUAL SIZE OF THE OBJECT"THE'.SCALE IN THE TITLE STRIP WOULD READ) SCALE: \"=y'-0'' DRAWN HALF SIZE OR OWE HALF DRAWN QUARTER ' THF. ACTUAL SIZE OF THE OBJECT SIZE OR ONE*QUARTER THE SCALE: &' l'-0" . THE ACTUAL SIZE OF EACH mew IH THE DRAWING TV1E OBJECT. THE 'EACH INCH lH THE DRAWING IS OWE MEASURES ONE-HAL.P IHC.H INCH. LOWS AS SHOWN'ON .THE RULED OH THE RULER. ' SCALE! EACH INCH IN THE DRAWING MEASURES . owe quarter inch on A B THE RULER Q T15URB DIS DRAWN DOUBLE SIZE ORTWICE. SIZE OF THE OBJECT. EACH OHE-ElGHTH ITiCM ON THE DR^WlHft MEASURES ONE.-QUARTER INCH ON THE RULER. ' SCALE.V DOUBLE Si&E. .` ` DRAWN h "SIZE OR. ^5 THE ACTUAL Sl*E OF THE OBJECT. EACH EODT.OH.THE DRAWING M5EEAASSUURAES ON THE'RULER.' SSCCAALLE! gw"=t`-0" . ' .` \s tjtttjt yrp-jr m , - A**- o" -. i 1 11 r| T \i z 2*0t 1 5M t- T ' ufi 3 1 D FIGURE 3 | WA-TEX 001251 ITEM NO. A-l4 TRAINING DETAILS r:\cm 46 Scales of smaller sises are most frequently used in Texaco drawings., as 1/2" = 18 ~0" 3 1/4" = l'-0" or 1/8" => l'-O". Some drawings are draw-* to no particular scale- to speed the draftsman's work slui 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 occurs, 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. - (c) 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 craftman 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; A"Tsobvious, lines play^rPImportant 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 Bhown as follows: (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, full lines, solid lines, object lines, visiFle boundary"lines, otc. I WA-TEX 001252 WA-TEX 001253 ITEM NO. A-3.4 TRAINING DEJAILS PAGE 48 (b) EXTREMELY .HEAVY THINKS - used to differen tiate between existing facilities and new installations. ThiB is done by the drafts- man so that the craftsman can readily pick out .he work to be done in an existing system. \ (e) DASHED LINES - or "dotted" lines as they are better kno\i, are used to represent Invisible ' surfaces or edges which cannot be Been. (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 dram 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'canuot 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 writing out on the drawing all Information necessary to show the kinds of material, thread, finish, measurements, and other detail. Therefore, symbols have been developed for this purpose. . WA-TEX 001254 ITEM NO, A-14 TRAINING DETAILS PAGE 49 8WTI0NALIZXNCL CROSSHATCHim. i--------- r -J WA-TEX 001255 m ITEM NO. A-lfr 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 understating of the particular object. When this happens, a sectional ' drawing is made. w Sectional drawings-generally show a part' _ 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 GUTTING 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 necessary 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 depleted, the cross-hatching is always in the same direction. (See.Figure 6) . Some objects, such as bolts, nuts, screws, keyB, rivets, oil cups, pipes,'pulleys, etc., are seldom cross-hatched when shown in conjunction with a sectional view drawing. (c) Ccnventioml Breaks.; Quite frequently, the heecf'arl'sesV due to 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) WA-TEX 001256 ITEM NO. A-I4 TRAINING DETAILS SECTIONED VALVE PAGE 51 1-Handwheel 2-Yoke Nut 3-Bearing Rings 4-Packing Gland 5-Bonnet 6-Ring Gasket 7-Seat Rings 8- Body 9- Jamb Nut 10- Aleraite Fittings 11- Bolt-Studs & Nuts 12- Paeking 13- Stem .. 14- Solid Wedge WA-TEX 001257 FIGURE 6 ITEM NO. A-lft l TRAINING DETAILS GONVENTIONAL BREAKS SQUARE SECTION PAGE 52 END VIEWS L.* WOOD (SQUARE SECTION) WA-TEX 001258 `A'Tr'TTD'c 7 0 ITEM NO. A-14 TRAINING DETAILS PAGE 53 CAUTION!. REMEMBER, THE DIMENSIONS SHOWN ON THE PARTS OR AN OBJECT WHICH HAS BEEN "BROKEN1' ARE THE ACTUAL LENGTHS - ALWAYS,' (d) Other Symbols and Markings?! As has been stressed several times, ,ne 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 5?),, 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 OF 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.) | WA-TEX 001259 ITEM NO. A-l4 TRAINING DETAILS ABBREVIATIONS ANI> MARTfTUGR American Petroleum Institute American' Pipe Threads American Society for Testing Materials American StandardsAssociation Angle . Ball Joint Bend tine 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 PAGE 54 API APT * ASTM ASA Bjgg gg gCD * bott br hrz gr, 01 ^ c_c 0 chfr J" Cr col Cone Cop C1bore Csk eplg cvi : WA-TEX 001260 ITEM NO. A-14 TRAINING DETAILS Degree Diagonal Diameter Discharge . Drawing Eccentric Elbow Elevation Extra Heavy Faced 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 eec 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 WA-TEX 001261 ITEM N0-fJ.4 TRAINING`D3STAILS Linear . Long Radius Low Pressure ' 'Mark' ' '" " Maximum '- Number Outside Diameter Piece (s) Plain end Plate - Pounds per square inch Pressure Raised Pace Plange Reducer Required Revolutions per minute Round or Round bar Schedule Screwed " Short Radius Slip-on Plange Specifications Square or Square Bar Square Feet Square Inches Stainless Steel Standard PAGE 56 lin LR ' LrE ; '* Mk0 max # or Wo. 0. D. - XJCif pc 3 PE psi press RP Fig. red. req'd RPM 0 sch scrd SR SO Pig. spec. SB std WA-TEX 001262 0 ITEM NO. A-I4 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 Turbines Tanks PAGE 57 stl suet sw nip* TW TL temp TOE thds vol wc . \aF WN Fig WP FEVPCTTit- 1 WA-TEX 001263 ITEM NO. A-l4 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 Planss 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 objecwith "itsparts 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) (d) Schematics; A schematic is a line drawing, 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 aaid instrument work. (See Figure 11) (e) Conventional Working Drawings: The interpre' tation of prints "depenHF'primarily on the ability of the Individual to translate a view or a series of views. The following aro types of projection drawings; 1. Perspective Drawings; A picture of an oEJec't' as it would normally appear to anyone looking at it Is known as a perspective drawing. WA-TEX 001264 ITEM NO. A-14 TRAINING DETAILS ' PAGE 59 I !i * i- | WA-TEX 001266 tTrmntt o ITEM NO. A-14 T T'RATNINQ DETAILS ASSEMBLY OP DRILL .JIG PAGE 6l >CT I II .......... -- IIIIWI II ...............1,1,111 I WA-TBX 001267 " " II .................. FIGURE 10 ITEM NO. A-l4 TRAINING DETAILS CONTROL CIRCUIT SCHEMATIC PAGE 62 FIGURE 11 j WA-TEX 001268 ITEM NO, A-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; tiie" 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 Drawing; Oblique drawings are coristructed'"on three 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 Drawings 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 Drawing; The most important type of drawing in"the petroleum industry today . is the isometric drawing. Three viewdrawings are sometimes rather complicated, thus this more pictorial type of drawing is used (See Figure 12 D),, The isometric drawing originates with three axes, repre senting three mutually perpendicular edges. j WA-TEX 001269 ITEM NO,*A-l4 TRAINING DETAIIjS METHODS Off PROJECTION PAGE 64 ! WA-TEX 001270 FIGURE 12 ITEM NO. A-l4 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 isometric line. Any other line on the drawing is a non-isometrlc line. Such lines will not show in their true length* as with non-isometrlc 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 of an object* whether, length* wicTBh* 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. . ' IB i WA-TEX 001271 ITEM NO. A-14 jm&mmLMmiS 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 elsewHbre between the dimension ' 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,1/4" 3/8% etc. or as decimal fractions, 0.25, 0.375j> 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 characteristicof' what the object looks like. (See Figure 13). , (b) Bill of Materials 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 an 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). WA-TEX 001272 ITEM NO. ft-14 TRAINING DETAILS Vs.sj6.CSJ . &LMC. ,;BILL OF MATERIAL .. . . .* . --"" ` REFINING DEPARTMENT PAGE 67 tO R,IK MWC ,*., rJ*PrJ.tf.. .. / ' b. m. no. EST. in\JtPxoDUCT~ Pipi^ Ja\Ssc.&s________................... ... " . . NO......... MADE B'i/Of/^SS . DATE . 'JATIONksS2?C/AXP.s '. . . CHECKED BY... . &/ .7 / fa > `* .' ' ' SHEET NO../OS'/. - . WidV.'S t1otit.s QUANTITY AND UNIT `, DESCRIPTION ......... . f,. --, . DWG NO. MARK furnished by JL_ 1 3 cop's? 'op- y/ozfX' '* . 2 ? 4 V 6' 7 81 * (i f i 6 ! /1 ' . VaS.*4>4<S, 4Z) pjp& ScsPPO/?7?$. Pp'k Ds/6 13~4s54_4 Os/x ... PtsP'/X P~/'Z/ & Oc/dT pussrp P-/7Z j c/ Px'X T>^ T>-4/4o /P P-4/44 4 55 15fl?^7>6<?7`t\/sri's: ' .. ._ > 1, 3. 4 7P-/~>9e... r?? /. `&ro>. Po :ei , . JL 4ii> rJsS} j< Sj *, * *. 7 TXp/A/6S> ?'<?. /Ps, ^E>X 7Z ' /z * 3L3&" Sr&Atepr .. ? /& Mcfv 4-5" .. 0 d& 4m4 X /-c? "*3 " &/<//rS/Asassf T5ez/J> J 7 Wi* / "^T^LA2TZSJ5&4 C//6?/SAS&s4it/YW&/. rr> p. ! /sk dV '4/6i><> 4bs/a447~zr --4co>& PS/ 4s4;a~ ) 3 i P/:nv)DS `4" "' *"" - i) /* ) z1 * J * - ' ,,, . . * _- ` ' ;1 , ti * - '* . -- ' ' : * ` ,' .. &-345 . -443 . -343 .. s/.zzs JF/sdx-, ' - /( .$ . -i i V wTrinm? ill 1 WA-TEX 001273 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 whlcMmaterial was ordered for delivery to the- Storehouse or Job. t (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 pro-fabricated. o. MATHEMATICS REVIEW FOE THE CRAFTSMANS In all crafts ` some^typi^of^maBh is useST-whether "ft 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. Cl) Fractions; A fraction Is a numeral with two 'Baslcpartsi 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 2/4=l/2* 8/3=1* or 6/8=3/4=12/16, (b) Like fractions - fractions with-similar denominators* such as 3A and 1/4. (c) Unlike fractions - fractions with dissimilar denominators* like 2/3 and 3/8. (d) Common.denominator - a denominator which can be common to all fractions to be added or subtracted, (e) ^ Lowest terra - the simplest form of a " fraction. Addition of like fractions is simple. The numerators are Just added . together and placed over the common , denominator* then the result is reduced to ' its lowest termB. EXAMPLE; 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" = 1-2A 2/4=l/2* thuB 6/4"=l/2n fwt_ -T73AV The overall dimension Is 1-1A" ----- -- u------- fes= WA-TEX 001274 ITEM NO. A-l4 TRAINING DETAILS PA TS 69 Addition of unlike fractions is more difficult,, for a common denominator must be found* For example, to add 2/3 and 3/4 the common denomin&rcr is found by multiplying^he denominators together* Thus, 2/3 + 3/4=? can be solved by finding.the number of l/l2*s in 2/3 and In 3A and adding . them together* There are 8/12 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 denomina tor * If two or more fractions are to be added together, such as 3Atl/8-t-l/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 ia divisible evenly by all of the denominators. Thus, 3/4-S/8, i/8=l/8, and l/2=4/8. Not? that a common denominator has been found, the fractions can be added. Then the sum of the fractions Is r5/3-KL/8-t4/8=11/8* Reduced to lowest terms the solution becomes 1-3/8* Subtraction of fractions is done in much tho same manner, as a common denominator must be found before subtracting* EXAMPLE; In Figure B, a missing dimension is' needed* To find the dimension, ono fraction must be subtracted from the other* 7/8"-9/16"=? Since 16 is divisible evenly by both denominators. It Is the common denominator* already in Its lot-root terms. (2) imaxss Another type of numeral denoting a part of a number that Is less than one is called a decimal. Examples of decimals are; *2. = two tenths *13 ~ thirteen hundredths *469 = four hundred oxtynine thousandths A fraction may be converted to a decimal by dividing the numerator by the denominator, as l/2=*5* Then *5 is the same as 1/2. . Decimals are added and subtracted the same as whole numbers. The only precaution to be taken is to keep the decimal' point's aligned* ; WA-TEX 001275 ITEM NO, A-l4 TRAINING DETAILS PAGE 70 (3) Solving Right Triangles with Square Roots The following fomuias~'ari given to find the length.of any side of a right triangle when the other two sides are known. A right triangle, by definition. Is any triangle that contains a 90 angle. (See Figure c) b= VaTTc2 A= s/sP - Cg g~ s/p ~ a2 .c The symbol V ' ' indicates that the square root of the quantity within the symbol must be found. The small S 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 'squaring8 the number. EXAMPLES Find the length >B when A15" and 0=2d'. s/{.15x315) + (20x20) = \/225 + 400 =V^5 B= 25s' . Squares and.square roots of whole numbers from 1 to 100 are found in a table on pages l67"l69 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 b,e found. (See Figure D). 4) Calculating an Angles In computing piping offsets, the pipefitter will use the six trigonometric functions of the angle of fitting. This calculation also makes use of the right triangle. (See Figure E) WA-TEX 001276 ITEM NO. A-,14 TRAINING DETAILS These functions ares Sine = set/travel* Cosine run/travel Tangent - set/run Cotangent run/set Cosecant - travel/set . . Secant travel/run PAGE 71 I f The angles equivalent to the sines, cosines* etc., are found in the Trigonomety Tables'on pageB 1T1"175 of The Pipefitter5s and Pipe Welder*s Handbook, by T W0 Frahkland,, EXAMPIEs 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. y,, *Ths equation means that the sine of the anglo of fitting equals the set divided by the travel. WA-TEX 001277 ITEM NO. A-l4 TRAINING DETAILS PAGE 72 d. Additional Print Information for the Pipefitterx ' Tiie pipefitter will come In cVntaWl?S^'var$Sus types of pipe drawings. Pipe is used in many plaeeB 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 io all that isnecei Ba^"oshow~mosfc 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) (2) Drawings; So that a piping drawing 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. I See Figure l6) NOTE; Figure 15 and Figure l6 are of the same assembly. . (3) One Line and Two Line Drawings; Piping drawings using <tHe"twoT3,ne system resemble The actual pipe Job more 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 t Anyone who has installed . pipefitHngs' arid valves"knows that they are complicated pieces of mechanism. It will be readily seen that it is a waste of time fof a draftsman to make complicated a working drawing of every gate valve to be Installed in the field. The draftsman kmfws that a gate valve is and so do.es a fitter, so a note on a print is all that is necessary to convey 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 boen , agreed upon and accepted by engineers and draftsmen. WA-TEX 001278 ITEM WO. A-X4 TRAINING DETAILS BY., S&S. date..VO-.\5"6>2> ..TXwo^y.\.c,w. SUBJECT., .S/S*.'X.sosAe.tr..'?.\a CHKD. BY........... DATE..................... ,??.VV.i,tiJ.<S...;........................ ... PAGE 73 SHEET NO____....... OF, JOB NO,.......................... e+- K. V" I t rr S (, S------ =-------- 1 H- ELEVATION FIGURE lf i WA-TEX 001279 FIGURE 1  ITEM NO. A-14 TRAINING DETAILS' SBSBY.. '... DATE..U-J.W.(o8 SUBJECT.,,,,^O.W3awa.\-N.'M.5....y&..StMGS.E.L\Jfjfc CHKD. BY ...........DATE...... ________________________________ __________.................................................... . jpAGB 7.4 SHEET NO........... ... OF JOB NO....-------------v-- DOUBLE LINE PIPING DRAW)MS - Cross Valve />ow--^. . >---i Check Y&fve-*, Ctoss-^ f * ,,, . - r^Ano/e ra/ve -QV/?? Coup/mg -i------ |>r i - G/ohe Ya/ve / <3/ohe Valve-* ^vv }bow. j_l--~{xn--i " Z<CSaa&te Valve ' * Reducing Coup/my Cao SINGLE LINE PIPING DRAWING | WA-TEX 001280 B FIGURE IT ITEM NO. A-l4 TRAINING? DETAILS PAGE 75 The symbols of common pipe fittings are shorn in Figure 18. Each symbol is. drawn as simply as possible and to resemble ` the fitting being described. Symbols arc given for screwed* flanged and welded fittings* (5) Piping Detailsi Used primarily in the pipe and weld ' sKops* pipingdetail 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) Dimensioning* The dimensions on a piping drawing are principallylocation dimensions most of which are made to center lines* both in double and single line representa tlons. 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 fend (See Figures 19-24 for examples of types of dimensioning.) j WA-TEX 001281 ITEM' NO. A-l4 TRAINING DETAILS STANDARD PIPING SYMBOLS .SINGLEr-LINS. ' flgE,7.6 UNION .' ELBOW STREET ELBOW TEE CONCENTRIC . . . REDUCING ELBOW ECCENTRIC REDUCER LATERAL RISE OR DROP IN LINE CONN. TO MAIN - PROM- TOP " " " - PROM SIDE ^ "" ANCHOR " - PROM.BOTTOM `' EXPANSION JOINT ' PLUG COCK VALVE - . . GATE VALVE GLOBE VALVE ' -. CHECK VALVE ` ANGLE VALVE DIAPHRAGM OR CONTROL VALVE MOTOR OPERATED VALVE QUICK OPENING VALVE RELIEF VALVE MULTI-PORT VALVE .' SCREWED FLANGED __ lIlt__T_ WELDED _JU JL `H-- 'll---HI-- ----' k. --l~OR--- --JKS-II-- .i --Si-CHf-- --til-- ^^ ------------ ~il3-- HBtt- --!K>31--r rH!x3l-- *"**{X3| "-- i~^}| [--1*' "* --*|t?j<3[-- ---- r-SHS? --{B^}(-- ---- Hc^ai- FIGURE IB' WA-TEX 001282 ITEM NO. ft-14 TRAINING DETAILS PAGE 77 charc'sESTTIsr'CfVM' iTiTLE@ FCCU V-40G GWC RS. IO)6-lvw-5!DATr:^-8-471 R-Et'EF- VALVE SWTfc^1 S APPD E%A pL.NCt ) ASSEMBLY SKETCH Pf\QE:>77c;o 1..-V-1 ,WV AS- K>t&` DISASTUEED y,,-A, >, -&/ WA-TEX 001283 \1V / i / 1 V . /1Si 1 W1 ! W 9 V .' * REP . DWG APPD `SgyftHgrr S'.4 UP'IH^U ' 1 * " Uli.M . ".tet'K.UJ V~-*HCXo i uA/'vwy u-/"v ' ' DATE ^-lg-47 VALVE 'S.V&TEM '' PS-\Ol6~2L ` -------- cf*QjO ,* + *+. Q/M4t55 * . ,* DATE iSSUi-D Dina's E?y .NAcKWIGWT. req'dJL.MARKftS. 1014"7- SPEC ... REG'S &fu rF>O.vR SIZE !sch i WT | GRADE eona IfifAi ' 4 ft An 357 /? 2 .4" - STb * . f d\ ff 46 -p o. F yi?i *. F fcc FH?tiZtl . U ~5~&b . i ? | i . y. * | . , r^^r.rr.rT?^ stress RELIEVE JEiEt TYPE description ' . PUR.* BY RFWN PL^W < USD0 lA/e'LD ELU SMLS PlPECeRS) 7 ** . .' " * Sa Mt*-.9 42.S5 (g W .. ' ' ' *' * " * WA-TEX 001285 WA-TEX 001286 * V \4A | * 1 f i M /1 V /1 \ l / i \l/1 > i/1 /j i \ i / n /1 vi/ ` TEXACO, INO. PUGE-T SOUND PLANT PAGE 83 TRAINING DERAILS DEPARTMENT: * 'PIPE. . r. . DATE; JULY 1, 19TO CLASSIFICATIONs PIPEFITTER (TRAINEE) > ITEM NO. A-15 '* ------ - SUBJECT;. MEASURING AND LAYOUT . METHODS AND TOOLS' ' J a. MEASURING; _ {!). Principles of piping measurements 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. ` () The greater majority of piping jobs in a refinery will normally be replacement or addition to existing lines. b. REFERENCE POINTS r~ (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 1/2 the outside diameter (OD) of vhe pipe. | WA-TEX 001289 ITEM NO. A-15 TRAINING DETAILS PAGE 8h " Repeating the process at another section of;the pipe will locate a'Second point; and A line eonneetiag'the two points will be the top"center line; Applying the same method to the vortical leg of the square will lotS&te tho quarter point Center lines# Bottom center lines may he 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) it* ^ 1 .* . > Place a straight edge'on the top of the high elevation and across the top of the low elevation# Bevel the top-of straight edge# Take a measurement at point "A", from top of low olevation to bottom of straight edge, . 'Point "A" Is the same measurement as point "B # Giving you the center to center elevation difference between tho tno lines# j WA-TEX 001290 } 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 30 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)s Settings for Various Angles Degrees 5 10 15 20 22-1/S 25 30 35 , 40 45 50 P 60 65 TO .11 .90 Set On 2'/p" ' 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/% 21-15/16 21-11A6 21-3/8 21-1/32 20-9/32 WA-TEX 001291 ITEM NO. A-15 TRAINING DETAILS PAGE 86 .Fox* a 45 degree angle, bend the'rule at the first and second Joints, setting the end on 22 and 32/32 Inches as indicated in Table' above. The desired angle wi&l 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 lVPipeFitters and Pipe Welder's Handbook" on pages 31, 32, 33 end 34. (6) Patented bending machines are available and are-used to a great advantage, especially for bending small pipe sises. 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 fits the outside radius of the bend. This helps to prevent the pipe from flattening. '" The bending process is one involving skills that must "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 001292 ITEM NO. A~15 V`*1 *' .>' * ' ' ' 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. ( WA-TEX 001293 ITEM. NO. At15 TRAINING DETAILS PAGE 88 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. WA-TEX 001294 I TEXACO IMG. PUGET'SOUND PLANT PAGE 89 TRAINING DETAILS DEPARTMENT; PIPE ' CLASSIFICATION PIPEFITTER (TRAINEE) DATE; JULY I, 1970 ITEM NO. A-l6 ' SUBJECT; CARE AMD 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 22f? 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 checked for broken or chipped punches and dies. Keep machine greased and area cleaned. 1 WA-TEX 001295 FA-73 \NV TRAINING DETA.I :JS DEPARTMENT ; PIPE DATE; Jl'.Y 1, 19.0 CLASSIFICATION; PIPEFITTER (TRAUBBX ' "" % ITEM NO. A-17 SN33ECT-: TAKING FIELD MEASUREMENTS ---------------- a. FIELD MEASUREMENTS (1) This unit; of instruction will' b<? devoted to the illustration of various reference points from which measurements are taken. . (2) As seen in Figure 1, the measurement "M" Is taken from center to center., and 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 "M" is a Face to Center measurement., "c" is a center to center measurement, but allowances would have to be made for the weld neck flange and welded ell already in place. WA-TEX 001296 ITEM NO, A-17 TRAINING DETAILS PAGE 91 00 Figure 3, illustrates a measurement taken between two flange faces, which could be a Face to Face measurement, (5) In Figure 4, the welded ell dimension "F" is deducted from the measurement "M" to determine the length of the cut "0", The dimension "F" is known as the "take off". The "M" measurement is a center to end measurement. WA-TEX 001297 ITEM NO* A-17 1 TRAINING DETAILS "AGE 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 (I to F) Figure 3 " Face to Face (F to F) Figure 4 - Center to End (SL 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, l.e. (Pipe Fitters Manual-Tube-Turn* Welding Fittings and Flanges). (The Pipe Fitter's and Pipe Welder's Handbook). ) WA-TEX 001298 ITEM NO. h~Vf TRAINING DETAILS PAGE 93 * WA-TEX 001299 ITEM NO. A-17 TRAINING DETAILS PAGE 94 ^m w ss & ) WA-TEX 001300 ITEM NO. A-17 TRAINING DETAILS PAGE 95 c. JOB PLANNINGt (1) Before measuring or laying out a pipe Job* you ' should pick a route for the'%ew line. Be sure you have a clear path from starting point to finish point. Avoid running lines that will cause stumbling hazards such as, too low across aisleways* 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 outs 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. CAUTIONS 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 cafe 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. CAUTION: IT IS ADVISABLE THAT SLIP-ON-WELD FLANGES ONLY USED ON THIS .TYPE OF JOB. ONE TO THE INSIDE WELD BEAD ON HIGH HOB WELD FLANGES PIPE PLUGS ARE VERY DIFFICULT TO EXTRACT FROM LINES. d. JOB PLANNING-WORKING FROM BILLS OF MATERIAL AND PRINTS: (l) Read the Bill of Material to be sure the proper fittings and pipe have been ordered to complete I WA-TEX 001301 ITEM NO. A-17 I 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. % (2) In most cases, a print is provided with the * Bill of Material. Read every detail Dn this print, trace the lines out from starting point to flniBh point to insure a clear layout path. , (3) After completing job, return all toolB, equipment and excess material to its proper storage area. Glean up the job and leave It In a safe working condition e. SCREWED PIPE AND FITTINGS; ' , (l) In Figure 6, showing a screwed fitting, "F" represents the fitting dimension and "M" the measurement. (2) To determine take-off nTn, subtract "L" (thread make-up) from "F". The cut length "C* is determined by subtracting MT" from 11M". (3) This principle applies to Installation of all screwed fittings. I WA-TEX 001302 ITEM NO. A-17 PAGE 97 (4) Pace 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 following tables are recommended: TAKE-OFF TABEE SCREWED FITTINGS 125-POUND CAST IRON TAKE-OFF TABLE SCREWED FITTINGS 250-POUND PAST IRON SIZE 90 TEE 45 SIZE 90 TEE 45 1/4" .3/8" 7/8" 3/8" i/4" 7/8" 1-3/4" 3/8" 1/2" 1-1/8" 7/l6" 3/8" 1" 2" 1/2" 5/8" 1-1/4" 3/8" 1/2" 3/4" 1-1/2" 1/2" 3/4" 3/4" 1-1/2" 1/2" 3/4" 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" .331- 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" 3-7/16" 2-3/4" 1" 2 1-1/2" 3" . 15/16" 2" 1-3/4" 3-1/2" 1-1/4" 2-1/2" 1-3/H".. 3-1/2" 1" 2-1/2" 2" 4" 1-546" 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" 1-13/i6" 5" 3-3/4" 7-5/8" 2-1/4" 6" 4-5/16" 9-7/8" 2-3/4" 8" 5-1/8" 10-1/4' 2-3/4" 8" 5-9/16" 11-3/8" 3-3/16" I WA-TEX 001303 ITEM NO. A-IT TRAINING DETAILS TAKE-OFF TABLE FORGED STEELSCRBWED"FITTINGS ' 3QQ0-P'0UND W.OoG. ** PAGE 98 SIZE 1/8" 90 1/2" TEE 1" 45 ' 1/4" UNION 1/2" COUPLING 3/8*' i/4" 5/8" 1-1/4" 3/8" 3/4" " 1/2" ` 3/8" 3/4" 1-5/8" 1/2" . 15/16" 3/4" 1/2" 3/4" 1-5/16" 1/2" 15/16" 7/8" 3A" 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-"XA" 1-5/16" 2-5/8" 3/4" 1-5/16" 1-1/2" 1-1/2" 1-13/16" 3-1/2" 1" 1-5/8" 1-1/2" 2" 1-3/4" 3-1/2" 1" .1-1/8",,., 1-7/8" 2-1/2" 2-7/16" 5" 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 00X304 'TEXACO INC. PUGET SOUNP~PMNT PAGE 99 TRAINENG DETAILS DEPARTMENT! PIPE CLASSIFICATIONS PIPEFITTERS (TRAINEE) DATE: JULY 1, 1970 ITEM NO. B-l SUBJECT! ASSEMBI35 AND TRANSFER TQgLNlND^QtJIFMIf A. TOOLS U) 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 room. 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 job 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 001305 TEXACO INC. PUGgT"SOl!r?IP.NT PAGE 100 TnA fNlNO DVPAUfl DEPARTMENT; PIPE CLASSIFICATION: .>1PKFITTSR {TBAINFE) DAT*?; JULY 1, 1970 i mi iinuriln i i" 11 - ** ITEM NO. B-2 SUBJECT; MOVE MATERIALS A. PALLETS U) Plat pallets are provided for moving materiel packed in barrels, sacks and crates with a forklift. (S) Straddle carrier pallets are provided for moving materials such as pipe, exchanger heads, motors, and pumps. (3) Metal straddle carrier box pallets are provided for hauling valves, PRV's, large quantities of fittings and tools. This same type of pallet is provided on shutdowns for salvaging fittings'and bolts, ' B. BOLSTERS ' (1) Bolsters are provided for moving pipe and plank with the straddle carrier, C. BUNDLE RACKS (l) Bundle racks are constructed to cradle a tube bund,*'prevent rolling while moving with the straddle carrier, D. SKIPS (l) Skips are provided for moving material such as dirt, sand, broken concrete, and coke with the lugger truck, Tn 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 bacw to proper storage. * F.' DISPATCHER (l) VJhen 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. j WA-TEX 001306 TEXACO INC. FuoSrirsiMirmNT PAGE 101 TRAINING DETAILS DEPARTMENTS PIPE CLASSIFICATIONS PIPEFITTER (TRAINEE) ITEM NO, B-3 SUBJECT! LOAD AND UNLOAD MATERIALS 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 fo^ 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, equiproent, and tools is the perfect setting for an injury or accident, ge~aler~for rolTihg^^'peT~Bu'rr'8^""oh metal, ~and above* all, - improper HTtihg......... i WA-TEX 001307 TEXACO INC. PUSET-^EOCM1'^ST' PAGE 102 TRAINING DETAILS DEPARTMENT? PIPE CLASSIFICATIONS 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 stick. 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 2" tape yon 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 001308 TEXACO INC. PUGET SOUND PLANT PAGEjl03 TRAINING DETAILS DEPARTMENT; PIPE CLASSIFICATIOfT: 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 whSH 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 threadsto 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 eome-a-long or chain fall.) (These are stored in one of the designated storage areas.) WA-TEX 001309 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 mav slip causing pipe to rolloff and cause injury to personnel. (8) When lifting single Joints of heavy pipe, it Js 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. WA-TEX 001310 m> x^jg.o PAGE 105 { /: 'TIRATNlEFKSr' ''DEVILS ` BEPABTMENTJ! .. PIPE . aUS^XmmfXMf^IPEFITTBR (trainee) BATE; JULY 1, 1970 ITEM NOm B^S } , SUBJECT; DISMANTLE PIPE AKD PITTIMGS All pipe used in tee refinery la either screwed or welded and fittings are either.screwed* weeded or flanged0 . When dismantling screwed fittings* be sure you are using the Fight slsse wrench and that .your pipe wrench has good jaws* Do not use a "wrench as a hammer- , ,, . Screwd fittings include unions* yalves, flanges, ellg* tees* and nipples i' - ... '. , ; B# sure that all fittings are in good condition a*?d properly doped if they are to be reinstalled- ' ;/ ! 1. @ iI i I WA-TEX 001311 TEXACO INC, PUGET'SOUNDPLANT PAGE 106 TRAINING DETAILS DEPARTMENT; PIPE CLASSIFICATION; PIPEFITTER (TRAINEE) DATE; JULY 1, 1970 ITEM NO. B-7 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 All diaphragm operated steel control valves should be salvaged, tagged and transported to 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 Bhould 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 3teel 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 cl XH Tees - 4", 6" and 8" -3", 4", 6" and 8" -3", 4", 6" and 8" m-TEX 001312 ITEM NO, TV7 TRAINING DETAILS PAGE 107 Series 150 and 500 slip-on flanges -3% 4", 6" and 8" Series 150 and 300 weld neck flgngps -3% 4", &' and 8" All cast iron"blind flanges 125# and 250# only -All sizes through 8,r 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 le'ft 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. Mat-pr-ials auestionable for salvage shell 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 Instr.-Elecfcr. Foreman or his Assistant shall be tagged for junk. WA-TEX 001313 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. O WA-TEX 001314 TEXACO INC -. PUQET SPUN!) PLANT PAGE 109 TRAINING DETAILS DEPARTMENT: PIPE . CLASSIFICATION PIPEFITTER (TRAINEE) DATE: JULY 1, 197Q ITEM NO. B-8 SUBJECT: USE HAND DIES a .1 STOCK AND DIES . U)' Hand'pipe threading dies and stocks (handle) are . * available in the .Main Tool Room in sizes from 1/8*' . 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. i. * ,b. CUTTING THREAPS ' . (1)\ 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 lengthy 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.) ' i >'` > , NOTE; It is recommended that a fitting he screwed on .. ;the first thread cut to be sure the dies are In 'adjustment. v CAUTION: Brass pipe Is very soft, the end being " threaded may easily be egg shaped. It is . . recommended that a spud wrench be inserted '"" through the dies Into the end of the pipe. i I WA-TEX 001315 ITEM 110. B-8 TRAINING DETAILS PAGE 110 -lo. FIELD DIES V'\', `'Field dies are available In the Main Tool Room in four ` sises:' '3", &'V 6" and.-S'1. These dies may be manually , ` operated'with a ratchet handle or power operated with an , air-motor. Pipe to be threaded should be out square. Take i: 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 fend 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 r. ! enough travel to out the proper length of thread. (3) .`l 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 . ... .. 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. j WA-TEX 001316 TEXACO INC. peoet 'smaip PACE .331 ' TRAINING DETAILS DEPARTMENTS PIPE CLASSIFICATION! iPIPEFITTER (TRAINEE) DATES JULY 1, 1970 ITEM NO. SUBJECT." OPERATE POWER TOOLS A." 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. 1 (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 tool* 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 Khoeker motors. These lubricators should be checked and refilled several times each shift ' while being used. Notet When using a power hack saw, use cutting oil on the saw blade. (3) Pneumatic sump pumps should be suspended a &jn inches from the bottom of ditches and holes when phtoping 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 recepticles are located throughout operating units to hook up power tools. Extension cords are - provided and may be found on electric storage pallets. J WA-TEX 001317 # IRC PAGE 112 MTOT'-SMEiy- MmmmiWi pipe CIASSIFICATXCiT^PXPEriTOR (TRAIKgg > bates July i. 1970 - "1 ITEM NO, B10 SUBJECT* OPERATE PUMPS PUMPS A, Sump Pumps . (1) .Are used to pump watr* oil, etc, (2) We have gas and air operated sump pumps, (3) Be swr' to have sufficient suction and discharge hose, "Test Pump ' Test pumps are a dangerous piece of equipment and should be operated with care. Be sure a relief valve set at testing - pessure is installed on test pump. Before starting pump* jen bypass valve and know testing pressure. Be sure all air out of system. Pipefitter running tept must stay with test Close bypass valve slowly and raise to testing pressurec &U jump and test pumps should be drained and cleaned after J0$ fpleted. Return pumps to storage area. ' i WA-TEX 001318 TEXACO INC. puGET^ogi^Ti^mr PAGE 113 TRAINING DETAILS DEPARTMENT! PIPE . CLASSIFICATION! PIPEFITTER (TRAINEE) DATE! JULY 1, 1970 ITEM NO. B-ll SUBJECT! OPERATE COMPRESSOR I__________ ' COMPRESSOR 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 1b ready for use. Be sure tractor out of gear before engaging compressor. WA-TEX 001319 PA$3 114 depar CLA$S iteh no, B-is TiamiNa -betaies (trainee) DATES JOEY l, 1970 ^ ---------- SUBJECTS . OPERATE HOISTS A, AIR HOIST Connect Hr hose and be sure hose is Ions enough for travel and safety wire Is put in hose connection,, gur&-lead, is properly rigged before lifting, " Bs ELECTRIC HOIST Check capacity of hoist and insure that load is properly rigged before lifting, .. e0 AIR TtraOBR . ** . Tie tugger down, with a cable to ta$geHanchor Just out from unit slab. Run cable through pulley a1i$$se of tower to top of 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 aj?ter being properly cleaned, ' WA-TEX 001320 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 Holsts; Both have a rated capaolty.of 5000 lbs. (2268 kg.) with a rope speed of 85 feet (28.9 meters) per minute. Both are virtually identical in construction and features except that Size K6UAU 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: t Powerful, six-cylinder, piston-typo reversible motor- permits full control of the load by the throttle at all times. >i* Heavy-duty, two-segment, sett-energizing, high-ca pacity brake. t, Three-stage gear reduction, with power transmitted to the rope drum through balanced planetary gear ing. ` ji Rubber-faced throttle valve--assures a positive seal at all times, never needs lapping, and greatly re duces maintenance. 4) 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. - * i.wiv, . -ei Size K6UA Hoist SPECIFICATIONS-----performance figures or. at 80 psl (5.6 kp/em') air pressure P` ........SIZE................. ....................K6UA ..................... K6UAL !_ Copodly 5000 lbfc__ 1. 2268 kg. ! 5000 lbs. ; 8468 kg. j ' ; _ Repe speed per min. ol rated load . 95' j 28.9 meters .i 95' ; 289 meters ; i Sire and maximum length of wire rope ' 54" x 600' ! 54" x 183 maters _ %" X 420' j 54" X128 meters 54" x 1200'; 54" x 366 meters : 54" *840* : 54" x 2J6 meters j Weight without wire rope .* 1315 lbs. |: 596 kg.. ' 1550 tbs. ` 703 kg.. Doth sties have a 1J4" hose connection pipe tap, V/i" (38 mm) hose is recommended. e Slit K6UA Hoist used to lift materials fa various working levels on a huge construction prelect. ! WA-TEX 001321 TEXACO INC. PUGET SOUlfo PLANT PAGE 116 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION: PIPEFITTER (TRAINEE) ` ITEM NO. B-13 SUBJECT: DATE: JULY 1, 1970 CUT GASKETS i 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 l/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 : on 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 ciittlng 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. ' . "c. 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 OD of the gasket to -be. cut, TSet the measuring bar at 1/2"the Dnofvthe1 gasket'being'cut,- lock the guide in position. Set the center hole-of the gasket material on the . ' measuring.bar-peg and Install hold down nut. (it 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. iI WA-TEX 001322 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. CAUTION: ALWAYS CUT THE OUTSIDE DIAMETER OP A BASKET FIRST..... ' (2) After the gasket has been cut to the 0D. size, remove excess gasket material leaving the gasket attached, to the measuring bar. Unlock, measuring guide on the measuring bar and set' at l/2 the measurement of the I.D, (inside diameter) df the gasket being cut. Then follow the cutting procedure, a. 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..hold measuring "Bar 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 thiB board to fit the measuring bar centering peg. The centering peg is pointed on one end to penetrate the gasket material, allowing the gasket cutter to turn in .a rotating motion. e. CUTTING GASKET Set the measuring bar at l/2 of. the QK 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 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 l/2 the I.D. and follow the cutting in instructions above, ; CAUTION: DO NOT CUT METAL GASKETS WITH THESE GASKET CUTTERS. '1 WA-TEX 001323 'TEXACO INC. _ puget~5oun5~pTant PAGE 118 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION: 'PIPEFITTER (TRAINEE) ITEM NO. B-14 SUBJECT: DATE: JULY 1, 1970 ' USE HAND TOOLS ` a. CARE OF HAND TOOLS (l) Knowledge of the proper tools to us and how to use them is necessary to good handling of pipe ano * fittings. Select the right type and right size tool'for each piping Job. . ` (2) Wrenches are used on practically every piping Job, and If used improperly can cause serious damage to materials and' tools. 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 OF HAND TOOLS (l) The pipe wrench is designed for use on pipe and ' 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. . , Notes 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. (4) Open or box end wrenches and socket wrenches are necessary when tightening flange bolts. It is important to use the right size wrench since slippage is ' dangerous to personnel and damaging to materials 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. 1 WA-TEX 001324 ITEM NO, B~l4 TRAINING DETAILS PAGE 119 : * -'in-*' (5) - There are two types of" common vises. The pip.; vise Is . used to hold pipe only. The combination vise may be ttisedfor 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 parbs crut : of working-alignment. ' .'-Notes Always open a valve part way before screwing . J.-.it on a pipe joint. If a nipple or'joint of I-,;. - pipe is screwed too far into a valve, damage ` is done to the paddle seat. If the valve is '"7 . ' in the closed position, this would lock 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. WA-TEX 001325 TEXACO INC. PUGET SOUND PLANT PAGE x20 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION: PIPEFITTER (TRAINEE) ITEM NO. B-15 SUBJECT: DATE: JULY 1, 1970 SHARPEN TOOLS * a. 'GRINDING . ` V-': (1) Stand aside from the wheel when starting it up. t< *. ** * (2) Use the work rest whenever possible. It helps to hold :;,the work and gives.added protection, I t \ ; ; * / *t - . v1-//1-". (3) If the tool is too "large to be sharpened with the work "" :.rest "ih place, remove It-entirely and replace it after .the,job is finished." Make sure the rest Is properly adjusted /and'.securely tightened, : ' . . . CW. Don't use the side of the wheel for heavy remoyal 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. 'i: . , (5) -When a great amount of stock is to be removed, use / only a moderate pressure against the wheel and move . ,t>he work" from side to side across the face of the wheel. Thl.3 -.will cauBe the wheel to wear evenly and prevent grooving. " '" (o) .-.When1 grinding thin material, such as sheet metal, .... p' . -: `fiat- edged, or pointed tools, such as a screwdriver " ";'dr'"h scriber, " do not hold the work-at the top with the flat e '.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. . . This type of work ` whould be held with the thin ' edge'"up or. at least. 45 above the horizontal and with the 1. hands, in a. Bafe position so that they will not be pulled into the wheel.- " , ' ' "' "!'/(7).- When grinding the contour of thin metal objects !;puch as shims, hold the work firmly and flat against -the work" rest, Under no circumstances tilt it up. The .. . wheel will knock it out of your hands and may cause an injury. ;, j.'If the rest is not convenient, hold it above the rest and . 'tilt;it slightly downward or turn it 90 and grind in a ,, vertiple position. ' ;; . CAUTION: - EVEN THOUGH GOGGLES ARE WORN, A GRINDER r: . SHOULD NEVER BE USED UNLESS IT IS ' ' - " PROPERLY EQUIPPED WITH A GUARD. INCASE I WA-TEX 001326 ITEM NO. B-15 TRAINING DETAILS PAGE 121 THE.WHEEL SHOULD BREAK, THE GUARD .X. HOLD THE PIECES FROM FLYING OFF AND CAUSING A SERIOUS INJURY. SAFETY; 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 ::.f 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 'he. 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, (10) 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. ' 'V (ll) The heat from grinding is harmful to the work because , art: causes expansion at the point of heat which may .' eause the work to crack. .. , (12) Be especially careful when grinding sharp edged tools, '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 1 wili:eauBe the tool to "check.1' 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. j WA-TEX 001327"' (' TEXACO INC 'iaow T^fiKT" PACE 122 TRAININff DETAILS" DEPARTMENTS PIPE CLASSIFICATION! PIPEFITTER (TRAINEE) DATES JULY 1J 1970 ITEM NO. B-16 SUBJECTS CLEAN UP 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 helper; 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-TEX 001328 TEXACO INC. PPGET SOUND &ANT TRAINING DETAILS PAGE -123 DEPARTMENT; PIPE ,% CLASSIFICATION: PIPEFITTER (TRAINEE) DATE: JUDY 1, 1970 ITEM NO. B-17 SUBJECT: TIE KNOTS AND HITCHES There are many different knots 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. AND HOW TO TIE THEM IN KNOTTING--A Rope Has 3 Parts 1. THE END is the end of the rope with which yon 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 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 around an object--often another sec tion of itself. A ROUND TURN is taken by looping the rope twice around an object, as shown. "OVER-AND-UNDER" SEQUENCE. In tying a knot, whenever two sections of the rope cross each other, one must go over and the other, under. Be careful to follow this "over-and-under" ar rangement exactly--otherwise you get either an entirely different knot or no knot at alt. - "DRAWING UP" Once formed, a knot must be "drawn up" or tightened, slowly and 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 yams twisted together. THE LAY of-a rope is the direction in which the strands are twisted. Most rope is "right-laid" -- the strands -HtCHTLAu* spiraling upward to the right--when you hold it vertically. KEEPS ROPE ENDS FROM UNRAVELLING 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 strange of the rope are also whipped for the same reason. To make the whipping, a.fine yarn, marline or spun- yam, 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 yam 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 bade out of sight Both ends are then cut short to make a neat finish.' ' WA-TEX 001329 ITEM NO. B-17 TRAINING DETAILS PAGE 124 useSTOPPI& KNOTS TO KEEP ROPE ENDS FROM SLIPPING THROUGH AN OPENING End or Stopper Knots are generally tied to keep a rope end from slipping ont 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. thi 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. we 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 ``fair' 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 THE SQUAREor REEF KNOT 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. DOtS'T TIE 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 001330 -yt ITEM NO. B-17 .y TRAININQ DETAILS . PAGE 125 :USB LOOP: KNOTS TO HOLD 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 aronnd 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. . . . .. - SOME USES OP THE BOWLINE BOWLINE --USED FOR MOORING, HITCHING, LIFTING, AND JOINING.- . . Sometimes called the' "Mug 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 lie: Make an overhand loop with the end held . toward yon. Pass the end up through the loop, then up behind the standing part--then down through - the loop again. Draw up .tight Tm> tntertockin boostdhJoin .A..p..ts. Acqotnibtr Tht Bowline is 71tdin a Hnwstt end Ihtown , artr o Asst wfun Uoerlnj A Bowline ts Tiedin Me end ofa dope for Hoisting~ A Bowline eonit tiedos oMiei- wbvurmrinq aboaterfilMlof o Aon*. theDOUBLE 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 forms die seat. J WA-TEX 001331 ITEM NO, B-3.7 TRAINING DETAILS * USE THE BOWLIN! on BIGHT TO LIFT AN INJURED MAN PAGE 126 To Tie; Double the rope, make over hand loop C, and draw loop-end D up through it. Then .pass loop end D, to wards you, down and over 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 o 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 imBWt HITCH USED FOR TOWING AND HOISTING Form three loops, as shown, in any central section of the rope. Turn the large center loop ArB 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, sucb as logs, spars, etc., also in handling cargo, to hoist small crates and bales. It is used with one or more Half 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. Used for Hoisting in a Horizontal, Position & Used for Hauling Logs Used for Hoisting an Object on End { WA-TEX 001332 ACklMCo pmWWvm^FBtwr-' - PAGE 1ST TRAINING DETAILS DEPARTS?? PIPE . .. BATE? JULY 1, 1970 cMssz&xms'^FT^pzPMPxmm' (fmimsf-- * 5 -- im wo. bi8 SUBJECT? RIGGING AND HOISTING OF M^nrrfofe and EQUIPMENT*^ " ' RIGGING Rigging is a very 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 u$@d. 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 Due allowance must be made for all variations and unusual conditions of operation of the particular sling application. As in ' all wire rope practice* the handling of the load should provide .a slow smooth start with no jerks* and the rate of acceleration and deceleration 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. IjSuch damage is done to slings by carelessly attaching over rough or harP corners. Therefore* . suitable blocking should be used. V WA-TEX 001333 SLING ANGLES ROPE IDAM ETER INCHES ITEM NO. B~l8 es ss CO Urn >"* ! as as o se o UJ 3S TRAINING DETAILS PAGE 128 0qq.9MUZ23 -sa iml .QCg a>(V}^UMOrsO>Q>HOrMH ^wMrOt HcaNP * -B5 <4 vN Si-iNWCOCO^^tOONCGOlO Ia0z0e0X* unOzu. Sas iUtPnf2 OUHW**1 3uhX1mCUUX*nta"9ctv!-lf g tM=> 'v5B> 1^ "S, /\.. h< I ^--5-^ |i-o v5>S<22 *_T,i"` S* ^* 5a' S*rrS4*O-4O{MUC5'loWO*"04-<X-J>CNJrH.OMrH c55'S^iofooqr^LO*i;li>CNjr-it HHH fo* Sc* S'^wOJr-CJOcJlftclfollO^lCDOf-l'OWONC-MfOtfJrN-C*W-f*) S* S` 0e4 ti4o mw oj io 0* iwn > 0 0Hw4 Huto>N0qOiqI ^^#wNp# ><3lv* DO*cNc*>f-NyiAn0rJ)^W*f>ioat>trifi)isC'J h' Gw)* 1W0* 0* Hh Hid qw iwfi w 10 <h0 Ncn 0rq- w0_H0 J5 tU4> ^ ^1J0,C0 H N ^ CO ^ *4 r4 fH *|S n w sis jttoS ic&=5eIiq"i ?S S|BS Sw--o2-"3e *c"O-,2uj'oOS3 u"p 3W Wr-w . &ua A4SS(9> I c o 35 g cj wStS^TJ 3cs>JC*^<i*Dc<M9claO0*n-*5"8g? 5 5'?-o| j=8f-2 I Hrii Sag'S (s9 E W 3 to a) S t*Sof-iSSs E3: o**3t? a c I *o fQ a> 0- m 0 ra to 0 0p pp CO p 0 3m 0 <M 0 ?H 0 ^3 0 P CO n -P ho 0 H 0 01 XPp 0 0a p S1 >1 0 U) p Jd c Pm 0w 3 ra p O03 P 0 >jp 3 P M CO U ?4 01 0 CO P hD> O to PP !3 P P 0 O j--1 01 >sP xs C0 O0 OO XI > P O T5 3 43 0 0 O OS m ta 0 p a> a X3 Eh iB-) +03 p E XJ 1--1 0 0 0 a 0 0 0 0} 0O Pm p < m H 0 PO XJ 0 w bO 60 0 P p 00E C 0 0 i> 01 p P P p 0 p P XJ 01 p 0 XI 01 0 0 0S P 0 0 C 0 0 O a0 pP S3 m pP 0 SP E O 0 0 O 3p 3 . 0 O0 P a 0 P 01 ap P 0 H a 60 60 Ol P B bO 0 . 60 3 O 0 0 P c 0 S 0 60 O 0 H P H a 0 01 a .60 01 H a0 C H XI *\ XI *rl XI rl *v m 0P 00 P rH 0 0 60 3 CO p CO P in 60 0.^t- 01 0 0 n C 50 60 U c0c 0 P XI C 0 CO 1-4 > 0 P O s> +> 0 TJ 0 P 3 ap 0 0 a 01 rH p Q> 0 X5 X 01 CO w i~i 3 0 E 0 0 0 XJ Pp 0 p 0 0 01 CO 0 0 0 0 CO E 0 p 0 to * c O c O a43 0 6 BJ ""**3 SS S s OOOCOO00HC9fCOM ClMDJN- OHTiOnO 0Mw^Cc in in in tf) tn in tr) r* h** oo c inoinoinou>inoif)c r-4 wcsj ol co co ^ *tutm 1 M | WA-TEX 001334 ITEM NO. B~l8 TRAINING DETAILS PAGE 129 SUNGr Rttloil Capacities it) Tims of 2,000 pounds f Rope Diameter Inches .Single filing Straight Choker i'nii Hitch >< .10 .14 31S .29 .22 .52 ,39 % .50 .60 ?B U .82 r>-iB1 1.6 1.2 2.0 1.5 $16 2.0 1.9 f* 3.2 2.4 % 4.5 3.4 H 6.1 4.6 l 7.9 5.9 10.0 7,5 IX 12.3 9.2 Tivo Legs or Sasfcot Hiteh* Vertical 30 . 45 60 1 /I /I /I .38 .58 1.0 1.0 2.2 3.2 4.0 5.2 6.4 9.0 12,2 15.8 20.0 24.6 .33 .50 .88 1.4 1.9 2.8 3.5 4.5 5.5 7.8 10.6 13.7 17.3 21.3 .27 .41 .71 1.1 1,5 2.3 2.8 3,7 4.5 6.4 8.6 11.2 14.1 17.4 .19 .29 .52 .80 1.1 1.6 2.0 2.6 3.2 4.5 6.1 7.9 10.0 12.3 Loop Dimensions \V Inches Mm 2 3 315 m4 5 6. 7 8 9 10 L Inches 3 3 4 5 6 7 8 9 0 12 .4 10 18 20 | j 1 WA-TEX 00X335 f ITEM NO. B-3.8 TRAINING DETAILS PAGE 130 Measurement for Lengths of Rope with Fittings on the Ends c 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 coders this specialty more fully. Factors of safety may run from 4 for some special cases to 8 or more -- usually averag ing 5%, 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 case being the same. && tcid UHwa.wSrttl uMe|mill. Levi Uiwtnf fiCLfftrmtem4tf- s 5736 8.7 10 2878 17.3 15 1931 25.9 20 MfiO 31.2 25 \m 42.2 30 1000 50.0 5 872 57.3 40 778 frl.3 45 7Q7 70.7 50 653 76.5 55 611 8I.S 60 577 83.6 55 552 BD.O 70 538 93.0 75 $18 0(U SO .508 0S.4 85 502 90.6 so 500 100.0 WA-TEX 001336 ITEM NO, B-18 TRAINING DETAILS PAGE 131 " STANDARD CRANE SIGNALS For use with power equipment and rigs. hand with fingers pointing downward thumb indicating boom down hand with finger Hand outstretched thumb indicating boom up Hand outstretched with finger pointing direction of travel .(! J{ TRAVEL si I HArvDS ARE 'jfoii ;: -t( itttiVcOtcUTKwDn oinr ''''0 t/ travel 11 w- mt' Rotate hands in direction of travel desired Finger to palm of other 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 WA-TEX 001337 ITEM NO. B-I8 TRAINING DETAILS PAGE 132 GOOD AND BAD RIGGIHG PRACTICES 1 WA-TEX 001338 m mma p p l ic a t i o n rope WA-TEX 001339 B ow line ojj a E ls b t TEXACO INC PACE 134 DEPARTMENT % PIPE CLASSIFICATION^PIPEFITTER (TRAINEE) DATES JULY 1, 197Q 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 for; 1. Chisels with mushroomed heads. 2.. Loose hammer heads. 3-c Pipe wrenches with worn out jaws.. 4. Channel locks that either have a loose rivet or worn out adjusting positions-o&^hoth. 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 001340 TEXACO INC. PUGET SOUND PLANT TRAINING DETAILS PAGE 135 DATES JULY 1, 1970 ITEM NO. B-2Q SUBJECT? INSTALL AND REMOVE BLINDS AND ORIFICE PLATES " BLINDS (1) Blinding Is a large portion of the pipefitters work at a refinery. It is by blinding that we are able to enter and work on various types of equipment, . (8) A Safety Work Permit must be obtained. (3) Blinding is done by loosening the bolts on tUfe flange and taking out one less than, half of the holts, spreading the flange with a wedge pr flange sprayer, removing old gasket, ' cleaning both flange faces with scsSaper,. putting panCa.kd blind or figure eight blind in between flanges With gasket on both-sides trf-bT3rnd7'"tigh.tening---bolt3~on-lang,e by- snugging them evenly on all four sides first and then going back and tightening all bolts sufficiently, ., <*) 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 df the units. Pipefitters remove and install them after, calipering# (2) A Safety Work Permit is required (3) Installation and removal of orifice plates require the same procedures as blinding noted above. i WA-TEX 001341 TEXACO INC, FlWMg lowP ' fAw~ PAGE 136 THAIWIHEF DETAILS DEPARTMENT; PIPE . CLASSIFICATIONt PIPEFITTER (TRAINEE) DATE; JULY 1, 1970 ---------- *------Umm ITEM NO. B-21 SUBJECT; UNREAD AND HEAP-UP VESSELS ANP3IMILAR Equipment ' Reading and unheading equipment is done by having the ; night 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 'must be taken to unhead equipment. -I ; WA-TEX 001342 i! IffiM NO. B-21 TRAINING DETAILS PAGE 137 ; SECTION 1 ' * 'Heat Exchanger Nomenclature ' N-2 NOMENCLATURE OP HEAT EXCHANGER COMPONENTS ' . For the purpose of establishing standard terminology, Figure N-2 illustrates various types of heat ex- j- i changers. Typical parts and connections, for illustrative purposes only, are numbered for identification V ' in Table N-2. . ' table w-a ' 1. Stationary Head---Channel . ! , `2. Stationary Head--Bonnet : . ' 3. Stationary Head Range--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 WA-TEX 001343 T4tE4MXtAA.XC>VOV iI>SWCv + PAGE 138 TRAINING DETSHL5 DEPARTIN'!?: PIPE CLASSIfrECATICWt PIPEFITTER faMINER-)' DATES JULY 1, 1970 ITEMED. B-22 SUBJECT? MOVE AND ASSEMBLE ONE AND fgrsa'fc#gg!M----------- The following illustrations give In detail the proper assembly of SafWay scaffolds anc accessories. All planking mtost be of sound quality, rough grained and free from knots. Also it .-should overlap at least 12 Inches and be eleated at both ends. [ WA-TEX 001344 t 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 calls 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 all scaffolds are plumb and level at all times. Anchor running scaffold to wall approximately every 28' of length and 20' of height. Use additional core when using pulley arms. 5. Do not force braces to Fit. Adjust evenness of scaffold until the proper fit can be made with ease. ' 6. Guard roiling should be used on all scaffolds regard less of height. 7. Use ladders 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 spans of greater than 20'. No putlog should have less than 12" of overhang at point of support. 10. Always use putlog supports where spans are greater than 16'. - 11. When using 16' and 22' putlogs in parallel, be sure to brace between them. 12. Do not omit or fail to tighten alt bolts and wing nuts that dre a part of the scaffold. Horizontal bracing should be used to prevent racking of the structure. 14. All planking used on a scaffold should bo of sound 1 quality, straight grained, 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 care. (a) Towers of a height greater than three times the minimum -base dimension must be guyed at ail 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 o rolling tower without sufficient help. if) Provide unit lock arms on all towers. |g) Do not extend adjusting screws more than 12". (h) Use 5" casters on towers under 36' in height and 8" casters on everything over 30'. (i) Horizontal bracing is to be used at the bottom, top and at intermediate levels of 30 feet. |j) Do not use brackets on rolling towers. 16. Guy all fixed rowers every 30' of elevation. 17. Do not 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 to ability of Safway to do a particular job,, sonsult 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 not rent or loan Safway 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 overhead ELECTRIC POWER LINES on every job where scaffolding is to be used. CALL POWER SERVICE COMPANY FOR ADVICE. I WA-TEX 003,345 i. -Q 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, Safway developed almost two dozen other types of frames and a complete line of accessories to. meet every scaffolding requirement. Each home is constructed from highest quality structural steef tubing,. fabricated under quality controlled conditions, and tester' and approved by the Pittsburgh Testing Laboratory Underwriters' Laboratories, Inc. nir F-3 Frame 3'0" high, 5'0" wide Used primarily, with other Safway frames to obtain intermediate planking heights. As with other t "t" frames, the F-3 may be used upside down or fight side up for cither an 18" or 36" planking height. Has 2` stud centers for braces. F-5 Frame '0" high/5'0" wide Basic Safway frame with 4' stud centers. Can be used with ail other 5'wide frames. FO-6 Frame . FO-6L Frame ' , 6'4- high, 5'0"*wTde ~L , Open end frames allowing [ head room clearance along entire platform for person nel and 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-4 Frame 4'0" high.. 5'0" wide Offers the useful 4' planking height re quired by many trades. Has 3' stud cen ters for braces. F-6 Fiamt* 6'4" high, 5'0 wide Offers normal standing height be tween platform levels. Has 4' stud centers for braces. F-46 Frame 4'6" high, 5'0V wide For specific use in those areas requiring a 4'6" planking height, i'6" stud cen ters take the B-73(S brace only, making a scaffold section 5' x7' x 4'<S" high. . FO-5 Frame 5'0" high, 5'0" wide Open end frame frequently used for straddling equip ment on inside jobs. Has 4' stud centers for braces. Has G'7" head clearance useful for pedestrian pas sageways. FO-10 is de signed for two sets of cross braces with 4' stud centers. Where side clearance is re- quired, only theupper braces need be used. ..... . ....... ALUMINUM SCAFFOLDING Whets extreme light weight or extra good appearance Is desired, Safway offers the following frames and accessories In aluminum {die prefix "A" indicates aluminum): AF-3, AM, 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, A5U-5, ASU-6, AP-22 and ACP. jfit utmost tIidhy,.sofety and feltaWiity) wing-nut itssefiiMy , *;if;,-!forj'attachlng-.apss'btaees7is''sfill favored in roany-^aioa*.' tinthrendedvlebd-lrr makes-wlng.nut attachment'quick' `jOkma easy. Deep threaded ttudf and .'complete 'weldmentsffyfo thocfcame*Vowd safe, ithbte.;ednlieettorts.,,,,AUthCBes.V ^illustrated In mis catalog.ale-shown',with standard'Sjofveay."ywing ,nulsf Unless "Quicit-LacV am- specified, ail frame ' I'infers will be-sfijpped with winsfiwt attc ' ' ' ' ' WA-TEX 001346 'S/sr" ITEM MO. B-22 TRAINING DETAILS 4' ---j i > j PAGE. 141 r ~i * FL-3 Frame 3'0" high, 5'0" wide > Ladder frames provide multiple planking levels within each frame. The FL-3, low est of the group, has 18" or 38" levels. May be used with other frames for inter mediate planking heights. Has 2' stud centers for braces. < _, > .. _ i i i ,,. p* FL*5 ri-wft !>'0" 3'O' .vc<!e i h | This sire 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. * ........... ..........; i i V- i LS-'j ; c< 1 FL-4 Frame 4'0,/ high, 5'0" wide >. Provides three planking levels. 4' high mason frame is preferred in many areas. Has 3' stud centers for braces. . j > _1 FL-46 Frame 4'6" high, 5'0" wide '] i Ideal as a mason frame in those areas de siring a 4'6" high lift between full plank ing levels. Has 3'6" stud centers for only the B-736 brace. i ** ! i r 1 FL-6 Ffomb : * hicifi, C O'* wtd& Provides head room clearance between full planking levels and throe inter mediate planking levels. Permits per sonnel movement along entire platform length. Has 4' stud centers for cross braces. LS-6 . LADDER SECTIONS 2' wide ladder sections may be assembled Into separate scaffolds ar used with 5' wide frames to fit around obstruc tions. Idea! far 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, 2' 0" wide............4' stud centers. LS-66' 4" high, 2' 0" wide............................4' stud centers. LS-10.......... .10' I" high, 2' 0" wide............4' stud centers. LSB-1........... 3' 7" high, 4' 0" wide............2' stud centers. - vs i.S-tr. 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 QulckLoetc you cart attach cross braces with only one hand. lust slipping the brace over the stud (even from a tower level) locks the braces firmly in place. To remove the brace, raise the latch and the brace comes, off,. All Safway frames are available with Quick-Locks or 4* WA-TEX 001347 !.SR-1 R Goss B.a-e: Cross braces join together any two Safway frames of the same size, attaching to the frames with Wing nuts or Quick-Locks. All Safway tubular steel braces arc center piv oted with aircraft-type rivets, increasing stability and load distribution. Stud centers on each frame and the distance to be spanned between frames determine the proper size of cross brace. Specifications; Frame Height Brace Distance Stud Number Spamied Centers For 3'high frames B-32 B-42 B-52 - B-62 B-72 B-82 ,,B-102 For 4' high frames B-73 3' 4' S' 6' 7' 8' 10' 7' 2' 2' 2' 2' 2' 2' 2V- 3' For 4'6'f high frames B-736 7' 3'<J" 'b-34 B-44 For 5', B-54 6'4" - B-64 and 10'1" B-74 high frames B84 Lb- io4 3' 4' y 6' r S' . 10' 4' 4' 4' 4' 4' 4' 4';. Coupling Pin Connects two frames vertically. Of slightly smaller diameter than the frame legs, coupling pins lit into >' tegs. Legs,of the next higher frai^y fit over the pins. Pins extend 4" into u each leg, providing a safe, stable connection. The V' swaged collars on the pins separate the frame legs end must be Considered when figur ing height ofdesired scaffolds. Semi* CP fixed coupling pins .available upon request. . UnH Lock Arms Positively lock two vertical scaffold legs b.y connecting to gether the studs on each leg with a steel strap. ULA-ff locks together 3', 4', -i'6" and S' high frames, and any oftheseframes on top of 6'4" frames. ULA-6 locks 6'4" high frames together or to any smaller frame below. .,}!l |V. ` ` FE-1 provides extra 5" high i, planking platform when placec i"'-' upon coupling pins at highest ) work level. Extension post. (FE-3 and FE-4), used with tht appropriate sleeve size (FE-5) provide 2" increments ol ,, height adjustment up to 2? , v ' Extension posts and sleety, j also may be used on lowei I scaffold legs to adjust for unJ even ground.. Hcn'.-.tn'.i. '.V.'ed l r; \m% ea`";-;ons ilart.es , >23,..................... . 034........................ C-4S........................ .............. Two of each neededperframe, U f-oo r.vA r./is nnA c,k Reinforce scaffolding subject to unusual stress- Provide increased rigidity and stability, particularly on high towers. Sub stitute for cross braces when open areas between frames are desired, provided each adjacent bay is cross braced. Specifications; HB-5, 7 and 10....Horizontal Braces.... 5', 7' and 10' long. HBS-5, 7 and 10....Spring-Loaded Hor izontal Braces....5', 7' and 10' long. I HDBS-5, 7 and 10....Horizontal Diago i nal Spring-Loaded Braces....5', 7' and 10' long. s WA-TEX 00X348 i.m i Pk-i , Ki.i- on* Hein* f'trzt-j tf'-: " ji/.l-; Be Fit Into legs of aii Safway frames to provid a stable footing for built-up scaffolds. O soft ground, sills are recommended unc base plates. BP-1 is used on level grouuc BP-2 on sloping ground; BP-3 for offsettin frames to reach receding structures, i. e spires, obelisks, etc.; BP-4 is same as BP- with extra long flanges; BP-5 permits settin two frames close together; BP-6 permit setting two frames dose together on top c another frame; BP-7 permits setting fram leg close to walls or obstructions. ITEM NO. B-22- TRAINING DETAILS PAGE 143 Putlog Hangers Used as structural spanning members between scaffold towers, reducing need for solid built-up scaffolding. Also used to pro vide cantiloveredplatforms-and to erect finely adjusted staggered . towers- built upon other scaffold towers. Pour sizes of putlogs are available: 8C 12', 16' and 22' long. Each putlog requires two putlog bangers to attach putlogs to frame scaffolding. Sirttd^io fog PH-l permits mounting putlogs parallel to any horizontal frame member. PH-2 permits mounting putlogs at rigfit 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 16* and 22' putlogs. Ph- ?H 5 Putlog Support Used for putlog bracing as extra safety equipment. &.-jZXt Hoists Substitute for cross braces to provide open area between frames. Useful for building platforms over fixed equipment or obstrucions. 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). Adjustable Screw Jacks AL-i Used to level scaffolding on uneven terrain and to finely adjust scaffold shor ing under formwork. Have maximum adjustment range of 18". AJL-lA has removable handle and is recommended near pedestrian traffic or confined areas. Both jacks can be used with casters or base plates. u AL-1A I------ 1 l Combination Adjustable I Jack and Base Plate J c I Frequently used where repeated `usage allows the AL-2 to be used and stored in the set position. Has maximum adjustment range of 5". i 1 L.. H-3 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 tach to a frame leg. - 0--Hang 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, over beams or around other obstructions. Three sizes of side brackets attach parallel to the frame, and two sizes of end brackets fit at right angles to the frame. I Swiveling Casters Inserted into the legs of frames, costers provide rolling scaffold towers. Double brakes lock both wheel and 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 arid Steo! Hcmk -"ny r.T re Lni'gsjj r C'f'-irySriQ? f'r( '>f\i\Afirf'ffit *4* !*-'j iTW-.V. .: jfy'.i'Vv-.f' ('5", .r..r..,.., TO.'! AP-6 AP-7 W-6 SP.7 Sturdy, lightweight steel or aluminum plank have rough, raised surfaces for safe, secure tread. Made for 6'or 7'spans. Idea! for rolling towers. AP ... aluminum plank, SP .., steel plank. Cli;:- PC 9 Locks planking where desired on scaf fold as extra safety precaution, Also a quick, simple means for attaching toe boards to guard rail posts. Oiiw-rent 'no lr*of? Provides support for two guard rails, 22" and\4(>." above frame legs. With a base similar to a coupling pin, the posts fit into the top of frame tegs. Guard rails attach to posts with standard wing nuts. Many areas require guard rails for scaffolds over 5' high. ^ Guard Rcits, GFf--(Ic-llfith Cli SIMlll Attach to guard rail posts with wing nuts. Available in 2', 3', 4', 5', o', 7', 8' and 10' lengths. Safety chains are supplied for spacis over 10' long. . C 1 cSR-S GR4 J 163: GP.-7 bj: jt GRC Guard Rail Clamp Provides a wing nut and stud for attaching guard rails or cross braces to any part of a scaffold frame or accessories. Folding Devices Attaches over wing nut stud, permittingassembled 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, DB-57 for 7' spans ondDB-510. for 10'spans,lockthe scaffold sections in position. FD-1 Climbing Ladders 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 nigh as the scaffold. Self-locking de vices securely attach the ladders to the end frames. Five ladder heights offered: 3', 4', 4'6", S', 6'4". LA-6 LA-5 pu JII* - LA-3 =s-n.=i| > St(ES? rr Steel Stair Units Provide an interior stairway within scaffold bays. SU-5 is designed for 5' high frames, SU-6 for 6'4" high frames. Both units are built for. 7' long spans. SUM-5 hori zontal braces must be used on the bottom frame for at taching the lowest stair unit. biyh, y'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 prevent planks from sliding off. May be used on either frame leg. Frcmc Clamp Steel clamp for tying adjacent frame legs together. May be used on all other adjacent parts ofSafway frames. [ tf* FC J J* dt-rs "L" Eroco Brocket Permits attachment of guard rails or cross braces at right angles to the frame. Also used for "tying in" with guard rails. I'vanicntql Biace Bracket Allows cross braces to be placed horizontally between frames where additional rigidity is desired. HBB attaches to frame studs. For use with B-74 braces. j WA-TEX 001350 HBB TEXACO me. fET~somr-pftNr- PA0E 145 TRAINIHS DETAILS DEPARTMENTS PIPE CLASBIEICATIOITs PIPEFITTER (TRAINEE) DATE? JULY 1, 1970 ---- ----------- ITEM NO. B-S3 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* i; i i WA-TEX 001351 I TEXACO INC. PUGET' SOUND PLANT PACE 146 TRAINING DETAILS DEPARTMENTS PIPE CLASSIFICATION! PIPEFITTER (TRAINEE) DATE: JULY 1, 1970 '1 ITEM NO. B-24 " SUBJECT: LAYOTJT AND PREFABRICATE pipework !` Layout and prefabrication of piping is covered extensively in Basic Training Item A-15 and Item A-17. In addition, you should always remember the followings 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 001352 TEXACO INC, PUGET SOUND EftfF" PAGE 147 TRAINING DETAILS DEPARTMENT: PIPE ,t CLASSIFICATION! PIPEFITTER (TRAINEE) DATE: JULY 1, 1970 ITEM NO* B-25 SUBJECT: 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'1/2" and 3/4", 1" and 1-1/4", and 1-1/3" and 2". J3xti*0me care should be taken when threading pipe to be surf ^Pp^are set for the right pipe size. (2) Listed below are standard*pipe threads: Nominal Diameter ' Inches,- 1/8 1/4 3/8 1/2 3/4 1 1-1/4 If 1/2 a Threads Per Inch 27 18 . 18 14 14 11-1/2 11-1/2 11-1/2 11-1/2 WA-TEX 001353 TEXACO INC. EASE 14S .....'TRAINING DETOXES DEPARTMENT! PIPE classificationT"PIPEFITTER (TRAINEE) DATES JULY 1, 1970 ITEM NO. B-g6 SUBJECT! 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 product in the line. Primarily, pipe tending is used on lines for catalyst and steam tracing. The following pages illustrate the operation and application of pipe benders. WA-TEX 001354  ITEM NO. B-26 . TEXACO INC PAGE 3.49 , ' METHOD OF USE .. OF THE Newly Designed Attachment far Making 180 Bends With Tal Pipe Benders The 180 attachment consists of the following parts: #100 #101 #102 f 4 Guiding Plates, 2 on each side. 4 Rollers and 4 Roller Pins 2 on each side. front and rear. #41-1 #38 2 Corner Formers and 2 Corner Former Pins 1 on each side. #105 Pipe Release Pin #104 2 Spacers to be used with 3" Pipe Bender. One under .each corner former. | WA-TEX 001355 ITEM NO. B-26 TRAINING DETAILS TAGElp^:. Before starting bending, 180 attachment should be set up as in Illustration 2, with rear rollers and pins (#101-102) out. WA-TEX 001356 --ITEM NO. B-26 TRAINING DETAILS mfi 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 001357 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 001358 -s*.- ` COPYRIGHT 1956 BY TAL BENDING EQUIPMENT, INC., MILWAUKEE 2, WISCONSIN ' ITEM NO. B-26 . TRAINING DETAILS . PAGE 153 . _ - BBNDING"lNsT~RtIOTIONS"'....... ~ ......... ' *' for PIPE. TUBING, and CONDUIT when using TAL HYDRAULIC PORTABLE BENDERS The following'illustrations, table, and 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 or linear figures for lay-out and marking on a straight length* It la 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. nAH angle of bend "B" or l,C" distance to completed bend "H# 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 benas 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 where nAn angle of bend is 90 degrees. Since 11LD represents the bend setting location on a straight length, then since HDn represents the diameter of the pipe or tube, and "R" the bend radius both are known. B" or "O1* are also known since they locate the completed bend which Is governed by your requirement. L= B + x * .. L-- 0 ~ 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 8" (R), The distance to the bend is nBn = 10n or "0tt = i8n whichever can be determined most con veniently. Then by finding x or y in the table and substituting num bers for the letters 10* and or L = l8wl J&l<i i WA-TEX 001359 ITEM NO. B-2S ,t ' ' . , TRAINING DETAILS BENDING INSTRUCTIONS PAGE 15^ l $0 obtain straight line I dimension for laylng-out 180 tends , =etq X.- EM* 2x The values for q and x are obtained from the Table on Page 3 Band Starting points on straight lengths. Plaee onC of Ram L "-------- To obtain straight line dimen sions for laylng-out OFFSETS to angles shown In Table on Page 3 ts z 8s C- k T?Cf x.n+2* The values for z, k, and f are obtained from the Table on Page 3. This Illustration shows the multiplicity of bends that can be made by the use of all of the preceding instructions to find rtL". nTtt or nSM which are the linear or straight line dimensions for locating in the Ram and Former, In any plane besides that shown. Bends can be layed-out and made one a$ a time, or they can all be layed out on a straight 'length at one time and then made. WA-TEX 001360 fO y vy 5 j *. 1* v3 UP C4 ** A! . J5 M N H ro*> UP v <* it J n3 2n tfr 4 IS N N JR tp S5 $j' N *5 V 3* * 2 ffO $ * ^9 pi % **^ \. 5^ N vO0 ^J* S* M jS c4 LM 5 rf Vl V- N ga & !K JR mn* #.# $ .Ni H. *S, sS Wi iM u5^Sfs M i?Q m* ?ss f 45 (Vl`T -9 .Strrjfe(M5 w ^*' Mr & as TL>, CM CM ^5 jR A # sJO tSN A M S 5^ (M 1 st <0 "co > _ InS . Pi HS aS flC\f 3l 3f CO ^ N *SQ sM _______l5Mi"cM *$ CM m to ^1| M> OJ 8^ - j s & N 4 vll fcC CM 0 N W N 5& %A $M Ufl oe h Id y * 2d !8s f tOjCO <Oj CO CO V ? r- 4 00 sJp'^J 35 -.Ml 6^ $ 4 *"' }" *- in v* ! **' *-- -- Mf ~-.l s^j. N -^jl4 ait 5^; . CS> CM CMiffT (n St- m. - 1 <M vsS 3 t*t^ $ si M CM CM 5l in lsS M cJ .N 9 5^ C^jto^ is <nn iS -iP9 . CnI w l$N mn D <o 2 u. u (0 It j0 i as N fsl to N * s? AM *fif* ur $ A . v && P) ir X wN MQ f "! *) 1 ist -n5 v*fl *0 *0 vfl NICO 6> -si C4 fR vM vS CM rS; xr 5, CM iCM cm! cm jgsh^s CO fO -^i IT v ifl f f h-<y> wm U-, as vS JH n > V to i ^1 sS i** q*N t)N MM Csl 0 CN l N W CSS tr> $ SS & 6 N w\ $ 3 * ass gj t>Vl CO <y> O Wl c) >y mm SS0 to <o eft co $ S-ffi to J3L 'Cfr to to vs r SR <o 64 * 2 D flf H UP 31 CM CO 10 * V* 2^ l N 29 u$ or w \S P*- 0 00 tr ?s O o CM tnK&r to CM o C4 <9 tM tJ . Pi ^5 VJ 8 & 34 CO Kn cO 55 Cfl s> 3a a to j^4 -npfr rm <vT sotf> 1Z If z c a o V9 M as $? (M CU CJ T $ N * S*5 CO M M $ *$ S >5 to 4* iX oo 90 tn # c^ a* V*4r-r m* !? w 0 & CM $ f 'cm' & CM it S^ CvJ- "Etv <& Q0 % * 3 aR ! V) to. n CO? * D V- 8 y vw Za a uz gQ 8 ? iS? X <M In <v> o- * $> & I'm o o aSO CM Oi cm ro % CM -$M CJ 31 JJ to ro tj' >9 5S g it vlS f t-~ CO a 5R < CM a <9 B CO >* fl CM 3 a wt 4 lO to v5 64 Cl CM \ IS 1?X Q ?b *9 5*5 cu X N "W :$! N oto CO t o51 & O) "w co fi M tg CM CMy w v,.4 in 5 or *0 V3 00 h> * 6) (T> sy 9 CM AS ro Wft IQ < CM OO I t 3J Cm P> WK 10 ** 1 <* w p' u. Iff ,5 Q tr* Js joT it - i sr i 34 i CM < tJ (O' 1 o to l it l rOx 34 10 s v5 1 34 *, lv i 31 r<r 1 1 WA-TEX 001361 I 4 ITEM NO. B-26 TRAINING DETAILS PAGE 156 i INSTRUCTIONS FOR OPERATION OP 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 ' to the left side approximately 90 to center line of h machine; Remove the Radius Key, push the Slide Bar. out and ' " place the tube under the Slide Bar and Ring Gear between i ` 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 with the machine,' Move the Slide Bar back into place and insert the Radius Key. ace the tube against the Grip Bar Shoe, press the a.. ip U-Clamp down over the tube and Grip Bar Shoe. r REMOVING FINISHED BEND; , .' t Before removing the handle, return the Former Roller to its feystarting point. Remove Radius Key and Grip U-Clamp drop fej^inished,bend out of machine. ^^OPESATOR MUST STAND ON FLOOR PLATE WHEN INSERTING AND P " ' REMOVING TUBING AND DURING BENDING OPERATION. ; TO CHANGE OVER FROM-ONE SIZE TO ANOTHER; . b* > ^ Remove the Spring Key from the Center Post. L ' Remove Slide Bar and Ring Gear. Remove Former Shoe and replace with desired Former, making spre same sets down over the Angle Pin. - DO NOT use a hammer on the Radius Key or the Grip U-Clamp. . To make a 180 bend, it is necessary to bend the tube more p'an 180, allowing for "Springbaek.,f PSilzpeo - GAUGE FACTOR Degree Plumbing and of Band Heating Electrical %" /' 2254 43 90 i" i%" 3" 54" 2254 45 90 2W 3" mu %" . 2214 294" 45 |T 3%" 90; - 654" SPtiepas 1" 154" 154" CHART GAUGEFACTOR Degree Plumbing and of Bend Healing Electrical 2254 3%" 45 4 90 m-iyk 3%" 4%" 714" 2254 4" 45 5%*mv 90 * 3" Mr 4" 5%" 834" 2214 4W 4%" 45 e%" 90 9%" PSiizpee 2" 254" 3" Degree of Bend 2254 45 90 2254 45 90 2254 45 90 GAUGE FACTOR Plumbing and . Healing Electric BVb" 7" 1034" BVb 7W 10%' 654" 9" 1454" . 954' 1454' 7" 10" WA" 7" 1054" WA" y-JjHf T.-y WA-TEX 001362 ITEM NO. B-S6 TRAINING DETAILS PAGE 157 Np. 3 PH - 3" PIPE BENDER Bends standard pipe %" to 3" <X to 2 Mi", XX to. W>. Includes SEVEN short radius bending shoes %" to 2" (Box III, plus two stand ard radius: ZW and 3"* (below) Heaviest part 57 lbs. No. 2 PH - 2" PIPE BENDER Bends standard pipe from %" to 2", (X lo 2", XX to 1%">. Includes SEVEN short radius Bending Shoes %" to 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" lo 2". No, 3 PHX ind p?rh $piu, of RedloM for Rodloni Heel. Hoot Shoos on pose Savcn 5hort Rodtu Shot?* for pipe. All No. 2 & No. 3 benders have only two main parts: ONE hydraulic unit and ONE universal frame (page 4i. They are assembled with a U key in less than ONE MINUTE. THIS IS THE BASIC PIPE BENDER USED WITH ALL VARIATIONS shown Sam, (under vud ,t .Copper (Cl) or Steel lobe (EHT) bender. Soma bender with demote Control RC (pope 4). Some bender with Motor pump No. MP--26 (page 4j. No. 3 C - 3" RIGID CONDUIT BENDER Includes FOUR bending shoes FOR RIGID CONDUIT: 1" to 2" (Box V), plus TWO: 2>A" and 3"* (Box 1). For extra long radius bending shoes see page 8. 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 extra long radius bending shoes, see page B. For bending Bus Bar with No. 3 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. I WA-TEX 001363 l 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: l" to 2", and TWO 214" and 3"* (shown). Heaviest pari 44 lbs,Benders for 2'A" and 3" Copper tubing have a special frame IShown). Larger sixes obtainable. WITH FRAME HO. S333 j No. 2 PH/CT - COMBINATION 2" PIPE & 2" COPPER TUBE BENDER j Incl. 7 short radius-shoes: V -to 2" (Box ID, plus 4 bending shoes, bars, and clamps FOR j COPPER TUBING type K & L l" to 2" (Box III). Heaviest part 3B lbs. No. 3 PH/CT - COMB. 3" PIPE & 2" COPPER TUBE BENDER Incl. 7 short radius shoes: %" to 2" (Box ID, TWO: 214" and 3"* (Box D, plus 4 shoes, bars and clamps FOR COPPER TUBING: 1" to 2" (Box HI). Heaviest part 57 lbs. No. 33 PH/CT - COMB. 3" PIPE & 3" COPPER TUBE BENDER Is as No. SPH/CT above, plus extra frame No. 2533 (Box VII) and parts for 214" and 3" copper . tubing....... ...... ................... . -- USED AS RIPE BENDER USED AS TUBE BENDER . No. 2 C/EMT - COMB. 2" RIGID & 2" THINWAIL CONDUIT BENDER Incl. 4 standard elbow radius shoes FOR RIGID CONDUIT: 1" to 2" (Box V). plus 4 bending shoes, bars and clamps FOR THINWALL CONDUIT: 1" to 2" (Box HI). 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 37 tbs. USED AS TUB^ SENDER No. 2 PH/C - COMBINATION 2" PIPE & 2" RIGID CONDUIT BENDER Includes 7 short radius bending shoes FOR PIPE: %" to 2" (Box II), plus 4 shoes FOR RIGID CONDUIT: 1" to 2" (Box V). Heaviest part 39 lbs. Potented QUICK RELEASE SHOES Short radius for Piping Std. rodlui elbows for Elcdr. No. 3 PH/C - COMBINATION 3" PIPE & 3" CONDUIT BENDER Includes 7 short radius* shoes FOR PIPE: %" to 2" (Box ID.'plus 6 shoes for RIGID CON DUIT: 1" to 3"'(Boxes IV & V). (2%" and 3"$ shoes have same radius for pipe and conduit.^ Heaviest part 57 lbs. 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: 1" 10.3" Heaviest part Is 39 lbs. No. 3 PH/C -- CT-EMT -- COMB. 3" PIPE, 3" RIGID CONDUIT, 2" COPPER & 2" THINWALL CONDUIT BENDERS Includes 7 short radius shoes FOR PIPE: to 2". plus it FOR RIGID CONDUIT: 1" to 3"S. plus 4 EACH shoes, bars and clamps F.OR COPPER TUBING EMT: 1" In 2" Heaviest pari 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 win, Remote Control Shown with motor pump &!)(, No. RC 3 CH/C-MP will* remote control and motor pump. j WAHTEX 001364 ITEM NO. B-gb TRAXlSlftU JUJETA.t.Ut) /.nuji 1J7 No. 99 $nndanl 25 Ton Hydraulic Unit and Ram, and No. S8-XU ALL PURPOSE FRAME No. 5B-2XU ter all 2" Benders {net wgt. 28 lbs.) No. 5&-3XU for all 3" Benders (net wgt. 57 lbs.) NO. 5B/3 XI) No. 89 Hydraulic Unit fnefwgt. 39 lbs.) and No. 58 ALL PURPOSE FRAME arc the TWO main parts of all No. 2 and S 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. Sfondord model No. 2 or 3 used at PIPE BENDER Slondord.modol No. 2 or 3 used at TUBE BENDER Ho. 58/3X11 rl3H'f. A niS? AU SENDERS CAN BE HAD WITH MOTOR PUMP MP26 AND/OR WITH HYDR. UNIT NO. 99 OR WITH RE MOTE CONTROL NO. RC 10 (below! ' RC10For pipe v/ilh For Rodlcm) Haot No. RC 10 REMOTE CONTROL 10 TON, 2 SPEED, HYDR. JACK 1NCL. SEPARATE RAM, 6 foot hydr. hose and coupling. These powerful, lightweight units can be used with all No. 3 and 3 benders, in any position. Wgt. 37 lbs. Same price, whether benders ere ordered with the standard hydraulie unit No, 99 (above), or with the RC 10, shown. " No- ) ^"COMPLETE QUICK SELF SEALING COUPLING Incl. No. 12 M male and No. 12 F female part (%" pipe thread). fwmm & For Bus Dor 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. some as RC. II. Includes coupling and hose. No. 14 SIX FOOT HYDR. HOSE with coupling connections No. MP 26 - Vi HP LIGHTWEIGHT HYDR. POWER PUMP Incl. S' 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 Vs Hp 110-115 V. AC/DC motor. 1750 RPM. Gr. Wgt. 70 lbs. No. MP 30 2 HP POWER PUMP Incl. 6* hydr. hose and couplings, is the power unit for 6" 8s 8" benders, or for any other hydr. equipment. The double-piston, single valve, high pressure pump, with two V-bells, is driven by a 2 HP, 60 cycle. 3 phase motor 1750 RPM for 220-440 volts, de veloping up to 10,000 lbs. pres sure. Gr. wgt. 355 lbs. RADIANT HEAT WINGS & SPECIAL BENDING SHOES FOR ONE SHOT 180 BENDS These wings for any bender, make complete 180" bends in many different centers, IN ONE SHOT. & IN LESS THAN ONE MINUTE twith motor): WINGS No, 82X for No. 2 Bender No. S3X for No. 3 Bender No. 84X for No, 400 .Bender 180* bending shoes can be ordered separately as per re quirements in the following pipe sizes and centers: Centers: 6' Pipe sizes: .. 9" 12" %"--l" %"~V I`A"--1&" 15" St 18" I W~ Ho. T0A 133/2 or 3 Connecting Pori* for Tub* Benders consisttog Mo. TBA-3-2 or -3 Hydr. Unit Connection M&'TBA1-2 or-3 Relief No. 115/2 and No. 50/3 Rom Extension No. 38 Pair End Casting pins For No. 2 and 3 No. 37 U locking pin for No. 2 No. 3 Wo. TBA-2 Connection No. 438 End Casting pin* for Na XJ30. WA.-TEX 001365 i ITEM NO. B-26 TRAINING! DETAILS PAGE lbO . ALL LARGER BENDERS HAVE BOTH* MANUAL OPERATION AND PROVISION FOR TAL POWER PUMP ' WITHOUT MANUAL OPERATION, ON REQUEST ONLY for, pipe (X a xx), rigid and thin wall conduit, copper, steel And aluminum tubing, BUS BAR, RADIANT HEAT (180*1 BENDS, SHAPES, ETC., ,||| SIZES FROM %" TO 8" AND UR, W, WITHOUT FILLING OR MOVING THE PIPE Very Important! The Pioneers of the Portable "One Shot" TAL Benders Offer the Following Exclusive Features: . O THE ONLY PORTABLE BENDER powerful enough to bend in one shot X pipe* and adaptable lor XX pipe. 0 BENDING IN CLOSE QUARTERS! Provided with cosier* for easy mov ing, also whit? bending* Benders will rotate with one end of the pipe, while the other end can remain stationary* D THREE MAIN PARTS ONLYi One hydraulic mill Inti, ram and two frame plotes assure easy and quick assembly. MOST ECONOMICAL PRICE-WISE and in PERFORMANCE: I) takes 3 min. actual bonding time -- on the job -- to complete o 90* bend In B" XX pipe* SAVINGS UP TO 90% on welding or threading and on Expensive handling and assembling of oneccssary cut-up pipe wiih costly fittings, elbows, couplings and nipples* WITHOUT EXPERIENCE perfect, identical bends are guaranteed be cause of: Patented, tight-fitting, quick releasing bending shoes, BendIndicator and Bending Chart. {Copyright 1956). MANUALLY OPERATED, HAS A BENDING RANGE FROM %" 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 00* Bend In 4" XX Pipe: No. 400/26 with % 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 SHOT in any 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 14 HP motor. 6 >4 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 14 H.P. MOTOR PUMP . (noo-monuol -operation) NO* 5M> SAME A5 NO. *00 BELOW Proportionally imolte/ WITH 2 HP MOTOR PUMP, HAS A BENDING RANGE FROM %" TO 6" STD. PIPE (X Ot 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" iw!t* the appropriate bending shoes). S 1((| ,, , , __ __^ep Sec.^C far Ur,oil remote control irmf I WA-TEX 001366 ITEM NO. B-26 TRAINING DETAILS PAGE I6l | INCLUDING 2 H.P. MOTOR PUMP, AND AN B" BENDING SHOE (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 uiider "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 boro of 4 %", travels 50" and operates at a pressure of 5000 psi. The double-piston single valve pump operates at 10.000 psi Intermittent, or 5000 pst constant, has'2 V-belts. has a Universal 2HP. 60 cycle. 3 phase motor for 220/440 volts. The Bending Frame consists of 4 sections connected to an upper and lower plate, and fastened with pins to the hydraulic unit. The overall width is 1014'. 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. FOR PIPE (SHORT RAOIUS) Size jm- Roctfuf STD. RADIUS-fOR BOTH CONDUIT &-PIPE Size Radius SAME AS ABOVE BUT WITH TOP WINGS FOLDED TOGETHER Slid SPECIAL LONG RADIUS FOR CONDUIT Radius SHOES, BARS a CLAMPS FOR THIN WAU TUBING ^copper, lied, EMT, plum.) Nom. No. Six* Itadtuf Tgi TAL manufac* * to your specs. ONE SHOT 2245 2244 1" 1>/4" 5W 7-W SHOES IN ANt a>Zt* e.g. Conduit elbows up to 2243 2242 w 2" 0V4" 10" 48", 180 loops, etc. 3202 2283 2Vy 3" 15" 15" The snug fitting, PATENTED, TAL SHOES, assure perfect bends and have easy pipe release. Set 20 EMT;: r*. 1V2", Set 25 EMT : lV\ %W 2" Set 20 CT: l's *. W*, W Sot 35CT: lrG". 13h". W. Jhtn wo condo* \ WA-TEX 001367 ITEM NO. B-26 TRAINING DETAILS PAGE 162 ?%rs3 WITH AIL OF THE FOLLOWING OUTSTANDING FEATURES a TWO SPEEDS -- accelerate* bending lime. FRAME WITH REMOVABLE TOP PLATE allows THREE WAVS to lnsen pipe in bender: Drop In Irtm the lop, slide in from the side or hook ihe bender over installed pipe. # MAKES 180" BENDS for Radiant Heat in many different sizes and centers. . a BENDS EASILY REMOVED FROM SHOES because of push-out pins and posh-out holes in shoes, # EASY ASSEMBLING AND DURABLE CONSTRUCTION: No threads, the few ports are assembled with pins. For multiple .purposes: Pushing, pulling, lifting, straightening, as arbor press or punch press, etc. ALL THIS WITH ONE AND THE SAME BENDER WITH ONE AND THE SAME FRAME TOTAt, WEIGHT Oil t'os.. I hr liuhtr.-l .if nil "ON 10 SHOT Bunders, ami the m>-s nm. mimical. USrT same Bender "WITH* */t:T t'HANtlKS" for H.i. p- ,.- and Radiant Heat. ASSEMBLY. LKSS THAN I MINUTE ' TbI patented Bending Shoes are scientifically designed, with tight fit and easy pipe release. Guaran tee round bends. All main parts arc made in aluminum. !lf` 200 Pit for pipe with <1 .short radmbvndinif .hues for V lt `2' RC 20(1 (' fur rigid conduit with -5 -tandard otbuw radius bending I,',..-:, fin 1 in g", . f 'OF PLATE of Frame facilitate* merjing or removing pipe. rC ?Jv PH.X with 189" attachment, far man/ . ONE SHOT'* Rodion* Heat Bend*. P-l 300 C*B foi rigid conduit and busbar. The RC 2011 KAVi !> TiilRII on cost of ir.:u and time on cutting, mg. material lianui're a- c .1:. M-nbtmg. on tin- piping i.--. stallaluin of this rri.u rlel'm; juh in an old basement. Willi mottu pump, Ihe Aeluot Sending time (-,1 ci *0* -in 2 pj>P iv !ev thon I min 4tnrf m**0 m'A } nun. RC 226-PH for Pipe \ is RC 200 'i//i RC 226>C for Condyil \ motor pump HF-l* Pot. & PotcnK Pwto Cyloloo No 16-Srt, C irv Sfi A fc' (mil 3* Hydr 0mlt 5i*d Jir, B tor A to 3 CAN P.t USED ON THE FLOOR * IN THE (*.. I* * f>t IHE (fll)NC down o* l;i i*t> t'pw't * otKiinv1 the wall heuren r .*,, >\ut ^OjIHON : WA-TEX 001368 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 bends right on the spot. Basic machine available with all or any of the following rollers and bending formers: Roller Sizes %%"" %" 1" Bending Formers Centers 4" 6" 6" 9" 12" 6" 9" 12" 9" 12" Simple, light weight, easy to carry. In sturdy wooden tool box. BENCH attachment available. Wlttwul TAl With TAl BENDS ON THE FLOOR OR BENCH HUSH TO WML AND CORNER Bends W and %" O.D. HARD AND SOFT COPPER TUBING * > . Has one Forming Section with Two Grooves for Both Sixes. EASY QUICK EFFICIENT LOW COST The bender is made of light we'ght aluminum with ONLY TWO LOOSE PARTS. Nominal Tube Size Vs", %" Outside Diameter ot 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 vary 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. BO 1I0S0 Size %" 1" Weight 3 lbs. S Jbs. 8 lbs. | WA-TEX 001370 l 6 " -HYBRAUtlC PIPE BENDERPARTSDRAWING TAL BENDINGEQUIPMENT, INC., MILWAUKEE2, WISCONSIN PAGE 164 TRAINING DETAILS ITEM NO. B-26 TEXACO INC. PCaEy'SOTO? PliANT PAGE 165 TRAINING DETAILS DEPARTMENT: PIPE CLASSIFICATION PIPEFITTER (TRAINEE) DATE: JULY l, 1970 ITEM NO. B-27 SUBJECT: FABRICATE TUBING Bending (1) Biding 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 bfender 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 001371 ITEM NO* B-27 TRAINING DETAILS PAGE 166- . * ` . *yr TUBE BENDERS IMPERIAL HAND TUBE BENDERS. Designed to simplify bending of larger sizes of tubing. Bender puty be looked in vise if desired. Center pin may be lifted to release tubing. . ' Wt. Dir. Ind. Ret* 364FH'* Bends 1/4" tubing to radius of 9/16". 3/4 lbs, ea IEK CAE ea 12.7S 364FH Bends 5/16" tubing to radius of 11/16" 364FH Bends 3/8'* tubing to radius of 15/16" 354FH Bends 1/2" tubing to radiuB of 154"' 114 lbs. 114 lbs. 154 lbs. TKRE CYK TQAK TYRI TK 1C TUCA 15.40 t4.85 24.50 3S4FHA Bends S/B" tubing to radius of 254" 3S4FHA Bends 3/4" tubing to radius of 3" 10 lbs. 11 lbs. RTQK ADEK RAUQ AUCE 32.50 52.00' IMPERIAL HEAVY-DUTY TUBE BENDING TOOLS. Long leverage and adjustable operating lever makes It possible to apply lores with little effort, avoiding sudden strains which mlghl Injure tubing. The smallest bends are made with perfect accuracy In the heaviest tubing. Right or left hand bends. Removable handles. Furnished in steel chest. . 360FH Bends 3/6",1/2",5/B", 3/4" O.D. sizes Wt.ea2^lbs.uKy ^ 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. at02F size 1/4" 5/16" 3/8" . Length 10" ' 10" ID" Wt. 3 oz. 3 4 ea ' AJ A1 DY DA ea .57 DA .57 DC .66 7/16" 1/2" 5/8" ' 12" 12" ' 12" 6!4 654 . 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". 7l Packed 12 in display carton 1-1/2 lbs,' ea TKD. TRK ea .1.56 . ALUMINUM TUBING ALUMINUM TUBING. Pacific Metal Co. For gas heater and range connections. Soft AGA approved. . Pull Coll Cut Coll Rut. 3/8" OD X .035 x 50. ft. 100 ft TEYI TiUK ft .23 COPPER DRAINAGE TUBING only. 20 feet lengths Size Wall tMdmes 'teS: I-1/4" 2M" /2" !042 .042 - .809 1,07 3"` .045 . 1.69 ' f DWV 1000 ft or more, less TKSS Dealer lss, 1000* cut oft TQIKQ ITQO VUYTD CREU TTKRTQ TYREC 7.TQTEQ TCAIU Retail Ret. Full toih. cut 102.09 ft 1.23 115.71 1.39 153.24 1.84 .242.34 2.91 Imperial Hand Tube Bender 102F Basic Stock Turnover Item | WA-TEX 001372 1 5/3/ PAGE 167 felNINQ DETAILS DEPARTMENTS PIPE `, . classificationT""pipefitter (trainee) DATE*. JUDY 1, 1970 ITEM NO, B-28 SUBJECT? INSTALL BELL AND SPIGOT wHTmftffW.mYAWzff ' 1 - r "" ....... FABRICATE / You must- have piping aligned properly with spigot all the way into the hub. You theftaput enough oakum around spigot to seal the joint. Lead is thafpoured into hub to seal and- look oakum in the joint. . (a) When joint is ready, ydu'put in one small oakum ring at a time. BsIng caulking tool and-'hammer, you go around joint tartping lightly after each ring.- Y6u do this until you conie 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. . -rhour lead ip to fill the hub. The lead 1b then ready to be caulked with eaulirig tool which makes-,.; the joint,tight and helps seal theijpagBm. INSTALL To use bell and fplgot piping for sewer and drains, be* pure to have the proper fittings and the proper drop in the line to gravitate'.the material'-apd? Still flpat it also. The right amount of dyop to get proper gravity flow and still float the material is ne*=eighth inch drop to two feet of pipe.' Attached, is a c'otamer|pl standard regarding dimer&Johilj,1 tolerance and installation Of Kill and spigot pipework. \ WA-TEX 001373 ITEM NO. B-S8 TRAINING DETAILS -PAGE V68.' COMMERCIAL STANDARD CSJ 88-66 Supersedes CS188-59 CAST IRON SOIL PIPE AND FITTINGS [Effective 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 intendedto 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: 54 bends; long 54 bends---------- Long low-hub 54 bends...... 54 bends, low heel; high heel 54 bends___________ _____ ____ 54 bends, short sweep; long sweep 54 bends_________ abends.....-----------------------Ve bends; long 54 bends...------54 bends; long 54 bends---------- '/n; bends Y branches Y branches, cleanout-............ . Y branches, inverted Y branches, combination 54 bends________________ Y branches, combination 54 bends, cleanoutr. Y branches, upright Sanitary T branches Sanitary T branches, clean out._________ ________________ 4,5 6 7,8 9,10 11 12,13 14,15 16 17 18,19 20 21 22 23 24 25 Fittings:--cont'd Tapped sanitary T branches. _ T branches, tapped T branches T branches, cleanout____ Vent branches....... .......... .......... Offsets, regular....... ................... Offsets, V4 bend......................... .. Double hubs, long double hubs_______________ ________ Reducers Increasers...................... .............. S traps; full, 34,54............... .. 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 shall 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 8V----------- 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 ' WA-TEX 001374 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 iB 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.- . ,,, 2.2.1Ends 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 'A 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 aplicable. 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 patterns1 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 iB applied. . Fiouna 1> Single hob and double bub cast iron cot) pipe. 2.2.2 Dimensions ofpipe.--Single hub pipe shall be of 5 foot and 10 foot nominal laying lengths. The laying length shall be meas ured as shown in the figures above tables 1 and 2, and shall be within the tolerances on laying length specified in table 3. Double hub pipe shall be of the same overall length as single nub pipe of the Bame 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 and 2 as applicable, and be within the toler ances specified in table 3. The dimensions shall apply to pipe before any coating is applied. 2.2.3 Straightness ofpipe.--Pipe shall be straight to the extent that any deflections in the barrel of a 5-foot length of pipe shall not exceed 14 inch for sizes 4 inches and larger, and shall not exceed Vis inch for smaller sizes; for 10-foot lengths, deflections in the barrel 2.3.2 Wafer seal of traps.--Traps shall provide water seals as follows: Trap Size Minimum Water Seal inches inches 2 2--..................................................................................................... 3 to 6, inclusive.................... 216 8 to 12,.inclusive-.______ ... 3 15:.............-.................................. 316 2.3.3 Ends of fittings.--Hubs shall have lead grooves and 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 combinations of which shall make a satisfactory leakproof joint. Tapped open ings shall conform to 2.3.4. 1 Such as, for example, fiutngs known In the trade os "specials," when designated as being in conformity with this standard. WA-TEX 001375 ITEM NO. B~S8 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,' of 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." (2) Size of branch. (b) Reducers, increases, and offset fittings: (1) Size of inlet or run.1 (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- "Ceples may be obtained from the Superintendent of Docu ments, U.S, Government Printing Office. Washington, D.C., 20402. #, The run is that portion of the fitting which form* port 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. n 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 be 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 001376 TEXACO INC. pucet sound plant PACE m TRAINING DETAILS DEPARTMENT; PIPE CLASSIFICATION: PIPEFITTER (TRAINEE) DATE; JULY 1, 1970 '' ITEM NO. B-S9 SUBJECT; INSTALL PIPE AND FITTINGS A. WELDED ... ToWstall welded pipe and fittings you should have a blue print whichiwould indicate where the installation is to be made and the type gaskets, bolts, .etc. to be used for the job. , , s' In order to do the job safety and efficiently, be sure to use the proper tool3 and equipment. t. B. SCREWED .. , .i . To install screwed pipe and fittings you should Jqao* the location pipe is to be installed and the type of gasketfe%ggd 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 mo3t 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 -pftmented. t' 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 marks and burrs removed. Follow all the other instructions on illustrated material shown herein. ! WA-TEX 001377 ITEM NO, B-29 TRAINING PETAILS PAGE 172 teles P3bSb&^ 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 be used with Schedule 80 or heavier pipe. The chief advantage of threading is the ease of disassembly it offers. THERMO-cScEaAIl *> Thermal Bonding . p^urlwToot 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 regulatei heat uniformly and simultaneously to pipe am fitting mating surfaces so that true melting occur on the surfaces. Only hand pressure is needed fo join the components and as the material cools, , permanent homogenous bond results. ThTHERMO-SEAL tool may be used on a stan< for pre-fabrication or as a portable unit. Flanging One of the earliest methods for joining thermo plastic piping, flanging continues to be usee extensively for process lines. Thermoplastiflanges and flanged fittings are available in a ful size range and may be attached to pipe by solven cementing, by threading, or by thermal bonding as required by the particular thermoplastic ma terial. (penton, poiypropylene) "TfcmpIhfiV'--t. M. Tampil Corpofalio Saw pipe Jo desired length using either a hand saw and miter box or power sow. A $quore*cut end Is of utmost importonce.'Remove sow marks and burrs with file, sharp knife or sandpoper. While the loci lx heating, spray heating element contact surfaces lightly with silicone release agent to prevent hot plastic material from sticking to the male and female too) pieces. The THERMO-SEAl heat tool should be chocke periodically with "TempIlsHks" to ensure (he prop er temperature range. Caution; Hearing elemer reaches 5J0af or more; avoid touching. Ploce pipe and fitting squarely and fully an heating elements so that I.D. of fitting and 0*D, of pipe are In contact with heating surfaces. Rotate components slowly and avojd overheating. Remove pipe and fitting from tool simultaneously ond 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 15 seconds. It Is Important that the fool pieces be kept clean a possible. The smoll omount of residue left on th tool pieces should be removed with a cloth. At th end of each day, further cleaning may be done wit fine Jlcel woof. Cavthn; Hot plastic material <o causa severe burns; avoid contact with it. I WA-TEX 00X378 ITEM NO. B-29 TRAINING DETAILS SlV<biwt' Cemented - Joints (pvc,pvdq PAGE 173 Muke certain pip* end b square* Smooth with fine- Cleon connecting surfaces of both the pipe and tooth file. Remove sow marks and burr* with sharp ' . fittings with either methyl othyl ketone or acetone. knife or sandpaper. v Apply CPS Solvent Cement liberally with dean bwsj ,. first to fitting and then to pipe (O.D. and end) #. * - * r/ f. *f,r; .\j, * 1 ` , Cement should bo applied to oil of pipe 0.t>. to be covered by fitting. Allow V* * to Yz " lap for better seat. . , , . - ' When making Sch 40 PYC join}*, / Join pipe and fitting... bo sure pipe Is WELL SEATED into fitting .. twist Vi turn to distribute cement. If correctly assembled, o small "fillet'' or bead wf appear between pipe and fitting, v above procedure except Sch 40 Solvent Cement is a; ed to the pipe enly, not the fittings. Tfltr@gd!*cl Joints (AU MATERIALS, SCH 80 PIPE ONLY) Use standard stoat pipe threading equipment.' An Insert should be used In vise {aws to prevent scoring of pipe. . .. Insert wood or aluminum plug (longer than cutting dies) Into pipe end. This prevents distortion of pipe wails and avoids off-center threads. Dies should be clean and thorp, and those with 5 10 front rake angle give best results. With pow tools, use 5 negative front rake dies. Starting with entry thread, wrap Thread Tope tightly, covorlng all threads. Overlap each wrap a quartertneh. . * or apply CPS Thread Lubricant to threads. It I* Inert and acts as lubricant as well as a seal, When threading "Ponton**, use /vbr/canf of 50% iusof and 50% wafer. Screw fitting onto pipe end tighten with str* wrenches. Avoid excessive torque; one to two three past bond tight is adequate. j WA-TEX 001379 TEXACO INC PAGE 174 TRAINING DETAILS DEPARTMENT? PIPE CLASSIFICATIOWr^PIPEFITTER (TRAINEE) DATE? 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-241-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, B. REGULATORS To remove regulators be sure that the instrumentation is first disconnected. Then proceed as in Paragraph A, c. RELIEF VALVES Extreme care should be used- when removing and installing relief valves. 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. ! WA--TEX 001380 TEXACO INCa ffrwrmiw PAGE 175 TRAINING EMAILS DEPARTMENTS PIPE ,. CLASSIPICATIO^rr~^PIPSFITTER (TRAINEE) DATE? JULY 1, 1970 ITEM NO. B31 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. m WA-TEX 001381 TEXACO INC. PAGE 176 TRAINING DETAILS ISMSMBMW>|B0aeiMaQsm9iHMMM DEPARTMENTS PIPE , CIASSIFlCATIOUT"TMPIPEFITTER (TRAINEE) DATEs JULY 1. 1970 ITEM NO. B-33 SUBJECTS RENEW TUBES The steps in changing a tube in an exchanger bundle are as followss (l) Cut tube on one end Just Inside tube sheet. Use internal cutting tool powered by an electric or air drill motor. (g) 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 001382 TEXACO INC o PUGET gQUNPTONT PAGE 177 TRAINING DETAILS ' DEPARTMENT! PIPE CLASSIFICATION! PIPEFITTER {TRAINEE) DATE; JULY 1* 19TO ~ ITEM NO. B~33 SUBJECT! 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 flangipgup gas, tighten bolts up evenly. Tighten nuts back up on packing ring. - B. 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 burner tip needs repairing, it is screwed on and then is seal welded, you have to grind off weld and screw off tip bo repair, which in most cases would be a new tip. .Screw tip on burner barrel, seal weld and it is ready for service. WA-TEX 001383  i.'Z ! . TRAINIMa DETAILS. ... `~ # j . -. ' * ._,, '.' * *' : .* ,{VV* '"."'$* &'/: .; . . INSTALLATION AI!^; OPERATION INSTjHimCW& p MODEL GP TANDEBI C&]iBU$TION UttlT J0OR `* v r;" (&MBINATION NON-AERATED . .. `r^i-:-~--r -:v. f. - "' i- '.. :.'1;" . ` ... -- w 'V '*/ *. *' . - r-- T.T-------------- ..... ~ GAS'` AND .. , " OIL FUELS ' V . . .. '* ' - .* k - . . At-..-' .....* ; re n> > ftutm i '.' . ..3, :. gjzerr mmi&jm , . `' NATIONAL AIROIL BURNER : GP TANDEM UNITS ^ rf. . &J}IlB!ied lOIS^Inrorpowied I?H7 * . * ' " ~. . . ( " k INDUSTRIAL OIL BURNERS, GAS BURNERS AND FURNACE EQUIPMENT `: '' - . ' r 1284 E. SED.GLEY AVENUE PHILADELPHIA 34, PA., U.S.A. 1' ' .-Form ,525/- ' . SOBTBTOWEftN I>lVISlnN--aSia SOimt BflllUtVABn, HOUSTON fi, TEXA* NovMnfter W5? WA-TEX 001384 ' WA-TEX 001385 TEXACO INC. ptoITKoW "Eant PAGE 180 training details DEPARTMENTS PIPE classificatio5T~~11pminpntienwfiBxiitiwtuneiiwr^iM i(inT'imRi--AunwINiraEo--E) ITEM NO. B-34 SUBJECT; DATE; COILS JULY 1, 1970 A. REMOVE AND INSTALL In order to remove a coll 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. W&.-TEX 001386 FUGirMfS'mNT PAGE 18a TRAINING DETAILS DEPARTMENT; PIPE CLASSIFICATION PIPEFITTER (TRAINEE) DATE; JULY 1. 1970 ITEM NO. B-35 ' SUBJECT; STEAM AND AIR TRAPS A, REMOVE AND INSTALL To remove traps, make sore traps are out of service, theft 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 001387 ITEM NO. B-35 TRAINING DETAILS PAGE 182 The Why and How of Steam Trapping 8. Types of Traps By JOHN W. WELKER* MANY YEARS AGO Steam 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 Bteam 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.) siuga 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 insulator 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. "Application Engineer, Yarnoll-Waring This latent heat which islost almost Company ,* Vi POWER ENGINEERING i WA-TEX 001388 DECEMBER, 1955 ITEM NO. B-3S> TRAINING DETAILS PAGE 103 constructed and how each operates. Illustrations are diagrammatic, and in no way present details of design. They are used to Illustrate in simple terms the basic design and opera tional characteristics. Mechanical Traps The mechanical trap differentiates between condensate and steam by virtue of the difference in weight be tween the two fluids. . Open Top Float, Bucket Typo (Fig. 1) Condensate flows into the trap at A, and is usually deflected downward by a baffle B. The body of the trap fills with condensate, and the empty bucket G is buoyant and floats up ward closing the valve C. The bucket is now at its highest position and as additional condensate enters the trap it begins to spill over into the bucket at D. The bucket then Alls to a point where it is no longer buoyant, and sinks, opening valve C. Steam pres sure at A then forces the condensate out of the bucket through C. The bucket again becomes buoyant and rises before it is completely empty so that a water seal is maintained at E to prevent escape of steam. On start up and frequently during operation this type of trap will become fflied with air which must be released to permit sufficient condensate to enter trap to make it operate. An air re lease valve F, usually manually op erated, Is necessary. This valve iB opened to purge air, but must be closed to prevent steam loss. The discharge is intermittent and the trap cycles at Intervals deter mined by the amount of condensate handled per unit time. The weight of the bucket, which is a constant, must oppose the force created by the valve seat area multiplied by the operating pressure. The weight of the bucket establishes one of two limiting pos sibilities-- the maximum operating pressure for a given seat area, or the maximum valve area for a given operating pressure. Inverted Bucket Design (Fig. 2) On start-up, the open-bottomed bucket is resting on the bottom of the trap body which meanB that valve B is open. Condensate entering through A drives air out of body through B. Air in the bucket escapes upward through the fixed orifice C in the bucket top. After residual steam in the bucket condenses, condensate ultimately fills the trap body and bucket, and discharges through B. If steam reaches the trap it displaces the condensate in the bucket, and even though a small amount of steam escapes through C, the bucket be comes buoyant and valve B is closed, Ab condensate follows, a point is again reached where buoyancy is lost, and valve B again opens to allow con densate discharge in cycles. The size of the orifice C determines at a given operating pressure the air handling capacity. Steam loss through this orifice is determined in an inverse fashion. In some designs this orifice is closed by a ample thermostatic ele ment which must bB sensitive to a small increment of temperature be tween hot condensate surrounding the bucket and steam temperature within. The weight of the bucket opens the trap valve B, and its buoy ancy when filled with steam doses the valve. As with the open bucket, the area of valve and operating ratios are established by the weight of the bucket. Closed Ball Float Design (Fig. 3) At start-up the float is at its Lowest position, and valve B is dosed. If there is a lot of air in the system, a manual vent F must be opened to allow condensate to fill the trap. Al most all ball float steam traps today are - equipped with- high capacity auxiliaiy air vents operated thermo statically or by other automatic means. These vents are designed to release air at temperatures approach ing saturation temperature so that they will release air on starting and during operation. To prevent steam blow through the trap, valve B is usually covered by condensate before the float rises to open the valve. The float rises in proportion to the amount of conden sate entering the trap, and so long as condensate flows to the trap, dis charge 1b continuous. A bail float is sometimes guided so as to seal the valve itself, but most often it operates a lever system as shown. Closing power iB a function of the weight of the float; opening power is a func tion of the buoyancy of the float com bined with the mechanical advantage of the lever system when used. These factors combined determine capacity and operating pressure ranges. The valve opening, at any load within its rated capacity, is a func tion of the rate of flow of condensate into the trap (a function of the load, in fact). Thermostatic Traps The thermostatic trap differen tiates between steam and condensate by virtue of the temperature dif ference between the two. Balanced Pressure (Metallic Bel lows) Design (Fig. 4), These traps are operated by a sealed thermostatic element, usually called a bellows, having a flexible wall of a metal suitable for the operating conditions. The wall thickness of the flexible bellows is designed to give maximum resistance to- the pressure differen tials it must withstand and, at the same time, maximum resistance to fatigue. The sealed element or bellows con tains a liquid, which may be pure water, a mixture of water'and a suit able volatile fluid, or a volatile fluid alone, depending on the character istics of the element design. One end of the bellows is rigidly fixed to the trap body; the other end has the valve attached and is free to move. When cold, the bellows has a length permitting valve B to be open to pass air and condensate. As it be comes hotter the bellows lengthens, and finally at a temperature ap proaching that of steam the valve is closed. t Because of the lower boiling point of the mixture inside the bellows, a vapor pressure differential between inside and outside is established just before steam temperature is reached in trap body. The differential pres- WA-TEX 001389 ITEM NO. B-35 TRAINING DETAILS PAGE 184 jure causes expansion of the bel lows and closes the valve to prevent escape of steam. Condensate In the trap must subcool to a temperature where internal vapor pressure in the bellows balances that outside before the trap will again open. Vapor pres sure temperature curves for water and the mixture in the bellows are essentially parallel. This fact insures a positive differential pressure avail able for closing the trap independent of the operating pressure. ' Balanced pressure elements filled with pure water are expanded by the spring properties of the bellows wall. Beuow straps are normally not recommended for superheat opera tion. Superheat creates excessive va por pressure and tends to rupture the bellows, Discharge from a bellows trap is usually intermittent. Where condensate formation and tempera ture are constant, continuous flow can result. Balanced pressure traps do not need auxiliary air vents, for they are wide open when cold and freely release air up to temperatures ap proaching saturation. Metallic Expansion Design (Fig, 6) On start-up air passes through the valve B. Condensate follows and 83 it becomes hotter tube T (which forms a valve seat at one end) through which it is flowing, expands. This ul timately results in the seat being closed against the valve. The valve is adjustable to permit setting for clos ure just as steam temperature is reached. Such a trap has good charac teristics so long as steam pressure is constant. If pressure increases, the trap will close prematurely because closing temperature will be lower than steam temperature unless the valve is reset for higher pressure (and temperature) conditions. If pressure decreases, the trap valve will not be closed when steam reaches the trap resulting in steam blow through the trap. In order to have appreciable ex pansion for valve movement, the metallic expansion tube must be long which results in an abnormally long trap. Discharge is continuous and at a set pressure, it can be set to dis charge at any temperature up to steam temperature. Liquid Expansion Design (Fig. 6) This type consists of a liquid-filled thermostatic -element which expands and contracts on a temperature dif ference between condensate and steam. Liquid is used to obtain greater expansion per degree of tem perature difference; thus greater valve movement and a more compact design is achieved than with metallic expansion. On start-up air passes through the trap followed by condensate. As con densate becomes hotter, the liquid in the thermostatic element expands. Piston B which is free to move slowly closes valve C against seat D as the liquid expands. The thermostatic ele ment is on the outlet end of the trap Rg. 8, Above. A "labyrinth" type j trap. Below. An "orifice" type valve, and as steam reaches here, the valve closes tightly. Gradually the element cools, contracts and opens the valve once more. It will continue to sample the medium entering at A; if steam is still at the trap the valve will immediately close, but if conden sate is there it will stay open to a de gree inversely proportional to con densate temperature. The adjust ment at F permits setting the trap to operate at a definite temperature. This type discharges continuously except under light load when it has a sampling or intermittent action. Ca pacity is determined by both steam pressure and condensate tempera ture. It will close at a temperature below 212 F (assuming atmospheric, discharge). Liquid expansion traps should be used only on applications where con densate can be held in the heating surface until it cools to below 212 F. Unless this can be done, a cooling leg must be provided between apparatus' and trap to provide subcoohng be tween the desirable condensate tem perature and 212 F. Thermodynamic Traps The operation of this type of trap depends on thermodynamic proper ties of hot condensate and/or steam as either or both pass through some form of orifice or orifices. Impulse Design (Fig. 7) Whether valve F is seated on G or open is determined by pressure in chamber K above disk L. In either position part, or (if valve is closed) ail of the condensate passes upward through the annular space between disc L and tapered cylinder D into control chamber K. This portion of the condensate is known as the con 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 valve F, As condensate passes into chamber K and then through the control orifice into trap discharge, pressure is reduced. When hot water under pressure passes into a lower pressure it will flash to a greater or lesser degree depending on initial temperature and the pressure drop. The degree of flash determines the pressure in chamber K; this pressure in turn determines whether valvo'F is seated or open. Cool condensate flashes little, chamber pressure is low, and the valve is open; this results in the trap floating on the load and passing cool condensate as fast as formed. The trap is designed so that condensate close to steam tempera ture will flash sufficiently to raise pressure in control chamber so as to exert sufficient differential pres sure between top and bottom of disk to close valve before steam arrives at trap inlet. Control flow through the two orifices in series continues at all times and represents only a few per cent of total trap capacity. This flow makes the trap continuously and im mediately responsive to slow or rapid changes in medium reaching trap. New High Capacity Impulse Design (Fig. 9) Recent, modification of the twoorifiee-in-series design of Fig. 7 has resulted pipe size for pipe size in a much higher-capacity impulse trap. This design incorporates the same two-orifice-in-series principle for con trol of trap operation. However, in this design 100 per cent of flow passes through the two orifices, instead of only a small percentage as is true with the original design of Fig. 7. In Fig. 10, the trap is shown in the closed position. The two valves, one . conically-shaped A, the other flat- . disk B, are mounted on a common valve disk which raises and lowers as a lever at a fulcrum point C. When steam is turned on, upward pressure of air and accumulated con densate lifts valve A and simul taneously valve B; the mixture of air and condensate passes frorn line pressure at trap inlet through the Fig. 9. latest impulse design for high capacity service WA-TEX 001390 ITEM NO. B-35 TRAINING DETAILS PAGE 185 first or inlet orifice into the inter- wiAfiiatft pressure chamber D; thence i|||hrough the second or outlet orifice ^lnto the low pressure of the return system. Opening and dosing 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 in the lower pressure region on optlet side of valve B. Thm raises pressure in Rg. 10. Latest Impulse design for low chamber D sufficiently to close valves A and B. In dosed position, a small . capacity services 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. Eapid discharge of condensate flow ing to trap is obtained over complete due to condensation of eteam 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. temperature range from cold water to Kinetic Energy Design (Pig. 11) condensate near steam temperature. This trap consists of a body and New low Capacity Impulse Design cap, and a valve disk A. It employs (Kg. 10) the kinetic energy of the steam to The operating mechanism _ of this trap consists of a valve disc (A) mounted on a flat seat. This seat contains large inlet orifice (B), lo ss*. eated slightly off center, and four Wm smaller discharge orifices opening into annular discharge space below seat. (One shown -- "C") At start up, when pressure reaches trap, the valve disc tilts upward or rocks on its rounded fulcrum (0) edge, discharging condensate and 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 dose 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 the disk and builds up pressure in chamber P by recompression. This pressure in chamber F, acting on the full top area of disk A, exceeds the combined force of the incoming steam and that in the low-pressure 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 eycle 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 (Pig. 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 sure in control chamber is relieved is discharged to a lower pressure, a 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. Pig. 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, A*, A,, Ai, Aj, A,. The second design has an expansion chamber between each orifiea. When steam is turned on, air "cascades" through the orifice series, taking a pressure drop at each stage, but eventuaUy 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 too wide open, no control is possible and even steam will pass through the trap. If the setting is too close, only cool condensate can pass. This design can be set to pass condensate 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 as condensate reaches the trap. Con densate pressure and temperature control the operation. Only a manual change in setting can upset these re lations. Fig. 11. Diagram of kinetic energy type . of trap j WA-TEX 001391 ITEM NO. B-35 TRAINING DETAILS PAGE 186 Fig. 1. Relation between condensate handling capacity at various condensate temperatures. Curves based on test data for an orifice with area of 1 sq in. The Why and How of Steam Trapping 1. Selection ~~ Siting --Application By JOHN W. WELKER * Table I. Values of x = (T-t)/L used in text formulas for figuring trap loading Prwsure, P**9 5 10 15 20 25 30 35 40 50 50 75 IDO 123 150 2170S0 40 0.042 .042 .042 .043 .043 .043 .043 .044 .044 .044 MS MS .046 M7 M7 4)46 0 0.062 .063 .064 J}64 .064 .055 4)65 .065 4)66 .066 4)67 .06B .069 .070 .071 .072 SO 0.083 .084 .085 .085 .086 10T0emper1at2u0re rite, F 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 .087 .109 .110 .130 .132 .152 .154 .088 .089 ..111112 .133 .134 .155 .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 .189 .191 .192 .193 .194 .195 .196 .198 ..210919 .204 ,207 .210 .213 .215 200 0.208 .211 .212 .213 .214 .215 .216 .218 4219 4221 .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. I. Pressure or range of pressure at inlet: Pressure and condensate handling capacity are directly related in all 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 given * Application Engineer, Yarnall-Warinc Company POWER ENGINEERING WA-TEX 001392 JANUARY, 1956 t .p* ITEM NO, B-35 TRAINING DETAILS rflufi. xu( V Table II, Data for use when heat exchanger has excess surface which heats liquid in (ess time than required by process a. Dh//*q MW** ftfi* ST 5 Pounds per hour per square foot Steam preuuxo# prig------- - 25 50 100 150 200 260 300 350 400 450 500 600- 10 280 .28 .29 .30 .31 32 33 .33 .34 35 .35 36 37 ,37 38 ` 20 930 .95 .97 130 1.02 1.05 1.08 l.U 1.14 1.16 1.18 1.20 1.22 134 1.28 30 1,900 1.95 1.98 2.03 2.08 2.16 2.22 2,27 232 236 241 245 249 243 241 40 3,100 3,20 3.23 332 340 3.52 3.62 372 378 335 3.92 3.99 4.06 4.13 435 50 4,500 4.65 448 432 4.93 5.11 535 53B 548 548 5.69 530 539 5.99 6.17 50 6350 543 5.51 6.59 635' 7.10 7.30 747 742 776 7.92 836 8.18 833. 848 70 8,000 825 8.33 847 877 9.08 934 946 975 9.94 10.15 1032 1047 1045 . 10.97 60 10,400 1073 10.83 11.13. 1140 1130 12.14 1243 1247 12.92 13.17 1340 1342 1335 1436 too90 12,500 12.90 13.00 1337 1370 14.20 1440 14.94 15.24 1543 1533 16.13 1636 16,65 17.15 15,000 1547 1542 16.05 1644 17.03 1740 17.90 1838 1843 18,97 19.34 19.64 19.97 2047 125 22,400 23.10 2330 23.95 2443 2545 26.15 2675 27.30 27.80 2835 28.90 2930 2935 3073 150 30,000 30.95 3130 32.10 32.90 . 34.10 3530 3535 3640 3730 38.00 3870 3930 39.95 41.15 173 40,000 41.30 4143 42,80 4330 4540 4670 4730 4875 4970 50.65 51.60 5240 5330 200 50/100 5140 52.10 53,50 54.80 5675 5830 5970 60.90 62.10 63.30 6440 6540 66,60 250 82,000 8370 85.30 8775 90.00 93.10 9570 9830 100.00 102.00 10370 10570 10730 10930 300 h100,000 103.30 104.00 t07.00 10940 11340 11640 11940 12230 12430 12640 12830 131.00 13330 * Fm copper, multiply tablo data by 2.0 ** Mean temperature difference, P ** temperature of steam minus overage liquid temperature For brats# multiply table data by 1.6 5435 6840 11240. 137.00 Heat transfer data for calculating this table obtained from and used by permission of the American Radiator & Standard Sanitary Gorp. Table III. Radiation from heating surface H{tL -- t2|/l in lb of condensate /hr/sq ft used In formulas for obtaining trap loads Air temp, F *>1 -Steam pressure, pslg- 32 5 10 15 20 25 50 75 100 150 200 250 300 350 400 450 500 600- 32 .53 44 47 70 74 78 .81 1.02 1.13 130 146 170 1.86 1.97 2.31, 2.41 2.52 2.62 '3.14 50 .48 .49 42 46 1 .68 .71 74 .67 1.06 1.15 138 142 1 174 1.85 1.96 2.06 2.41- 242 Z7.I 60 .45 .46 49 .53 46 49 71 .84 1.02 1.10 134 147 1.58 1.80 1.91 230 235 246 "sr.85651 .44 .45 47 42 45 48 .69 32 1.00 1.08 1.32 1.45 1.56 177 1.88 1.97 2.07 243 2.62 70 39 40 .45 40 .53 .56 49 .80 0.98 1.06 1.21 143 144 1.75 136 1.95 2.04 239 249 75 38 .39 44 .49 42 45 48 .77 .88 1.05 1.19 140 1.52 1.63 133 1.93 2.02 2.11 246 Valve of beat lou . 24. vied (HJ 23 3.2 * Bated cn still (dr; for fbrced-alr circulation multiply above value, by 5 34 375 4.0 44 5.0 Table IV. Overall coefficients of heat Free con Forced con* transfer. (Under many conditions higher Type af heat exchanger vection, K yWOfl,IC Typical Fluid Typical apparatus or lower values may be realized) liquid la liquid 25- 60 150-300 Water UquId-to-Hqvid beat z**-: setting, correct operation depends on a constant temperature which means constant pressure. An impulse trap is designed for a wide range of liquid to liquid Uqutd to got* liquid to boiling liquid liquid to boiling liquid Oat* to liquid 5- 10 1- 3 20- 60 5- 20 1- 3 20- 50 2- 10 50-150 25- 60 2- 10 Oil Water on ......... exchanged Hot-waler radiators Brine coalers Air cooler*, erenomlzhrs pressure without adjustment or Gas* lo gat 0.6- 2 2- 6 Steam superheaters change of parts. Gas* to balling liquid 1- 3 2- 10 Steam boiler* 2. Amount of air to be handled: Condensing vapor to Bellows, impulse, orifice, metallic and liquid.. -.................... 50-200 150-800 Steam lo water liquid heater* and- con 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. Condensing vapor to liquid.......................... Condensing vapor to liquid., oooooo. 10- 30 40- SO 20- 60 Steam to oil 60-150 Organic vapor to water densers 3. Heat-up time required: H beat- Condensing vapor to up tune is not important, a trap can liquid............... 15-300 Steom.gasrr.lxture 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, Condensing vapor to gas*.f....... Condensing vapor fo . boiling liquid* Condensing vapor to boiling liquid............... 1- 2 40-100 300-000 2- 10 Steam to water SFe.am pipes In air, air heater* SeaJfl.fofmlng evaporator* metallic or liquid expansion, and Condensing vapor to impulse traps are suitable for appli balling liquid................ 50-150 ......... - Steam lo ell cation where continuous condensate discharge handling is desirable. Bel- *At atmospheric pressure WA-TEX 001393 ITEM NO, B-35 TRAINING DETAILS PAGE 188 lows traps (except where flow and temperature are constant) and bucket traps normally have an intermittent discharge. 5. Required discharge tempera ture of condensate: Some traps ban- die 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 ful review of a trap should be made to determine condensate handling capacity at various temperatures be low steam temperature. 6. Back pressure in return system: Increase in back pressure will nor mally decrease discharge capacity and in the case of some trap designs such increase is a limiting factor oh proper application. This detail should be checked with the manufacturer. 7. Available space: Space normally is not a factor, but dimensions such as the length of a metallic expansion trap may be significant. 8. Maximum temperature expected at trap inlet: Bellows traps are not normally recommended for use oii superheat, which plaees significance on maximum temperature to be ex pected at trap inlet. 9. Installation cost: Cost is usually insignificant when compared to the savings a properly applied trap can make. Certain types of traps that arc comparatively large create excessive installation expense. _ 10. Maintenance cost: Simplicity of design, the number of moving parts, whether a trap can be serviced quickly under pressure -- all are fac tors to be considered in maintenance. Once the type of trap has been se lected, condensate load must be cal culated to determine trap sine. Trap catalogs tabulate capacity-pressure relations, and a study of such tables shows that capacity generally does not increase in direct proportion to the pressure differential across the trap. These tables will also show that body and pipe connection size are not true indices of capacity. In the case of the impulse design the manufac turer provides a very simple selector bulletin. Trapsizes can be determined quickly by using this selector without the necessity of first calculating amount of condensate. Load front steam apparatus is expressed in lb per hr of condensate formed. Load char acteristics vary considerably. During start-up load is heavy as air as well as condensate must be removed in large quantities. Condensate is forming at a rapid rate during start-up because all parts of the apparatus and con nected system must be brought up to temperature; and this condition usu ally results in a lower pressure ?.L the trap inlet which reduces trap capacity when load is at Us maximum. When the system reaches operating temperature, condensate forma! ion may be relatively constant, or it may vary considerably depending on the application. To compensate for some of these variables, a factor of safety must be used as a multiplier of calcu lated load to determine the final fig ure to be used as a selection from catalog capacity tables. There are many methods to calcu late load, but generally calculations involve the use of formulas such as those listed below -- each formula designed for a specific type of appli cation -- (1) C = WSX Used for pressure vessels such as retorts, autoclaves, etc., where steam is applied directly to solid materials being healed. (2) C = WX + 970 (W-D)/L Used for dryers, platen presses, etc,, where steam loses its latent heat indirectly to solid material through metallic surfaces. (3) C = AY Used for pipe coils to heat air such as found in unit heaters and chamber dryers where steam loses its latent beat indirectly through a metallic surface. (4) C KAX Used for submerged surface where quantity of liquid heated is unknown. (5) Cl = GWSX Used for submerged surfaces where the quantity of liquid heated is known. Here steam loses its heat through metallic walls of coil or other metal surface submerged in a vessel when liquid is being heated. Cookers, heat exchangers, etc., where steam loses its latent heat indirectly to a liquid through a metallic surface represent the type of equipment involved here. Symbols used C = Condensate lb per unit lime W = Weight of medium being heated in lb S - Specific heat of substance being heated X = (T-t),L (Table I) (T-t) - Temperature rise of sunstance heated in deg F (Sec Table f) L = Latent heat of steam at trap operating pressure in BTU/lb D = Weight of substance heated after drying -- lb A w Heating area -- sq ft Y = Radiation from heating sur face H (t,-lj)/L in lb of condensate,-' hr/sq ft (See Table III) H = Heat los3 expressed-.in Btu/sq- ft/deg F/hr ' '` v ti Steam temperature at trap pres sure---deg F t. = Ambient air temperature--- F K - Coefficient of heat transfer (See Table IV) , G " Gallons of liquid heated per unit limn w Weight of liquid being heated -- lb/galion The formulae and data given above when applied to a specific problem will produce condensate load. The load must then be multiplied by a safety factor before trap capacity tables can be used to size the trap. These factors vary between 2 and 5 and take care of variations in steam pressure, discrepancies between as sumed and actual data (the latter of which is rarely known), unpredictable and abnormal operating conditions, etc. Generally a factor of 2 applies to submerged coils discharging to gravity, and pressure vessels. Dryers, pipe coils in air and sub merged surfaces draining to a trap located above the surface take a fac tor of -'i. Coils over which air is forced usually take a factor of 5. Catalog recommendations should be followed for the type of trap seh eii'd. ft is important to ascertain (be temperature base on which cata log (opacity tables are calculated. Since capacity decreases with rise in condensate temperature, the lower the temperature base, the higher the factor ot safety must be. The relation between condensate handling rapacity at various conden sate. temperatures is shown in Fig. 1. These curves are based on test data for an orifice having an area of one sq in. If the area of a trap orifice is known, these curves can be used to. approximate capacity (at a given , pressure) by multiplying the orifice ' area in sq in. by the rate of flow from the appropriate curve, and then by an appropriate orifice coefficient. Frequently heat exchangers con tain excess surface which results in hinting a quantity of liquid in a time fo.'s than the process calls for) This results in condensate being formed at a more rapid rate than expected. Special care should be taken to (Mlcuis.te the load under these condi tions so that condensate is withdrawn as soon as it is formed to maintain highest efiiciency. In these cases do not use formulae 4 or 5 but multiply I he submerged area by the applicable . factor from Table II to obtain the load. WA-TEX 001394 I ITEM NO. B-35 TRAINING DETAILS PAGE 189 The Why and How of Steam Trappang -' ' '' fCgF/Ek' J- Above. Bask trap hoak~vpr Trouble-shooting- tests fftser; h text 2,` Right. Taking fn and out trap temperatures with contact pyrometer I. Installation -- Moisifrss-ice Trouble Shooting By JOHN W. WELKER* 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 he 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 scries with connecting traps. respect to air flow through them. 2. Cheek flow directional arrows or 15. Be 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 8. Install a Dutch weave mesh densate. Multiply lowest line pressure strainer ahead of each trap. by 2 to determine maximum height. 4. Install test valve ata "T" fitting 16. Install unions .on both sides of ih discharge line to chock operation. a trap to facilitate removal. .5. Install traps at accessible loca 17. Never use piping smaller 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 exa-ssho back 7. Install traps (except thermos pressure. Use Pig. 3 to determine tatic types) as close to equipment as return line size. Enter chart from possible. left at orifice area. Where this hori 8. Install shut-off valves on both zontal line intersects the *'jtcr cent inlet and outlet to enable isolation of rated capacity" line rtrs"' a vertical for maintenance purposes when re line upward to the appropriate bai-k quired. pressure line. From this inunsvetion 9. Trap each coil or each heating draw a horizontal line to the right unit Individually. .to the appropriate "length of pipe" i 10. Where condensate is to be line. Draw a line vertically downward lifted above the trap, install a cheek to determine return line size- For valve between trap and riser, more than one (rap, twk each one 11. Install only self-draining traps through the chart 'and add areas to when they are subject to freezing get over-all pipe size. The "percent conditions. _ of rated capacity" line is determined , 12. Pitch horizontal inlet lines to by dividing 100 per cent by the factor traps to keep them full of condensate of safety used. 19. Install a water seal to prevent steam binding when trap can on|y be installed above lowest point in apparatus. Water seal Bhould 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. 8. Clean or blow-out strainers at frequent intervals. 4. Certain tools are suggested for checking trap performance: (a) Thermometers can be placed in ihormtvwolls before and after traps to check temperatures at these points - indices of performance. in) Pressure gage can be placed at inlet of irap to cheek actual pressure at trap which can in many cases be much lower than boiler pressure. The pressure at the trap inlet (not boiler pressure) determines trap capacity. (c) A portable contact pyrometer is probably the best tool for checking trap performance. Temperatures on inlet ami outlet can be closely esti- *Ertjsfnecr, Ynmall-Wariag Ciornptftiy FEBRUARY/ 19&S POWER ENGINEERING | WA-TEX 001395 ITEM NO. B-35 TRAINING DETAILS PAGE 190 SP mated by use of this instrument in' contact with clean metallic surface. 6. 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. fb) Open valve E. (e) 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 clogged. (f) If nothing discharges at G with pressure at trap, the trap parts may be worn or defective. If a bucket trap is installed, pressure may be too high, orifice may be too large for the ressure or venthole in bucket may e 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 held off seat by dirt. Mechanism may be holding valve off the seat. If a bucket trap is installed there is a possibility that there is no condensate, in the trap body to float the bucket. In this case close inlet valve to appa ratus for a few minutes to reestab lish prime. With an impulse trap, the trap may be too large or back pressure too high. 7. If no "T" is available or trap discharges as shown at "D" in Fig. No. 1, a "phantom" test is available by using a contact pyrometer--an instrument Used for measuring tem peratures of metallic surfaces. By taking a temperature reading on cleaned surfaces at both trap inlet and outlet, trap performance can be analyzed. The inlet temperature should be essentially saturated stearn temperature. The outlet temperature should be lower -- the degree being partly determined by the type of trap. Impulse traps for example dis charge almost continuously very close to steam temperature. On the other hand, bucket traps accumulate con densate which is discharged inter mittently resulting in varying outlet temperature. With any trap if inlet and outlet temperatures are exactly the same, the trap is blowing steam. Fig. 2 shows a contact pyrometer in use. 8. If a trap drains continuously at constant rate, there is a good possi bility that the trap is too smalt, or apparatus being drained, if heating a liquid, is ruptured and liquid is leak ing into the line to the trap. 9. On observing trap discharge do not confuse flash steam with live steam. When the pressure of hot condensate is reduced as it passes through a trap, a certain amount of this condensate flashes into steam at the lower pressure. This is actually a good sign of efficient trap perform ance. Equipment cannot be kept hot with cold condensate. No flash steam indicates such a condition. Most trap3 are Braall inexpensive devices. If they are properly selected,' installed and maintained, they can contribute greatly to overall process efficiency. Much large and expensive equipment can only function effi ciently by proper trapping. Thus trap application assumes a much greater importance than is indicated y the relatively small cost of the trap when overall economy of equip ment operation throughout a plant is considered. . WA-TEX 001396 ITEM NO, B-35 TRAINING DETAILS PAGE 191 You can step up the performance of steam-using equipment by seeing that its traps are working correctly. Here are tips on their care g>-TiUP manufacturers recommend that yon 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 . meat may operate all right, but much steam is wasted. Routine or preventive maintenance is best answer to these conditions, fgpiere'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. I, 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 overhaul 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 valye 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 he expected and learn the difference be tween live- 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, you 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 hacks 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 he properly drained. They should also check the size of the re turn lines when new equipment is added to an old system in your plant. '{II WA-TEX 001397 ITEM NO. B-35 TRAINING DETAILS PAGE 192 Trap hookups for plant jobs--Is Condensate returned to an open flash tank with the return line below the trap. 2s Condensate being returned to the atmosphere or an open sewer. 3: Condensate being returned to an open flash tank -with the condensate 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. 6s Bypass arrangements for single and double traps. A typical sample tag for identifying plant traps is shown below. Too Color to indicateyear BY GLEN CHASE The Yomall-Wueing Company A New trap g Serviced trap O Overhauled trap 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 minutes with new equipment, the operator can turn out 14 batches in a 7-hr day. If the trap loses efficiency to the point where a batch takes five minutes longer, there is a lias of two batches per day. When a number of kettles suffer from this trouble, the loss in yearly production can be tremendous. And it all traces to trap efficiency. Best time to find expected efficiency 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, valve E, 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 to 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 be 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 be 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 5 Month oN/iS or O so Steam pressure ot trap 33! Steam temperature of 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. Starting 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 stiff 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) i WA-TEX 001398 ITEM NO, B~35 TRAINING DETAILS PAGE 193 to bring the trap back to top perform* once. Each trap should be given On 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 band. Check old bellows on the t'fest stand. Accessories. While checking trap efficiency, it is good practice to look oyer the installation to see if any of the following accessories are needed. Dirt leg, at A, Fig. 5, is easily in stalled using a tee and capped nipple. It will catch most of the sediment form ing in the steam line and the equip ment cavities. Clean the leg when trap is serviced. Air vent on the equipment trapped often gives-better operation, steps up output. In Fig, 5 the area lo3t to heat transfer when a vent is not used equals the product of D.and the inside circum ference of the kettle. Using the air vent greatly reduces the cooking time, Vacuum breakers are used where temperature-control or motorized con trol valves are employed. In Fig. 5 the control valve closes after the procest 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. Chock valves ore important, prevent- 'ing the discharge from one trap backing up into that of another. When conden sate from a trap most be lifted, a check valve should also be-used, as in Fig. 3. While manufacturers recommend indi. vidual trapping of equipment for most units, check valves should be selected where individual trapping is not pos sible or group trapping must be used Install a check valve in the discharge line from each section of the steam-con densing equipment, ahead of the trap. Fig. 6 shows the standard bypass ar rangement. While the original idea of the bypass is good, too often an opera tor bypasses the trap, thinking he con increase production. If the safety factor for the trap is too low to allow the trap to itandie.the start-up load, the bypass 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 tions the trap can be bypassed by using the strainer biowofi. This acts as a sig nal, too, indicating the trap is out of service. If a trap cannot be spared while being serviced, it is advisable to use the double-trap bypass, Fig. 6, The additional trap often pays for itself in a few days, compared to standard by passing. Waste heat can be recovered from flash steam by a heat exchanger. The heat can be used to raise the tempera ture of boiler-feed water, hot-water heater feed, or any other preheat serv ice. Recovering this heat improves plant efficiency. Routine maintenance of traps can save money. Why not set up your pro gram today? POWER FEBRUARY 1556 WA-TEX 001399 I ITEM NO. B-35 TRAINING DETAILS PAGE 194 OPERATION OP THE ARMSTRONG iMWERTEB BUCKET STEAM TRAP Flg.2-l"Bucket full of conden sate--trap dis charging Fig. 2-2."Bucket full of steam- trap closed Fig. 2-3. A sort of Inverted bucket Fig. 2-4. The educated staln- less steel tomato can VE| S.S. SHELL AND . CAP C. WEIGHT HOOK AT END Fig. 2-5. 24 OZ. bucket In air Fig. 2-6. Wt. reduced to 21 oz. when full and submerged Fig. 2-8. Bucket Is a float In the Armstrong Steam Trap an inverted submerged bucket opens and doses the discharge valve. More is involved than the overly simplified statements, "When the bucket is full of condensate it sinks and opens the valve" and "when the bucket is filled with steam, it floats and closes the valve." These half-truths do not do justice to inverted bucket trap operation. Let's do a little homework to see what really goes or. in an inverted bucket trap. What small b&y has not thiown an empty tomato can in the pom! and ob served that the can will float upside down because air is trapped in the cant And if he was a good shot with a BB gun a puncture near the end nf the can let out the air and the can sank in the bottom. The inverted bucket in an Armstrong Trap is an engineered stainless steel tomato can. When the Irap is operating, the "can" is completely submerged in condensate. Under certain conditions the "can" is a float that will rlxe to dost: the trap valve. Other conditions make it a weight to sink and open the valve. The Bucket is a Weight, is Neutral, is a Float A No. 814 bucket, for example, weighs 24 ounces in air. When completely full oF and submerged in cold water the bucket hook, shell and east iron weight displace 3 oz. of wnirr. fin tin: hiickci then weighs 21 oz. This is I he maximum pull that the bucket can exert on the No, 814 trap lever. Now if we introduce enough gas. air or steam into the inside f the bucket to displace 21 oz. of water, the buoyancy of tho gas, 21 oz.. will (Wacllv balance the submerged weight of die bucket, 21 oz. The bucket has noi'llu-c weight to pull down nor bunyaiu-v to lift lip. The lifjuid level inside the. hue! ft is at the neutral line. Displacing more liquid with cis caust s the liquid level to drop In low the neutral line. The buoyancy u! the gas will ex ceed 21 oz., so the bucket will rise and lift the valve to its sv.it. Thus our engineered stainless steel tomato can is n weight, is neutral, or is a float. Hooked on to the valve lever in an assembled trap the inverted sub merged bucket will t !)-.( the valve or open the valve dvpending on the water level inside of the Iniekri. How the Bucket Controls the Trap Valve In the 0-15 psi No. SI4 trap the maxi mum opening or test pivssnre 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. 21 to 22 lbs., if the bucket were com-_ pletoly filled with water. There would be no margin of safety for higher steam pressures or for orifice enlargement due to normal wear. To insure long service life, the trap is offered for n maximum working pressure differential of only 15 pounds. Similar safety margins are provalcd in nli sizes and pressures of Armxlrniig Traps. Obviously at 15 pounds working pres sure differential the full weight of the bucket is not required fo open the valve. Instead of the 21 oz. weight to open at 21 psig only a 15 oz, weight is required for 15 psig. Fig. 3-1 shows the water level-; in a No. 814 bucket required to upon itjo valve nt pressures from 15 psi clown to only 1 psi. Operating drawings 1 through 4 show the operating cycle at 15 psi or maximum pressure differential. With n condensate load proportionate to trap capacity the operation will be intermittent. But us the steam pressure is reduced to' the 0-2 psi range (as with a temperature control ! I WA-TEX 001400 ITEM NO. B-35 TRAINING DETAILS PAGE 195 2. When steam reaches trap It collects at top ol 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. But the valve does not open until the condensate level rises to the opening line for the existing pressure diflerentlal between the steam and the condensate return header. (See Fig. 3-3) 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. NOTE: While the drawings above depict side inlet, side outlet traps, operation of bottom inlet, top outlet traps Is identical. * E:riu.1 -*'* * " .VfMftt'i'I K ' -S t n'T'-f*"' v * v' **! 'tt ' * valve) the trap operation changes char acter--it usually discharges continuously. Continuous Discharge from Inverted Bucket Traps at Low Pressure The terms "continuous discharge" and "Inverted Bucket Trap" will seem con tradictory to many trap users. But an inverted bucket tr.ip will discharge con tinuously at very low pressures or with very high back pressure. Observation of a glass bodied/glass 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 the 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 jo 1 safely factor for .25 psi operation tin's size would be selected to handle 466 pounds or 7456 oz, of condensate per hour. This is slightly more than two ounces per second. Fig. 3-1. Liquid levels In bucket for opening a %" orifice No. 214 or No. 614 trap at working pressures Indicated. 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 n second. The inertia of the bucket submerged in con densate prevents this rapid operation. So the bucket merely positions the valve to give the 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 veiy low pressure differ, entails. 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 close and will not blow steam duo to the high hack pressure. i WA-TEX 0014OX - ITEM NO; B-35 . TRAINING DETAILS' ' ' * l ' PAGE 106.' " ' B ARMSTRONG CAST IRON TRAPS FOR GENERAL SERVICEW DESIGN AND CONSTRUCTION The Armstrong inverted submerged bucket steam trap is a mechanical trap that operates on the big difference in density between steam and water. Steam entering the inverted Submerged bucket causes the bucket to float ana close 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 1811. In today's Armstrong traps this proven principle has been the 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. "Frictionle33" Free-floating , Valve Mechanism The heart of the Armstrong Steam Trap is its unique leverage system that multt^P|| plies the force provided by the bucket to *32? 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 capacity. 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 Farts . . 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 10o0F, 2500 psig. Valve and seat are chrome steel hardened, ground and lapped. AH other working parts are wear and corrosion-resistant stainless steel. Simplicity Only two moving parts, the valve lever assembly and thebucket. No fixed pivots, no complicated linkages, nothing to stick, bind or dog. 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 line. In the ride 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 teste with traps discharg ing condensate as dose as- possible to steam temperatureunder 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 Tup. It makes possible high capacity in a small trap and longlife with infrequent maintenance. A unique two phase leverage system is used in Nos. 213-813 and larger cast traps, and in the No, 312 and larger forged traps. Here's how it works: Hi Fig. 4-2. Valve in closed positlon.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 Fig. 4-4. Afterthevalve is. - the trap the bucket begins to well open, lower leverage' sink and pulls down onthe valve. fulcrum "B" takes over, High leverage fulcrum "A" bears ' allowing the valve to against the face of the valve travel further away from . - seat to give the power required' the:orlfice, tolnsure mini-'' .. to open the largest practical 'mum restriction- to con valve against pressure. . densate flow, ` . F* itfiKii\jUtJS tot Cl. wotflfij'fa1 i"(Srt....,vj : * -n\~ `hVs..-1 "iTvtrxz&rrnnr` ~ i ' * ' OPTIONAL CONSTRUCTIONS . 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 in trap 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 coupling at the top (Fig. 4-7). This simplifies in stallation and saves time and money. Fig. 4-5. Left-- Armstrong stain less steel Internal check valve. Fig. 4-7.Internal check valve In stalled In top of trap Inlet tube. Fig. 4-8, Trap bucket equipped with bi metal controlled thermic vent WA-TEX 001402 I ITEM NO. B-35 TRAINING DETAILS PAGE 197 Here's how Armstrong Inverted Bucket Steam Traps deliver everything you should get in trap Fig. 5-1, 200 Series bottom inlet, top outlet Armstrong Trap. 1. No Steam Waste Discharge valve 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 Posting valve mecha nism Is "frfctionless." 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. COi Venting at Steam Temperature Fixed vent passes C02 immediately--there is no cooling lag that would permit COs to go into solution and form corrosive carbonic acid. 6. Operating Against Back Pressure Slnco 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. M Fig. 5-2.800 Series side Inlet-side out let Armstrong Trap. Equivalent sizes of 200 Series and 800 Series traps have identical mechanisms. * st*rt3Jtn xx?rrzm,',A iuvttuxs!Uin'ter**uiLi&r>2rsi}irz^: 3R SPECIAL REQUIREMENTS f.n'Cr 1 r c.'--rre hi?v *,}*, - eating When Steam Is Turned On How the Thermic Vent Bucket Works 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 SO to 100 times faster than n 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. Fig. 5-3. KEY: Steam [ '[ AitEUi Where to Use: Single pipe coils; small ^Condensate on-and-off unit heaters; on-and-off mul tiple coils; drip points (particularly at ds of steam distribution mains); wher- er air will pocket and be discharged ahead of incoming steam. Operation of the thermic bucket trap is described at the right. 1. Thtp cool. Air cannot collect at the top of the bucket because the large vent is wide open. The bucket stays down and holds the trap 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 top 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 3 & 3. j WA-TEX 001403 ; ITEM NO. B-35 TRAINING UKTAiiij ARMSTRONG CAST IRON INVERTED BUCKET TRAPS f Wi'"'1*^ r?"" r-- ** - ` A i*>T * "-Wibw* - -*'1 w for pressures to 250 pssg... GENERAL SERVICE capacities to 20,000 lbs}hr Table A -6, CAPACITIES, ARMSTRONG CAST IRON TRAPS Capacities given are continuous discharge cqpadties in pounds of condensate per hour at pressure differential indicated. Data based on repeated tests under oporating conditions with condensate as close as possible to steam temperature. Trap No. 800 880 801 811 881 m 812 882 212 813 883 213 S 450 830 1600 2900 - 10 550 950 1900 3500 15 640 1060 2100 3900 0 630 880 1890 3500 25 460 950 1900 3800 30 500 1000 2050 4000 a 40 1<f s5o0 550 580 '635 770 1700 840. . 1900 900 2006 3800 4100 4400 8 70- 80 850 2200 ' 3800 i '80 690 800 1650 4000 100 640 860 1800 3500 125 680 950 2000 3300 150 570 810 .1500 3500 200 850 1600 3200 250 -- ' 760 1300 3500 8l< 314 4800 5800 6500 6000 6500 6800 5809 6300 6800 6000 6400 6200 6700 5700 5300 5700 215 7600 9000 10000 8500 9200 9800 8309 9000 9500 9200 9700' 10400 10900 9500 920.0 7000 216 14600 17300 19200 18500 20000 18000 2(8100 18200 19800 18300 ' 19000. 18000 zaooo 18500 17500 19960 Table B-6. LIST OF MATERIALS, ARMSTRONG CAST IRON TRAPS Name of Part Material Cap and Body 30,000 lbs. Min. Tensile Cast Iron inletTube* Alloy Steel Pipe Gasket Compressed Asbestos Soil and Nut Set No. 800, 801, 880, 8H, 881,. traps. 90,000 lb. tensile strength capscrews. All other cast body traps 80,000 'lb. min. tensile machine bolts. Valve Seat Heat Treated Chrome Steel Valve Heat Treated Chrome Steel Valve Detainer 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 Stainless Steel internal Strainer Stainless Steel Bushing Steel Strainer Bushing Gasket Stainless Asbestos *A7r standardin N/k. 800,880mid 801 traps Optional Accessories Jtaitteerinal Check Valves are spring loaded less steel and screw directly into the inlet or into an extended inlet tube e coupling at the top to save or 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, 801 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 stillation 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, Ho. 801 trap. Table D-6. SERVICE PRESSURE RATINGS--ARMSTRONG CAST IRON TRAPS Trap 450'F 800,880,801 150 psl 8U-8U 250 psi 881-883 211-216 250 psi No. 800 NO, 814 Fig. 6-3. Side inlet, side outlet traps. Cap and mechanism can be removed without disturbing pipe connections. No.'880 No. 883 Fig. 6-4. Side Inlet, side outlBt traps with integral strainers. This type costs less than standard trap plus standard strainer. Saves fittings. , No.'211 No. 216 Fig. 6-6. Bottom Inlet, top outlet traps. Cap and mechanism can be removed without taking body from the line. All dimensions are approximate. WA-TEX 001404 ITEM NO. B-35 TRAINING DETAILS PAGE 199 Table A-7, SIDE INLET, SIDE OUTLET CAST IRON TRAPS Add suffix "CV" fo Trap No, for infernal check valve, "T" for thermic vent buckeL Trap No. a* 811 812 813 814 Pice Connections Available "A" (Flange Diameter) "B" (Height) "C" (Face-to-Face) "D" (Bottom to C/L Inlet) ,lT"(Bddy Wall Thickness) Number of Bolts Diameter of Bolts Weight . Maximum Design Pressure, psi 54'0rM* H'orU" 'A'trVs- 34'Orl' I'or IN* Wi-.... 3)4' 5)4' r 8' SW m n3/,' ' 13)4* 5' 5' 6)4' ~wr 9' 2VT W VAT 7%' 5Sj' W 54' w W 66 G68 >A` W ' 'A` W dibs. 6 lbs. is lbs: 271bs. 45 tbs. **250 250 250 250 250 "Can NOT be furnished with both thermic cent 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 infernal check valve, "T" for thermic vent bucket. Trap Nd, 880* 881 882 Pipe Connections Available Strainer Slow-Down Connections "A" (Flange Diameter) "B" (Height) "C" (Face-to-Face) .... '^D'1 (Bottom to C/L Inlet) "T"(Body Wall Thickness) Number of Bolts Diameter of Bolts Weight Maximum Design Pressure, psi 'A"or yt` W 3H' 5'Ms' " 5' 3Ms' SAT ' 5' V 5)4 lbs. **250 Vi'or Vk" V 3%* I'As" 5' W %' 614* 6lbb. 250 'A'or J/* )4' 55F 95/a' 6)4' 5)4' 54* 6 .16 lbs. 250 883 WM'ortM' S4' V 12)4' m" VA` w 6 Vt\. 30 lbs. 250 Can NOT be furnished with both thermic vent bucket and check valve. Fig. 7-2, Dimensions, No. 880-883 traps. "Maximum operating pressure: 150 psi 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. 211 212 213 214 21$ Pipe Connections Avail. VT 'AWT W,VT,V 1M1/.' l'.M'.lH- "A'1 Flange Diameter W' Wt' WT 1VT 8*/r' "B" Height 6W 8* 10M'. \wt 14m.' rT' Body Wall Thickness W '/<' W VT 46' Number of Bolts 686 84 Diameter of Bolls Ms" Ms' VT Is )4' Weight 6 lbs. 12 lbs. 21 lbs. 35 lbs. 47 lbs. Maximum Pressure, psi 250 250 250 250 250 m IVT.l10Mi' 17' Ms' 1 ir S4' 78 ibs. 250 7-3. Dimensions, No. 211-2X6 traps. Use certified print for exact dimensions. . ii WA-TEX 001405 ITEM NO, B-35 TRAINING DETAILS PAGE 200 ARMSTRONG CAST 8RON TRAPS FOR LOW PRESSURE SERVICE- ....... liiWKinvH'JUmrrTBWue.ttm^ iWT^\ Ml m mi * For pressures to 30 psig,.. PHYSICAL DATA capacities to 6,800 ibs/hr Aimstrong traps for low pressure service have been developed especially for drain 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-op ana 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 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 based on repeated tests under opcrating conditions with condensate as close as possible to steam temperature. Trat> No. Orifice Size 54(7} Yil14) tas*. % (21) Si I'ge SSI !!= 1-5 a s r S M 16 zo 26 30 860T 54' 134. 65 200 100 240 125 270 146 340 195 330 230 425 250 450 27S 560 350 640 400 630 440 460 500 861T 54* W 131 139 300 220 395 280 450 320 590 425 630 490 750 540 830. 680 950 700 1060 780 m 940 lQOfl. 862T mr S6iT ftfi" W W 54" Vi* 350 191 950 535 1400 '950 580 389 1410 850 2160 1500 740 500 1618 1040 2600 1900 860 600 1880 1200 2800 2160 1140 820 2300 1600 3700 2800 1320 960 - 2600 1850 . 4160 3260 1480 1070 2780 2060 4500 3600 1600 1170 2600 2233 4600 3900 1900 1470 3500 2800 5800 4800 2100 1690 3900 3200 $500 6400 mo 3500 6300 1900 3800 6500 2050 4000 6800 Table 8-8. LIST OF MATERIALS . Name of pert Material Cap and Body 30,000 lbs. Min. Tensile Cast' Iron Inlet Tube* Alloy Steel Pipe Gasket Compressed Asbestos J3oil and Nut Set . No. 860T and 861T trips, 30,000 lb. tensile strength cap screws. All other cast body traps 80,000 lb. min. tensile machine bolts. Valve Seat Heat Treated Chrome Steel Valve Heat Treated ChromeSteel Valve Retainer Stainless Steel Lever 1 Stainless Steel GiudaPin Assembly Stainless Steel Stainless Steel, No. 863T and larger buckets have cast iron weights. thermic Vent Corrosion resistant "Dura- Bucket bi-metal flex" Body Thimble Stainless Steel + lnti>jflMi raised inlet end 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, S60T. Fig. 8-3. No. 860 Series O.F.&T. trap with internal check valve. Fig. 8.2. Openfloatand 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 these 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 ship 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.E&T. traps "fail open," n remote possi bility but an important safety feature. WA-TEX 001406 ITEM NO, B-35 TRAINING DETAILS PAGE 201. Fig. 9-1. Dimensions, No. 860T-864T. Table A-9. CAST IRON OPEN FlOAT AND THERMOSTATIC TRAPS Add suffix "CV" lo Trap No. for internal chock valve. Trap No. Pipe Connections '`A" Flange Diameter ` "C" Face-to-face "D^Bottom to C/Linlet `V' Body Wall Thickness No.Bolts . Diameter Bolls ' Weight, lbs. Maximum Design Pressure, psi Maximum Operating Pressure, psi 8B0rr m* ow 5' vw W "8 M* 1----250 30 861T I* 314 6* M* ` 514* ' 4* Mi* 0 'A" 6` 250 30 862T lid' 5M* W 04*' W >?4* 6 * 15 250 30 883T i>/r "llii* ' 8* mw 6 54* 28 250 " 30 ' 864T 2* 8* 13j/* 9Vi* TW 54* 8 `/i* 47 250 30 All dimensions are approximate. Use certified print for exact dimensions. I WA-TEX 001407 ITEM NO. B-35 TRAINING DETAILS PAGE dV'C Fig. U-l. No. 3X2-416 screwed connections. Fig. 11-2. No. 312-416 socket weld connections. Ffg. Zl-3. No. 312F-416F flanged connections. Fig. 11-4.No.5133F. No.5155Fand No.6155F with welded outletflange and Integral Inletflange. No. 5133F is shown, others similar. .Ttfi.* 'i-,'r.^ri* Table A-ll. SOCKET WELD DIMENSIONS Pipe Size S2 S-4 Min. Vi' .855 K' 1.065 14" l* 1.330 Vi IK' 1.675 K' ~W 1.915 w 2' 2.406 w 2.906 w r 3.535 %' Table B-ll. FLANGE DIMENSIONS Pipe Size F-l F-2 F-3 P Pipe Size F-l F-2 F-3 P *VdJ si s Vi' 354' 2*4' l'/s' rr 4V4' 4?4" 3K" 314" 1%' 2* W V %* 3. IK" rIK* 5VS' 614' 614" 3Tb' 414' 5" 2IV14,'' 354" w K" 1" 8N 14' 4K' 3K" 1%' 7/s" K" 514" 314" 1W I* V b'/e' 4* 2' 114" IivKr" 614" 7" 414' 4K" 214' Vk' 114" IK' 2' 814" 614' 354' 114" 1to3 Vt" K* V 414" 5V4' 5'y 3K" 314' 4' B4* 21`%" V%' 114' 1VS* 2ik' * 6rK' 814' W 4'4' $14" 214' 254' 354' 114' IK' 114' -- M4 14' 5K' 314' ik- t>/' V 5K' 3VS' L%" IK' 1' 6K' 4K' 2* LK" IK" r114' 87'K' 9K" 5K' 514' 614' 214" 2Tb" 344" I'/z' 2IK" ' F-4 same as ID. of pipe size used. Trap Ho. SCREWED orSW 310 Trap No. FLANGED 310F Pipe Connections Avail. K".K* "A" flange Diameter W "B" Height Screwed or S.W. "BB" Height Flanged 11" 6 "0" Body O.D. "K"C/outlet to C/inlet "T" Body Wall Thickness Number of Bolts w K" 6 Diameter of Bolts' Diameter ol Bolt'circle W 314" Weight Scr. or S.W. " 10 lbs- Weight Flanged 12 lbs. Table C-l 1. PHYSICAL DATA, FORGED STEEL TRAPS Add suffix "CV" to Trap No. for internal check valve. 312 313 314 315 .316 413 415 . 312F 313F 3MF 315F 3I6F 413F 415F !4".K" 6K" iQKi." 10Kb" W IK" Kb" 6 K" 554" 30 lbs. 31 lbs. K".K".t" 8" UK" 1114" 514* 1Kb" Kb" 8 54" 654" 47 lbs. 49 lbs. 1".1K" 854" 1354" 1451b" 5K" 114" 14" 8 54" 7K" 75 lbs. 78 ibs. I'.I'/bMV^ 'IK",2" K".K",1" 1MKMK" 9K" 1114" "~W 10K" 15" 1714" 104" 15" 15" 1754" 13" 16K" 654" 854* 514' 614" IK" 214" ttv 154" W 'Kb* W 'Kb* 9 10 8 9 54* W 54* 1* 8" 10" 714" 8K* 90 Ibs. 160 Ibs. 65 Ibs. 122 Ibs. 95 Ibs. 163 ibs. 73 Ibs. 136 Ibs. t416 5133 5155 6155 t416F 5133P saw 615SF IK",2* KV/bM" 1MK" 1244" 8K" 1054* UK" 1754" 1454- i6K" 24K" 1914* 16K" 20" 28K" 854" 7* 7W 2K" 1Kb" IK* IK" W 54" K" 1" 12 8 10 10 1" W Studs 1" Studs I>/i"Studi 10K" 654" 8K" 954* 195 ibs. 98 Ibs. 191 Ibs. 29516s. 200 ibs. lOSibs. 208 Ibs. 306 Ibs. fFabricated trap. Ail dimensions are approximate. Use certified print for exact dimensions. j WA-TEX 001408 i.  ITEM NO. B-35 TRAINING DETAILS ARMSTRONG OGCTBLE IRON TRAPS JIFpressures to 400 pssg... capacities to 1060 lbsfhr PAGE 203 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 die Nos. 811, 211 and 881 for pressures of 250 psi or Jess. 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 650K . Table A-12. PHYSICAL DATA - DUCTILE IRON TRAPS Trap No. 701 711 Pipe Connections Available Bolting: 6--'A* Weight s 80 * a 125 3 a 200 3 250 5 | 300 " 400 K'.W Carbon stool Cprbon Stool 120,000 T.S. 120,000 T.S. 7 lbs. 7 tbs. 81 0 950 60 760 510 590 Fig. 12-1. Dimensions, No. 711 . with horizontal straight through connections. M, Fig. 12-2. Dimensions, No. 701 with right angle connections. All dimensions Use certified print are approximate, for exact dimensions. MSTRONG CAST STEEL TRAP WITH INTEGRAL STRAINER for pressures to 600 psi saturated steam, ,,. capacities to 4400 lbsfhr 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 B-12. PHYSICAL DATA-NO, 983 CAST STEEL TRAP Fig. 12-3. No. 933 trap with screwed connections. Fig. 12-4. Dimensions, No. 983 trap. Dotted lines show flanges welded to body. Trap No. Pipe Connections Available "C" Face-to-face (flanged) Vi pipe she pipe size l" pips sire Shipping Wt. (Screwed Conn,) SB3 'A", Vi". 1' 1154' 11%' "1ST" 45 lbs. Also available with American Standard raised face or flat 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. I WA-TEX 001409 ITEM NO. S-35 TRAINING DETAILS PAGE 20k TRAPS POE DRAINING WATER PROM COMPRESSED AIR .................................................... . -..... ..................................... * *" *" * pressures to 1000 psig Armstrong compressed air traps are used Water Only Service Operation. The discharge from the No. 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 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 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 git or fine scale to lodge between the valve and seat of the No. 21 and thereby prevent clos Use Armstrong No. 213 BVSW Inverted ers answer large capacity requirements ing when the load decreases. To answer Bucket Air TVaps because the valve is at. for positive automatic drainage at pres this not uncommon problem, Armstrong the top. Gil is discharged first and the sures to 250 psi. Available in forged offers the Snap Action No. 71 Trap. 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 neavy 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 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. No. 71 Snap Action Trap. In this design energy is stored in a flat stainless steel spring that replaces the conventional float lever. 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 lbs/hr. bucket vent cannot condense. Instead it High Pressure Service. The No. 21-312, High Pressure Service. The No, 71-315 is discharged intermittently ahead of oil a forged steel version of the No. 21, but is a forged steel trap with the No. 71 and water. The yolume of air vented is with a larger float, is good for pressures snap action mechanism that operates at sabout 10 sefh. to 750 psi. pressures as high as 1000 psig. DETAILED INFORMATION ON LIQUID DRAINERS IS GIVEN IN BULLETIN NO. 401, AVAILABLE ON REQUEST INLET Fig. 14-1. 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-24. PHYSICAL DATA ARMSTRONG COMPRESSED AIR TRAPS . In ordering, specify trap number andmaximum operating pressure and slate "for water discharge." Inverted Bucket Model Number 213 BVSW Pipe Connections, in. ft.ft.l "A" Diameter, in. "B" Height, In. m 1054 weight, lbs. Zl Max. Pressure, psi@IOOF 250 far3 1 ICO C*of)d. wInaItdesr. of g 2c5m0 per Hour | jTM 9100 6000 5000 Guided free Floating Lever Drainers Cast Iron (ASTIW A-27B Class 30) Forged 1030 Carbon Steel 1-LD 2-LD 3-LD 6-LD 32-LD 33-LD 36-LD `At ft, ft n.i 1ft, 2 ft, ft ft.l 1ft. 2 3ft m I05/is 6ft 8 lift m8 10ft 17 iOMs lifts 17ft 4 13 Z2 80 31 49 163 250 250 250 250 500 SOD 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 ft, ft ft.l ft. ft ft, 1, lft" 6ft 8ft 6M 9ft 5ft 10ft lOfts 1554 8 29 30 92 So 25D 750 1000 1900 (ftsT 2500 800 (HO* 1630 550 mb* 1150 980 (Ms")* P* (Ms)*' (Ms')* *Pot optimum spring life snap action traps should not be used where load exceeds 120 pounds per hour. tft" outlet Connection All dimensions are approximate. Use certified print for exact dimensions. I WA-TEX 001410 ITEM NO, B-35 TRAINING DETAILS PAGE 205 M:nts for discharging air from liquids for pressures to 1000 psig Armstrong float type air vents are de signed to vent air from hydronic heating systems, water sendee lines, water storage . panics, centrifugal pumps, gasoline lines, ' - solvent filters, etc. Operation is com ' pletely automatic. Simple design and ' " ie-free and maintenance infrequent. , - A variety ofsizes and designs are avail able to meet service requirements: No. l-AV Automatic Air Vent is a com - pact vent designed and built for positive action and die 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 %" drilled and ' tapped test petcock connection in the cap, with or without petcock. Nos. 2-AV, 3-AV, and 6-AV Automatic Air Vents are ` cast iron, free-floating rfgfever vents for larger capacity rcquivcSpents 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 30-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.2J.-AR Automatic Air Vent is the deluxe vent that is widely used in critical services. The valve seat is flitted 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. 21-812-AR. More Detailed Information: Bulletin No. 451, Venting any gas from any liquid. Bulletin No. 454, No. l-AV Vent Hook-Ups of Air Vents KEY: . [gj Water Air Flg.15-1. After float closes valve,capac ity of vent is lim ited 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. m Fig, 15-3. No. l-AV cast iron vent. Fig. 15-4. Nos. 2AV, 3-AV, & 6-AV cast iron vents. Fig. 15-5. Nos. 32AV, 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." Riedel Number .pipe Connections, in. "A" blameter, in. Height,Tm Weight lbs. i Max. Pressure, psi 100F. SCFMot pressure shown, with traps "5. Jjj 40 back-vented, as iS 250 s1h.0o0wsnpIn.gFr.tgli.q1u5i-d2. EH jTMBinJ Guided Free Floating Lever Vents . Cast iron (ASTM A-278 Class 30) Forged 103Q Carbon Steal . l-AV 2-AV 3-AV 6-AV 3Z-AV 33-AV 36-AV /t, a* 3J4 #,*/ 5!4 5/<.i' m 1$, 2 lO'/js Vt,Vt 6)4 d 8 m.z na 514 8 10H 17 10M U%s 1755 3y, 160 4.3 8.0 . (150) 24 13 250 27 32 39 22 80 3i 49 163 260 250 550 son 1080 70 315 27 70 ' STS 72 289 50 72 289 88 352 61 88 352 (550)64 91 460 (900) 104 460 *&' outlet connection. All dimensions Eire approximate. Use certified print for exact dimensions. fixed Lever Vents Cast Iran Forged Steel 21 AR 21-312 AR iW~ !"5T ' 614 6!4 5V4 1054$ 8 30 '250 680 13 8 9 13 12 11 23 WA-TEX 001411 ITEM MO. B-35 TRAINING DETAILS PAGE 206 STEAM A T WORK, ,,. how the heat ofsteam is utilized jtwi^TgMiiMLWynfaytfpgAaiWlgTOtt1*? F?rt'V''t2VSSi)Sn*nrnV*Y-~eT Jit 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 boiler pushes steam out of the boiler into the distribution system, the steam in the pipes will be at a nigher 100 psig 337.9F temperature than the surrounding air. Heat then flows from the steam through the walls of the pipe to the air. This loss 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. Hero the transfer of heat from the steam to the air passing through an air heater, to the water in a water neater or to the food in it cookingkettle is highly desirable. Noth ing should interfere with this heat transfer. I Condensate Vapor 50.3 psig 297.97? PRV \) CONDENSATE DRABNAGE... why it is necessary tu j'iiw/ir*T>>r::s wx v>*r- Biutiisx&i<srgtt*" Condensate is the by-product of a steam system used to distribute and transfer heat. Condensate forms in the distribil- .. 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 he 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 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 CO* 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 boiler 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 --,ji'r-'c-sa The Need for Draining ' the Heat Transfer Unit i 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 stenm. See Fig. 20-2. Water Hammer. Hot steam in contact with condensate that has cooled below Fig. 20-3. Condensate allowed to collect in pipes or tubes is biown into waves by steam passing overlt 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. Table A-20. TEMPERATURE REDUCTION CAUSED BY AIR Pressure Temp. Df Temp, el Steam nixed with <psig Steam, No Various! 'ercentagesof Air AirPresent >y Volume) 1055 zo% 3055 T205..33 5750..33 100.3 ~240l 332232698078....1330 332221393620141.....93030 228.0 232805344..,815 321.8 224260..49 322179255...149 I\ WA-TEX 001412 ITEM NO. B"35 TRAINING DETAILS HOW TO WAP STEAM MAMS PAGE ^^electton of trap sizes to drain steam Spains depends on. the warm-up method that will bo used--Supervised or Automatfc. 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 takes no chances With such mains. , The "drip valves for free bbw to the ' atmosphere" as called for by die 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, tire 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 Tt-ap 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. Remember, 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: Table A-26. THE'WARMING-UP LOAD, Schedule 40 Pipe. Steam Pressure, psig 2 15 3D 60 | 125 180 Pipe Size Wt. of Pipe Per Ft Mbs.) ' 1.69 .030 iy* 2.27 .040 .2,72' - ,048 2 ', 3.65 .065 1 2!4' 5.79 ..104 3' 7.57 .133 - 3 , - 9.11 .162 4' 10.79 ' .190 5' 14.62 "fit,' - - 18.97 =-1* 28.55 .258 .335 .504 '10' 40.48 .714 \2r . 63.6. .945 14' - 63. 1.11 16' ' 83, ` 1,46 IS' 105. ' 1.85 20' :- 123. . 2,17 24* 171; 3.02 .037.050 ,059 .080 .126 .165 .198 .234 .352 .413 .620 1 .83 1.17 1.37 1.81 2.28 2.68 . 3.72 - pounds of Water Per Unoal Foot .043 .051 .057 .068 .069 ' JJ82 .092 .110 .146 .174 . .190 527 .229 . 573 .271 .323 .406 .439 .476 .569 .720 ,860 1.02 151 1.35 1.61 1.58 1.89 2.08 2.49 2.63 3.15 3.08 - 3.69 ' 459 5.13 .083 .085 .101 .136 515 582 .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 1.190 1.69 254 2.64 3.47 4.40 5.1b 7.15 250 .079 .106 ,127 .171 .271 ,354 .426 .505 .684 .882 1.340 1.89 2.51 2.94 3.88 4.90 5.75 8.00 Table C-26. ORIFICE CAPACITIES AT LOW PRESSURES. Use only for sizing Table B-26. PIPE WEIGHTS PER FOOT In pounds. .ft: Schedule .. 40 Schedule 80 V 1.69 - 2.17 1>4* 2,27- 3.00 W 2.72 3.63 2' " 3.65 5.02 214' ; 6.79 7.69 3*- - 7-57 -.1055 3V4' 9.11. 12,51 4' \ 10,79-' 1458 S'. .14.62" ~ 20.78 6' 18.97' - 28.57 8'- 28.55 43.39 10' 40.48 54.74 J2' 53.6 . 88.6 14' 63 .. 107. m. 83. - 137. T18' 105. 171. | 20' 123.. 209. . 24' 171. 297. Schedule 160 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. XX Strong 3.66 551 6.41 903 13.69 18.58 22.85 27.54 38,55 53.16 72.42 Pressure psig. Orifice %' No. 38 Vs" ' 7M" 4' ' W r ` : %' %' H' W Vir YtT 1M/ .5 1.0 2.0 Pounds per hour - 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 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. Be sure orifice selected toffi open at the maximum working pressure. . Fig. 26-1. Trap draining drip leg at riser. Distance **H" in Inches -i- 28 = psi static head for forcing water through trap. Fig. 26-2. Trap draining strainer ahead of P.R.V. "H" In inc hes 28=psi for operat ing trap during automatic warm-up. Fig. 26-3. Forged steel trap draining drip. leg on main under supervised warm-up. WA-TEX 001413 ITEM NO. B-35 TRAINING DETAILS PAGE 208 1. Rrovide 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 Wanning 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 load can be calculated using the following formula: W X (tj -ta) X .1X4 C= C = Amount of condensate W = Total weight of pipe (See -Table B-26 for pipe weights) . t4 == Final temperature of pipe t2 1=5 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 psfg to get pounds per minute, Mul tiply by 60 to get pounds per hour. Step 3. Pressure differential for trap siz ing, will bo 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 ana select trap size from the chart on page 26. Example: "Automatic" warm-up load is 7SO lbs/hr at warm-up pressure of 1 psig. Final pressure is 125 psig. Refer to the 1 psig column of Table C-20 where you find a %o" orifice will handle 841 lbs/hr. Going up the 125 psig pressure line of the charton page 26, you find that the No. 214 or No, 814 trap can open a %e" orifice. This is the size to use. ' The actual 841 -f- 750 or 1.12 to 1 safety factor in the preceding example will result in a really-gencrous 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 ratherthan on storage capacity. Even 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_ A X U X-(tj -- ta) E C -- Condensate in lbs per hour A -- External area of pipe in square feet (see table on page 48) = Steam temperature, degrees F t2 = Air temperature in degrees F L = Latent heat of steam U = Btu per sq, ft. per degree tem perature difference per hour from Chart A-27 .. E = I minus efficiency of insulation (Example, 81% efficient insula tion: 1 --.81 = .19 or E = .19 Safety Factors. Traps installed between the boiler and the end of the steam main: 2 to 1. Taps installed at the end of the main or ahead of reducing and shut-off valves that ore closed part of the time: 3 to 1. 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 oii these pages. Install a drip leg if needed. , . t '/ -. - . ' 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 for 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 - 15 30 60 125 180 250 Pipe Sq, Ft. jrer Size lineal Ft Pounds of Condensate per fir. per lineal ft t' .344 .05 -.06 . Hi' : .434- .06 .07 Hi' .437' SSI : .08 2' . ; .622- UK .10 214' .753- ,.1U .12 . 3' - ,916 .12- .14 mr 1.047 .13 .16 1.178 .15 .18 5* 1.456 .18 22 6' . 1.735 20 25. 8' ' 2.26 .27 .32 -10' 2.81 , .32 29 12' 3.34 .38 AS 14' 3.67 .42 .51 16' 420 .47 .57 18' 4.71 . .53 .64 20' 5.25- . .58 .71 24' 628 .79 .84 .07 .09 JO .13 .15 .18 20 22 .27 .32 .41 .51 .58 .65 .74 .85 .91 1.90 .10 .12 .14 .17 20 .24 27 .30 .37 J4 .55 .68 .80 87 .99 U1 123 1.45 .12 .14 .14 .17 .16 .19 ,20- 23 24 28 28 23 .32 .38 36 .43 .44 .51 .51 .59 .53 .76 .80 .94 .92 1.11 1.03 1.21 1.27 138 1.31 1.53 1.45 1.70 1.71 2.03 ISO* leo* -TEMPERATURE DlWREHCE ISO* 2D0* 240" 300* 400* 500' 700* ODD* !* I WA-TEX 001414 ITEM NO. B~35 TRAINING DETAILS PAGE 209 X SIZING TRAPS FOR SUBMERGED EMBOSSED COILS ' ^TP&ttvwesnxT?tsas#tn*B*vi*tai&T>'r'r 'wim Xn general the drainage of embossed coils is similar to the drainage of pipe coils of the 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 through 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 die 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 drcuit through channel 3 to dose 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 I and 2 reduces the heattransferrate and, therefore, thB pressure drop. Thus, ih. creased pressure in channels 1 and 2 will force out condensate and vent the air. Once purged the process will be re peated, - Thermostatic Control. 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 cou 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. 85-3. As the control valvp starts to reopen, incoming steam heats the air in the coil, causing the air to expand and build tip 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. i WA-TEX 001415 ITEM NO. B-35 TRAINING DETAILS -PAGE 210 SYPHON DRASNAGE AND HOW TO WAP DEVOLVING DRYERS When condensate must be lifted above Ae gravity drain point to reach the trap,. a syphon exists. Fig. 37-1 shows an ex ternal syphon -- one surrounded by air. Fig. 87-2 depicts an internal syphon -- 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 jaeessure drops above the condensate in ^gl&'phon pipe, flashing is likely to occur. jlery 28" rise in condensate level re quires a pressure drop of 1 psi. With .condensate entering the syphon at, say, 1S.3 psi a lift of 7 feet requires the syphon steam pressure to drop to 12.3 psi. Ignoring heat loss from the syphon some 0.64% of the condensate would flash Into steam. (See discussion of flash steam~Toffrnition--on. the inside front cover.) With condensing rate of 1000 Ibs/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 drainage'indiirate'the condensate ioad, 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 ns 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 tile 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 installed at ground level--an EXTERNAL SYPHON, After water seal fills with con densate, radiation loss will lower the steam pressure in the syphon. Fig. 37-3. Oversize syphon. 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 pips sizo smaller than nominal trap size but not smaller than Vi") 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 for draining revolving dryers need enliirged 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 the 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 MENDED FOR SYPHON DRAINED CYLINDERS Type of Dryer Pressure gangs Psi Dry Cans: 23'x 60' 23'x 60'and up Drum Dryers: 24'x 40' 28'x72' 36'x 84' 42'x120" Laundry boners-- Cylinder Type: 12'x 72' 14'x 81* . 30'x 100'or 120' 36' x 100' or 120" Paper Machine Dryers: 36'x 72'and 42'x 120' 5--2D 21-70 5-20 21-70 20-100 20-100 20-100 20-100 100 100 100 100 0-15 16-35 35-50 51-70 Trap Size 800 LV 800 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'x 240' 0-15 16--35 36-50 51-70 215 LV 215 LV - 215 LV 215 LV ! WA-TEX 001416 -- ITEM NO. B-35 TRAINING DETAILS PAGE 211 PIPE SIZING STEAM SUPPLYAND CONDENSATE RETURN LINES Definitions: lb/hr with a pressure drop of only 1 psi Steam Mains or mains which cany steam per 100 feet Rom the boiler to an area in which mul Steam Supply Pipes, When a new heat- tiple steam-using units are installed. tog or process unit is installed in an exist Steam Supply Pipes which take steam ing plant, Tables A-40-F-41 are entirely from steam main to steam-heated unit. practical for checking the size of pipe to Trap Discharge Lines which move con densate and flash steam Rom the trap to a return line. . Condensate Return Lines which receive condensate from many trap discharge run Rom 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 105psig. Unit is rated to condense 600 Ib/hr, and 100 psig minimum is re lines and cany die condensate back to quired at unit for quality production. the boiler room. Measurements show 75 feet of pipe re Pipe Sizing Select pipe sizes large enough to take care of reasonable future expansion. quired, involving three standard elbows lus a globe valve. Allowable pressure Srop not to exceed 1 psi. Assuming that a 2" pipe will be Steam Mains. The sizing and design of high capacity steam mains is a complex problem that should be assigned to a com required, use Table H-41 to determine equivalent length of pipe to be added to compensate for fittings. petent engineer. Tables A-40 through F-4I will prove helpful in checking steam main sizes or in determining main size for small plants. 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. Example; An existing 3" steam main may Adding this to the length of the supply applying one department of a large ttt with 3800 Ib/hr at 180 psi. Ques: Could the steam use of this depart- pipe gives a total effective length of 133,9 feet-cali it 1.34 hundred feet. Dividing our maximum allowable pressure drop of men be increased to 8500 lbs/hr without 1 psi by 1.34 gives us an allowable pres a new supply line? sure drop of ii psi per 100 feet. ' Table E-41 shows that 1 psi pressure Refer to Table C-41 for 100 ps! steam. drop is produced in 100 feet of 3" pipe With a pressure drop of % psi per 100 when supplying 3800 lb/hr. To increase feet, a 2" pipe will give a flow of 850 the flow to 8500 lb/hr would produce a Jb/hr, In fact, with a pressure drop of pressure drop of 5 psi per hundred feet. only A psi per 100 feet the flow would If the pressure drop and corresponding be 690 Ib/hr. However, a 11s" pipe would decrease in steam temperature is not ob require a pressure drop of 2 psi per 100 jectionable, the existing 3" pipe can be feet for a flow of 680 Ib/hr. Vi" pipe is used. However, if this much pressure too small and the 2" is the size to use. drop is not permissible, an additional 3" In the example just cited, if the steam mate will have to be installed, or the pressure in the unit is not critical, a IS" existing 3" main will have to be replaced pipe could- be used which would give a with a 4" main which can handle 8500 pressure drop of about 5 psi per 100 feet. or about 68 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 os 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. Usually 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 be 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 Rap. As back pressure goes up, discharges become shorter but are more frequent. However, the Rap 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 Rap is decreased. In severe oases, the reduction in capacity could make it neces- saty to use traps one size larger to com pensate for the decrease in operating pressure differential. . 1 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. * Table A-JO. STEAM PIPE CAPACITV AT 5 PSI ' Tsi)lop-S0. STEAM PIPE CAPACITY AT 15 PSi. Pip* Size ` Pressure drop par 100 ft. of pipe tangtfi Id. . . C 54 - W id '/< 1 ' ' ft ' - * is \ MV: g~* S2 4.`. P ai" 3. 354 - 4. ' 5-... 6 .- 8 10 , 12 ' . * ; 4-* 6'. . ia.! IS' -:> 24 . .'.Vv.52 - .81 . -- 31 16003- . 160 - 210 . m : 350 430 . 650 -730 . 970- 1,040 ' 1,370 ; 1,830 2,540 3,160 4,170 6,890 ' 8680 12,020 15,840 19,280 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 54 120 189 370 610 1,130 1,680 2,380 4,410 7,250 15.090 27,530 44,190 13 30 62. 140 210 430 710 1,300 1,940 2,750 5,090 8,360 17,400 31,760 50,970 Pipe Size In. , >/} Va X x% 1Vt 2 m: 3 m 4 s 6 8 10 12 n S 13 27 59 91 180 300 560 830 1,180 2,180 3,580 7,450 13,600 21,830 Pressure drop per 100 it. of pipe length 14 14 Ya . t . 8 18 38 83 130 260 430 790 1,180 1,660 3,080 5,060 10,530 19,220 30,840 It 26 53 120 180 370 600 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 10,220 21,060 38430 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 001417 ITEM NO, B-35 TRAINING DETAILS PAGET 212 T/. . ' i-.'W . . ' Table A-41. STEAM PIPE CAPACITY AT 30 PSI. iPlpeSIze In, U Pressure drop per 100 It of pipe length 54 !4 Vi 1 Vi 7 10 Vi , 16 ' 22 1 . 32 45 MS 70 . MS . 110 2- 223 89 156 316 ' VA ' 368 520 ' 3 675 S53 ^. 990' 1,405 1,420 2,020 5 2,625 3,720 6 4,315 6,100 8 9,000 , 12,700 10 16,400 23,200 12 26,350 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 79 174 270 640 900 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 2 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. Pipe Size . Tn. % ' Vi 8 Yt 20 l 40 VA ' ,89 Ml 139 2 282 2Vi 465 3 853 354 1,275 4 1,800 5 3,320 6 5,475 8 11.360 10 20,800 12 33,300 pressure drop per 10D ft. of pipe length Vi A Vi 1 2 12 28 57 127 197 409 660 1,205 1,600 2,550 4,710 7,725 16,100 29,40047,100 17 40 81 179 279 565 93D 1,690 2,550 3,610 6,660 10,950 22,800 41,500 66,700 21 49 - 100 219 342691 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 6,100 9,440 15,450 32,200 58,900 94,500 35 81 163 358 558 1,130 1,860 3,410 5030 7,220 13,300 21,900 45,550 83,259 133,200 5 55 128 258 .567 882 1,790 2,940 5,400 8,060 11,400 21,100 34.600 72,100 131,200 210,600 .' Pipe Size In. A ' Vi 1/ Mi VA 2 214 3' 314 4 5 '6 . 8 10 12 ' Table C-41. STEAM PIPE CAPACITY AT WO PSI, Pressure dropper 100 ft. of plpB length vs Vi 1 2 21 ' 50 100 220 - 340 . 590 1,140 2,090 3,120 4,420 8,170 13,420 27,930 50,970 81,810 26 61 120 270 420 850 1,400 2,560 3,830 5,420 10,020 16,450 34,250 62,500 100,300 30 70 140 . 310 480 980 1,620 2,960 4.420 6,260 11,580 19,020 39,580 72,230 115,900 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 -TableD-4L STEAM PIPE CAPACITY AT 125 PSI. Pipe Size in. Pressure drop per IDO ft of pipe lengih W Vi 1 2 a 23 Vi 54 1' 109 Hi - 241 Mi 375 2 " 760 VA 1,250 3 2,280 354 ` 3,430 4 4,850 5 8,950 6 ` 14,710 8 30,650 10 . 56,000 12 89,900 29 33 - 66 77 134 155 ' 296 341 460 532 930 1,075 1,535 1,775 2,815 3,245 4,200 4,850 6,930 6,850 21,000 12,700 18,070 20.800 37,550 43,400 68,500 79,100 110,200 127,100 47 109 220 483 751 7,520 2,550 4690 6,850 9,700 17,950 29,500 61,400 112,000 179,600 8 75 172 347 764 1,185 2,410 3,960 7,260 10,880 15,350 28,400 ,, 46,500 97,100 177,000 284,100 Pipe Size In. Table E>41. STEAM PIPE CAPACITY AT 180 PSI. Pressure drop per100 ft. of pipe length Mi 34 1 2 S a 28 34 39 56 88 Vi 64 78. 90 128 202 1 129 158 182 . 258 407 M 283 347 400 566 895 VA 441 540 624 882 1,394 2 895 1,092 1,260 1,785 2,820 IVi 1,470 1,800 2,080 2,840 4,650 . 3 2,675 3,300 3,805 5,390 8,550 314 4,040 4,930 6,695 8,050 12,740 4 5,700 6,980 8,600 IMOO 18,000 5 10,500 12,900 14,900 21,080 33,300 6 17,300 22,200 24,420 34,600 54,600 8 36,000 44,100 50,850 72,000 113,900 10 65,800 80,500 93,000 131,300 207,000 - Pipe Size In* w Vi 1 VA Mi 2 2Vi 3 3Vi 4 5 6 8 Table F-41. STEAM PIPE CAPACITY AT 250 PSI. Pressure drop per ICO ft. of pipe length A Vi ' 1 2 32 74 150 330 510 1,040 1,710 3,130 4,670 6,600 12,220 20,060 41,750 39 91 180 400 620 1,270 2,050 3,820 5,710 8,080 14,950 24,540 51,100 45 105 210 470 720 1,470 2,410 4,420 6,610 9,340 17,290 28,380 59,100 64 150 300 660 1,020 2,070 3,410 6,250 9,340 13,210 24,440 40,100 83,500 5 102 230 470 1,160 1,620 3.280 5,400 9,880 14,770 20,890 38,650 63,400 132,000 Table G-41. CONDENSATE RETURN PIPE CAPACITY IN LBS. PER HR. Pipe Low pressure Size, In. Gravity Vacuum return return High pressure return, steam pressure In psi 26 so WO ISO 200 250 Vi 236 312 419 560 682 1,074 1 200 350 474 617' - 823 1,120 1,385 2,150 Mi 400 600 989 1,306 1,755 2,330 2,880 4,450 m 700 950 1,610 2,126 2,850 3.800 4,710 7.350 2 1,200 2,000 3,280 4,325 5,785 7,700 9,550 14,875 214 1,650 3.350 5,400 7,160 9,640 12.800 15.850 24.800 3 2,600 5.350 9,890 13,070 17.550 23,300 28.850 34,750 314 3,800 8,000 14,700 19,400 25,900 34.500 42,700 51.350 4 6,500 11,000 20,800 27,360 36.550 49,200 60,900 73.350 5 10,400 19,400 38,850 52,925 70,000 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* A A Ys Vi . 1 Mi VA "Pressure drop hi psi per 100 ft. of equivalent length used in deter mining capacities given. Table H-41. EQUIVALENT LENGTH OF PIPE TO BE ADDED FOR FITTINGS Size of pipe,In. Standard elbow Length in feet to be added to run Side Gate Glebe outlet tee valve (*} valve (*) Angle valve(*) `A 1.3 Vi 1.8 1 2.2 IVi 3.0 1V4 3.5 2 4.3 2V4 5.0 3 6.5 3!4 8.0 4 9.D 5 11.0 6 13.0 8 17.0 10 21.0 12 27.0 3 4 5 6 7 8 11 13 15 18 22 27 35 45 53 0Valve in fall open position 0.3 0.4 0.5 0.6 . 0.8 1.0 U 1.4 1.6. 19 22 22 3.7 4.6 5.5 14 13 23 29 34 46 54 66 80 92 . 112 136 180 230 270' -'7 10 12 15 18 . 22 27 34 40 - 45 56 67 92 112 132 , I WA-TEX 001418 ITEM NO. B-35 TRAINING DETAILS PAGE 213 INSTALLATION OF ARMSTRONG INVERTED BUCKET TRAPS rc -.rwCTTi^ki,;r77Ttt^v^ui:V'srjv.<>*naaitsracgy'<,>>-sat Igpfore Installing ' TUm pips 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 Hoek-llps. 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-OffValves ahead of traps are needed '' when traps drain steam mains, large wa ter heaters, etc., 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. Jfy-'ppaasses (Figs. 42-6 and 42-7). Use mTKev'ep'wbhye-npacsosenstinauboouvsesetrravpicse is as a must. shown. -Unions, If only one is used, it should bb on discharge side of trap. With two unions, nvoid 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 i$ 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 nnd 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 nnd half unionsj put 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 cheek valve or shut-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 hack 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 stopping scale and core sand. Clean periodically. Syphon Installations require a wnter seal and a cheek valve in the trap. Syphon pipe should be one size smaller than' nominal size of trap used but not less than S" 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 slmtoff valve is used. Fig. 42-9 shows three possible locations forexternal check valves --also an Armstrong Internal Check Valve (See page 4). Recommended locations given below. Discharge Line Check Valves prevent back flow and isolate trap when test valve is opened. Norm-ally installed at location B. When return line is elevated and trap is exposed to freezing conditions, install check valye 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 stenm is coming to the trap. If'the steam supply should be shut off, the trap should he drained manually or automatically by means of a thermo drain or pop drain. ~-- SKUM A ---- fcnj- omnwnsT**^0hJf hi-CK *. .. * . 5Hiir.0H> . . . .' VAIV8 " .. ` C '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 ba 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). CHECK YAlVt Fig. 42-2. Hookup No. 211-216 traps. ' Fig. 42-5. Alternate hookup for No. 800 814 with Inlet at bot tom. [M'-J--' vBSiTtwRA-We!t*t r VAlUg h--jJj---- i--. : Fig. 42*3. No. 880-883 with strainer blow Fig. 42-6. Bypass hookups for No. 800-814 down valve. ' and 8SQ-883 traps. Fig. 42-9. Possible check valve locations. WA-TEX 001419 f3LTEM NO.- B-35 ' ` TRAINING DETAILS PAGE Sl4. ' TROUBLE SHOOTING INVERTED BUCKET STEAM TRAPS : ^^'The following summary will prove help . .. ful in locating and correcting nearly all ' ..' .steam .trap troubles. Many ofthese trou- ' bles are in reality system troubles rather than trap troubles. Whenever a trap fails to operate and . the 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 matter-other wise, it will be necessary to break tbe discharge connection, . Cold Trap--No Discharge. If trap fails to discharge condensate, then! A. Pressure may be too high. . 1. Wrong pressure originally specified. 2. Pressure raised without installing new pressure change assembly. 3. K ft.V. out of order. 4. Pressure gage in boiler reads low. 5. Orifice enlarged by normal wear. 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 replnce as required. 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. E. .Trap body filled with dirt. Install strainer or remove dirt at source. - Fig. 44-1. Venfrscrubblng wire for use when pit plugs vCnt.' Trap inlet tube must be 'removed. ' F. Bucket'vent filled with dirt; Prevent by: . ' 1, Installing strainer. 2. Enlarging vent slightly. . 3. Using bucket vent scrubbing wire. 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 try a No. 46 drill. If this is not enough, then use a No. 42 drill. Make scrubbing wire as shown in Fig. 444 to tbe length shown in Table A-44. Tho hole in the center rib of the trap should be %/'. Enlarge vent with No. 37 drill. Table A-44. SCRUBBING WIRE DIMENSION - Trap Number 800,880,801,811,881,211 812,212,882 813,213,883,814,234,215 216 Length "A" ` 214-' 3' 5' 6!4 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, ' 3. Vacuum in water beater coils may prevent drainage. Install a V" cheek valve as vacuum breaker between steam admission valve and coil. 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 vnlve parts. B. TVap 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, Thrp too small. '. ' l.A larger hap, of additional-traps should be installed in parallel. 2, High pressure traps mny have be used for a low pressure job. Install right size of pressure change as-' sembly. '' \\ B. Abnormal water conditions. - 1, 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.mny discharge intermit tently. .Try next-size-Inrger 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, Inrgerthnn-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 (TVap 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 (TVap 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 tho 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 001420 ITEM NO. B~35 TRAINING DETAILS PAGE 215 INSPECTION AND REPAIR OF INVERTED BUCKET TRAPS sHrequency. All traps should be opened at least once a year to check operating rneclmnism. Valves and Seats. If the valve seat has a sharp smooth edge, and if there is a nar- - row bright ring nil the way around the ball valve, chances are that the valve is tight. Valves and Seats which haye be ' come wire drawn or badly grooved from wear'should be replaced. Do not use a new seat with an old valve or vicc-oersa. Valves and seats are Factory-lapped to gether in matched sets for perfect lit. ' or experience have proved tf-at when valves and seats have worn enough to nyptfre renewal, n new lever and guide pin assembly should also lie installed in "get maximum mileage from the new valve pints. . 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 tbrends, but rather by the contact between the ground end of the valve- seat and the beveled seating area at-the bottom of tile tapped hole, See Fig. 45-1. Make sure-that this sent- j||||g area is perfectly clean. METAL TO METAL Fig. 45-1. Important! Valve seat seat is made at point of contact in dicated, not by threads. Be sure to read para graph above. Raplacc Lever and Guide Pin Ar.asmnty. When new valve parts aro used with an , old lever, bucket travel, valve opening and (rap capacity are reduced. Willi used and wont guide pins, the valve b not guitb'd as closely to its seat. Poor gtiirl mice develops leaks quickly Iwtmg't valve can strike side of seat instead of center. Whrin you install a new mechanism Dirt In Trap. Remove all sediment and loss btt'ikef or a pressure change tntstno- other dirt fromtile trap body. The mechi. Mv, you make the !rap as good as r.r>v nnism may require cleaning by immers ing in gasoline or kerosene. .If there is Guide Pin Assembly Installation. Install an exceptional amount of dirt, install a- with hooks pointing away from adjoin strainer ahead of the trap.- The- strainer ing gasket surfaces as shown in Fig. 45-7. will have to be blown down or cleaned Alignment of Guide Pins. To check the alignment-of the guide pins, hold the at periodic intervals, By-Pass Valve Inspection. If traps are lever assembly against the valve seat with the valve contacting,its 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 eqtinl side-to-siae movement installed with a by-pnss, 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. . 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 mat the lever can drop .until it rests on the guide pin hooks, Internal Check Valve Installation. Since . November, 1946, all Armstrong TVap bodies have been tapped on the. inside to take Armstrong spring-loaded check valves. To install one of these check valves after ft trap has been installed in the line, simply remove the trap cap-and extended 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 inlet tube from the body and screw the check valve- in position, or replace tube with check valve, coupling and tube com bination. . pins before the guide pin assembly is Check Valve .Inspection. Make sure that fastened into position. check valves ahead of trap, in trap, or in return line, are tight and in good condi Buckets. Cracked or corroded buckets- tion,. ......... .. .. ., should be replaced. - Pressure Changes. An Armstrong TVap Bucket Hooks. Since July 1, 1940, all free-floating lever Armstrong Traps have been furnished with stainless steel buckets. Normally wear is limited to tiie rril! 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. - bucket book. In the Nos. 212-812 and If it is necessary to changethe working larger sizes, these hooks arc now riveted pressure of the trap to obtain greater to the bucket cap, so that the' hooks can capacity at lower pressures, or to enable ' be renewed. the trap to work at higher pressures, a complete pressure change assembly is re Thermic Buckets. Hold over steam jet or quired. This comprises a valve seat, a lighted match to see that disc seats prop valve, valve retainer, valve lever and erly when bi-metal strip is heated. guide pin assembly. Fig. 45-2 showsCORRECTALIGNMENTofguide pins. When correctly aligned, lever can be moved sideways the same distance to the right (Fig. 45-3) as to the-ieft (Fig. 45-4). Fig. 45-5 Fig. 45--6 Two examples of INCORRECT ALIGNMENT. Guide pins should be bent in direction of arrows until they center in holes as Shown ip Fig. 45-2. Nos. 211.212,213 Nos. 214,215,216 Nos. 310,312,313 Nos. 314, and larger Nos. BOD, 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 001421 ITEM NO. B-35 TRAINING DETAILS KV*v (..VS.v,r.*.i PAGE 216 Tfaese traps, due 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 of float. In cases ofthis type the trap fails in the closed position and the trap does not - blow through. -- Safety factor: A safety factor of Hi to 2 times the maximum load is recommended for the nor mal operation. Greater safety factors may be desirable to get the benefits ofoversized 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. DUAl GRAVITY ___ APPLICATIONS "3L The ball float in the Clark duo-gravity drainers is weighted to sink in the lighter of the two liquids and to float la the heavier liquid. When the heavy liquid enters the drainer; the float be comes buoyant ar J ------- *u- J---*------------ , tbe he, IVpn elude: removal ofwater 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 tbe tank or fluid line, the liquid flows con tinuously into the trap and the float will reach a point of equilibrium, holding the discharge valve open sufficiently to discharge the liquid at the same rate it enters. MAINTAINING CONSTANT LEVELS 1 v l-f ClarkfloatTfapsmay be used tomaimainconstant levels in tanks and reservoirs. As liquid level rises, the float buoyancy increases. When the buoyancy is sufficient to overcome the force exerted by the gas pressure against the valve, die float mechanism will open the discharge valve. Pressure then forces the liquid out of tbe ' trap, lowering the liquid level. As the level drops die float loses buoyancy and sinks to- close the dis- charge valve. V:\ WA-TEX 001422 ITEM NO. B-35 TRAINING DETAILS PAGE 217 CLARK GLOAT TRAPS discharge as accumulated Jtquid flows by gravity into (he trap body, causing ball float to rise and open the discharge valve. There is always a liquid level present at discharge over the 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. AOF, 2710, 540, S42 are of high pressure cast iron (A5TM Class 35) for pressures to 250 psi--450F. or 300 psl--* I50F, Trap No. 701DF is of forged steel construction for pressures to 300 psi --500F. forking parts are of stainless steel with Clark-loy (heat-treated stainless steel) seats and discs. Floats are copper-plated steel or optional stainless steel. Trap No. In and Out Equal Conn. Conn. Dimensions Continuous discharge coppcllle* In #PH# at In* dicatadl pressures* Orifice diameters are shown at Iho maximum oporatlng pressure for each trap* HT. DIA. wr. 15 30 50 75 80 too 125 150 200 250 300 60F )/j"or%" 'A" 5%" *5'/." 5 % 'A %t V* & Vu VU .9 1.3 1.3 i.i 1.1 .9 1.0 540 Vi" <%" 4%" 9 y 1.2 Vu 1.6 Vu 1.3 Vu 1.5 Vu B Vu .9 (it 1.0 yis .6 '/ .7 542 %"<*%" Vt" 6"M" 5A ii Vu VU %i Yu fU Vu Vu 1.2 1.6 2.0 2.5 2.5 1.7 1.9 Vu 5t 2.0 1.2 1#.42 Vu .9 S42 271G >A"or%" Vi" a%" *5%" 12 %2 2.9 ?/ 4.0 & 2.7 fit 3.1 ft 3.1 Vu 1.7 Vu 1.9 ft \A 4 1.2 Ut 1.2 l/u \3 701DF '/r"or%" iVu" 4% 9 %2 2.9 % 4.0 *M 2.7 55j 3.1 ft 3.1 Vu 1.7 Vu 1.9 %2 1.4 %t 1.2 % 1.2 Vu 1.3 'Face to Face Dimension SERIES SOB -- 2806 CLARK TRAPS are of high-pressure cast iron (ASTM Class 35) construction for pressures to 250 psi --450F, or 300 psi-- 150aF. Available for pipe sizes Vi" --2* in 80G Series and Vfc"--H4" in 280G series. Equipped with stainless steel working parts and Clark-loy (heattreated stainless steel) seats and discs, Duo-Srep leverage standard for greater capacities at lower cost Copper-plated steel floats for pressures to 200 psl or optional stainless steel floats for pressures to 300 psi. 80-6 >IpeSlze %*#%" Hqvefljr ConnecHon %" Heigh! ay," Oiometer Weight 16 280-6 Vi" ll'/a" *7H" 21% 81-6 281-0 82-G 84-6 l',1'/4" lVz".2* y<" %" . l* l'/i" 9%" 13" H'A" 14%" ?%" 28 40% B'A" 41 ll'A" 80 Dimension I -. See back of this folder /or complete (harts of con tinuous discharge capacities in G.PJd. 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 facrory. WA-TEX 001423 ITEM HO. B-35 , ' " ` TRAINING DETAIL' PAGE 218' . / SERIES 640, 740 AND 4200 CLARK FLOAT TRAPS SERIES 640 and 740 CLARK FLOAT TRAPS cure of fabricated steel for maximum pressure of 600 psi at 750F. or 1000 psi at 150F. Equipped with stateless steel working parts, Clark-loy (heat-treated stainless steel) seat and valve disc for long wear and low maintenance, Duo-Step beverage fot greater capacities at lower cost. Chrome-plated steel or optional stainless steel Hosts. The 641 and 644 can also be furnished ip all cast stainless steel construction. 640 .740 4200--CLARK FLOAT TRAPS are of fabricated steel for maximum pressure of 600 psi--750BF. or 1000 psi at 150F, Stainless steel working parts and Clark-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 640 641 642 643 644 4200 740 741 742 743 744 4201 Pips Sire Equalizer Connection %",1",1%" l",iy4"1i/a" ir.tr %" 'A" - %" i" 1" 1".1'A Holght s%" 1114" 12"h" 14" i5/,," 12'Vu" Diameter 6Vt" W" 10'/." n%" 9'/" Weight . 23 46 75 106 147 76 Note; Above traps can bo furnished with tocicetweld connection. 740 series and 4201 can be furnished with 600 )b. ASA Ranged connection. See bank 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 mainmum operating pressure for each trap. For rising dual-gravity applications, forward your requirements to your load representative or the factory. WA-TEX 001424 TEXACO INC. PUGEy^oiNS'Vl^NT TRAINING DETAILS PAGE 219 DEPARTMENTS PIPE classification! pipefitter (trainee) DATES JULY 1, 1970 ITEM NO. B-36 SUBJECT? INSTALLATION AND REPAIR OF PLtMlHG " Installation of plumbing includes toilets, sinks, showers, hot water tanks, water coolers, septic tanks, sewer lines, water lineB, 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 -eighth 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. %2 i WA-TEX 001425  TEXACO INC,, PAGE 220 TRAINING DETAILS DEPARTMENT: PIPE CIASStPlCATIOWr^PIPEFITTER (TRAINEE) DATE: JULY 1, 1970 ITEM NO. B-37 SUBJECT $ 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 connec 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. WA-TEX 001426 TEXACO INC,, PAGE 221 TRAINING DETAILS DEPARTMENT? PIPE CLASSIFICATION PIPEFITTER (TRAINEE) DATEs JULY 1, 1970 ITEM N0C B-38 SUBJECTS STEAM RADIATORS A. REMOTE . 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 boltB 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 radltor apart to repair the leak. Put a test on the radiator to locate the leak. Then clean the area thoroughly and resolder. Sometimes radiator headers develop holes. If this happens, cut a patch to cover the hoxe and have it welded on. i WA-TEX 001427 TEXACO INC. PUgE'f' SOSro PLANT DRAINING DETAILS PAGE 222 DEPARTMENT: PIPE J ' . DATE? JULY 1, 1970 CLASSIFICATION! PIPEFITTER (TRAINEE) ' ---------- ITEM NO. B-39 " SUBJECT: INSTALL PIPE HANGERS AND"'gtlPPOR?S^ 1 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 @els necessary to do the job. Attached is Information and illustrated drawings of various pipe hangers and supports. [ WA-TEX 001428 ITEM MO. B-39 adjustable ring tig. 269 TRAINING DETAILS .PAGE 223 ring clevis adjustable clevis, light weight fig. 69 nizo range! H through 8 Inch, material! Carbon steel. finish: Black or galvanized; furnished black unless otherwise specified. servicer Recommended .for suspension of non-insu- lnled, stationary pipe lines or conduit ` maximum temperature: 650F. approvals.* Underwriters' Laboratories listed and 1'aclory Mutual approved for % to 8 inch pipe only when galvanized. Compiles 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* ma* recant wgl (approx) il load, lb* lb per 180 'i 610 610 1 610 V.i 610 t'4 610 z 610 Zli 870 3 870 3*1 870 t 1250 3 12S0 C 1600 10 14 15 17 25 28 37 43 47 SO no 154 e I860 270 4 Wnh minimum safely factor oi S. dimensions inches) rip* it A iI i 51 2 34 H n 4*. 3 I 1*. 4 5 I 5 8 y. BC m, 25f, 223%fs I 2% m f. 3 4% Mi 5% Mi 6 Mi BH 1 7% % 4% 11% D 1 254 3f 2% 3% m m 3% 4 Mi Mi carton - 25 25 25 25 25 . 25 25 25 25 10 e. . . MM MM rod take-out B 1% 1% 1% .. 1% 1% 2% 3 3% 3%. 3% m 5% BJf, aditmlmenl F 1 1 1 154 m m 154 154 154 l?4 2 2 2 size ranges % through 4 inch. material: Carbon steel, finish: Black. service: Recommended for suspension oi light loads, pipe or conduit. maximum temperature: B50F. 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, vary` ing with the size oi 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 steo maximum recommended bad, lb* weight (approx) lb per 100 150 54 150 54 250 1 250 m 250 250 12 13 27 28 32 34 2 250 Mi 350 3 350 40 81 80 m 350 . 39 i 400 130 * With minlmym safety {actor of S. pieces per carton 100 100 100 100 100 100 100 50 50 25 25 dimensions (inches) pipO size of steel sire upper lower % 54 % Jft* 54 % Kix 34 34 i 154 #13 U.S. Gauge x% IK 2 zK 54* IK 3 KxiK KxiK KxU4 3K 54*154 VtxiVt 4 %xi)4 'Axl'4 AB c D adjust* E raentF % 134 134 254 34 % 34 154 2ki 254 % 34 34 2% 334 2K 2% i% k34 3% 354 334 2K 2K 2% 2K 154 m y. 3% 434 2K 2% 154 % 354 54 4% K 434 4% 254 6 354 E54 3 2% i?li 334 254 3% 134 K 4% e% 2% 4 1% K 5K 254 354 MS 2%: | WA-TEX 001429 i ITEM NO* B"39 TRAINING DETAILS PAGE 224 |lpe bangers and supports clevis adjustable clevis lig. 260 size range! yt through 24 inch, material! Carbon steel. . finish! Black or galvanized; furnished black unless otherwise ordered. service; Recommended for the suspension of noninsulated, 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. ,. 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 o dimensions (inches) ' Pipe size X % 1 11* 1% 2 2'A 3 314 4 5 e 8 ^ 10 Si 12 ^ 14 18 18 28 24 30 maximum recommended load, lb" 610 610 610 610 810 610 1130 1130 1130 1430 1433 1940 2000 3600 3800 4200 4000 4800 4BD0 4800 6000 weight (approx) lb per 100 . 34 39 44 45 ES 61 140 152 170 213 244 357 486 $78 1140 1481 2100 2437 4256 4843 6850 pieces per carton 100 100 100 too 100 100 50 50 25 25 ** .... *** * .... (l,.... .** .... .... .... size of steel upper lower %xi %xl %x i %x i j?9 U.S. Ga. x 1 #8US.6a.xl %xi% Htxifi %*i% %xl% >4*1% %*i% %*i% %xl% 34*2 >4*2 %*2% %*2% %X 3 fix 3 fix 3 Mxl fix 1 fix 1 >4x1 fixl fix 1 %xl% %xl% %xl% %xi% Htxifi Htxlfi Htxlfi fixlfi fix 2 >4x2 >4X2>4 MxZ'A fix 3 fix 3 >4x3 With minimum safety factor of 5 AB >4 2Ht %m X 3>4 X 3% % 3Hi X 3% X 4% X 4% X 4% X 5Hi Xm fi 6% X 8% % 8>4 X 11% 1 12% 1 25 VA 153* v/t 17% VA 38% VA 24% adjust. men! C DE F G 2% 2% 3% 2% 3% 2% 1% 2%* 2% 4% 2% 2% 4% 2% 2% 4% 2% 2% &14 3 8% 3 B'% 3 3% 3% 4% 7>% 9 10% 3% 3% 4 4% 5% 5% 12% 4% 7 15% 4% 8% 17% 4% 9% 19% 23 24% s% 10'% s 12% 6% 13'% 27% 7 14% 31% 39% 7% 17% 8% 21% 1% 1% 1% 1% 1% 1% 2 1% 1% l'% 1% 1% 2% 2% 2% 2% 2% 3% 4 4% 5 % % % % % % X X % % % %, X % % % 1 1% VA VA VA Ii WA-TEX 001430 [ ITEM NO. B-39 TRAINING DETAILS PAGE 225 adjustable clevis for Insulated lines fig. 300 alloy; fig. 300R vv clevis cize range: % through 12 inch. material: fig. 30D -- carbon, steel. fig. 300A--carbon steel yoke and clevis bolt; chrome molybdenum steel U-strap. finish: Black. service: Recommended for suspension of insulated, stationary pipelines. maximum temperature: fig. 300 650F fig. 300A-- 105DF approvals: Complies with Federal Specification WW-H-I71c (Type 1) and Manufacturers Standardi zation Society SP-69 (Type 1). Installation: Hanger load nut above clevis must be tightened securely to assure proper hanger perform ance. adjustment: Vertical adjustment is provided, vary ing with the size of the clevis. Tighten upper nut after adjustment, features: ' Designed for 2 inches of insulation on % through 1% jnch pipe and 4 inches of insulation on 2 inch and larger pipe. When properly installed, clevis bolt is outside the insulation. ordering: Specify pipe size, figure number, name. loads weights dimensions finches) pipe !* H I. m 2 25} 3 3?$ 4 $ 6 B 10 12 maximum recommended load, lb* BIO 010 610 610 610 1130 1130 1130 1430 1430 1940 2000 3600 3000 weight (approx) lb per 100 sire cl Blool upper lower SI %xl SB y,x i Axl Axl 64 %xl %*1 72 #9tT.S.Ga.xl Axl 85 jjf9trf.Ga.xl Axl 191 %xlA %*i% 201 %xl% %xlA 210 %xl% %xi% 247 Ax IX %*i% 301 337 ' 673 Axl A AxiA A* IX %xi A %xi% %xi% 1102 %x\% Axi% 13B2 %x2 Ax2 With minimum safely factor of S. AB CDE adjust ment F a H % 4% %5 A s% 5% 2% 5% 2% 6m 4 1% 4% 1% 4% : 1% A 5% A 7% A 9% 6% 2A B'Jfi 2% 9% 3 4% 1% 6% 1% 7% 2 A 8A 10% 3 7% 1% A 8% 10% 3 7% 1% A 9% 11% 3% 8% 1% % .9% A 10% A 12% 12% 3% 8% 1% 14 4 9% 1% 19% 4 11 2 A 13% A 15% 18% 4% ,21% 4% 12% 13% 2% 2% A2 A2 A2 A2 A4 A4 A. 4 K4 A4 A4 A4 %4 %4 %4 I WA-TEX 001431 ITEM NO. B~39 TRAINING DETAILS PAGE 226 double h&M pipe elsamp fig. 295 steel damps size range: % through 24 inch, materiali 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 whore fieri* bifity of the clamp is desirable--within the limita tion of temperature and loads shown below, maximum temperature: 750"F. approvals: Complies with Federal Specification WWH-171c (Type 3) and Manufacturers Standardization Society SP-69 (Type 3). installation: Attachment to the clamp 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 toad bolt and attachment will extend outside of 4-inch thick pipe covering. o toad ratings meet USAS code requirements and are substantiated by laboratory-test,. o Rounded corners on clamp ends provide greater safety for personnel. ordering: Specify pipe size, figure number, name. loads weights dimensions (inches) max recent load, lb* for service ierap pips ha - esooF ?80P '% l m 950 950 . 950 850 850 850 m 1545 t 1545 2% 1545 3 1545 3)4 1545 4 2500 s 2500 s 2885 8 2865 1380 1380 1380 1380 1380 2230 2230 2555 2555 10 3240 12 3240 M 4300 2880 2880 3835 18 4300 18 4300 20 5490 3835 3835 4900 24- - --J500 4015 wet (apples) lb pet 100 70 76 81 234 258 272 304 328 688 638 1145 1315 1881 2225 3788 4137 4487 5725 6590 B % lift m 1% 2% 2% m 3 3% 3% m 5% 6% m 9% 10% 11% 12% 14% C % % % 1% 1%1% 1%6 1% 1% 1% 1% i% 1% 1% 2 2 2 2 2 '* *' -Uwn n IJSAS Cod& for Pressure Piping. P 2% 3 3% 4% 5% 8% 5% B% 7% 8% 3% 10% 12 13 14% 15% 16% 17% 19% E 2% 2% 2% 4% 5% s% 5% 6% 8% 7 8% 8% 10% 11% 12% 13% 14% 15% 17% F % H % H % % % % % % % I 1 1% 1% 1% 1% 1% G %xl %*1 %xl %xl% %xl% %*1% %*1% %xl% %x2 %x2 3$x2% %x2% %*2% %x2% %*3 %x3 %x3 %*3 %x3 H 1% 1% 1% 2H 2% 2% 3% 3% 4% 5 6% 7% 8% 3% 10% H% 12% 14 16 j WA-TEX 001432 ITEM NO. B-39 TRAINING DETAILS PAGE 227 steel clamps heavy duty double holt pipe clamp tig, 29SH t-C size ranges 6 through 24 inch. materials Carbon steel, finish: Black. services Recommended for suspension of pipe re quiring up to 4 inches of insulation and where flexi bility of the clamp is desirable. 750F. 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. . loads * weights dimensions (inches) maximum rocammsndodload.lb* pipe ferxprvlce tempomhira It# wgKapp'x) In. 850T 750F lb per 100 t 3500 3125 t 4800 4285 in 5500 4910 1200 1850 3025 12 7000 M 8500 in 10000 6250 8495 8930 4200 6000 8000 IS >3000 12325 JO 15300 13695 n 16300 14555 11500 14000 19000 B m 8 m B% 9% 10% 12% 13'A m c i?4 2 2)4 z% 2% 3 m m 3% D 10% U34 13% 14% 15% 17% 18% 1934 22% * fcusott on tbo allowable stresses shown in the USAS Cods lor Pressure Piping. EF GH e% 10% 11% l 1% 1% %*2% %*2% %x3% 6 7% 9 12% 1% %*3% m 13% 1% %x4 n% 14% 134 34*4% 13% 16% 2 17% 2 19% 2 1 x4 1 x5 l *e 14% 16 18% f WA-TEX 001433 ITEM NO. B-39 pip hangers and supports steel pip lamps medium pipe Sump fig. 212 TRAINING DETAILS PAGE 228 size range: % through 24 inch* material: Carbon steel. finish: Black or galvanized; furnished black unless otherwise specified. service: Recommended for suspension of cold pipe lines or hot lines where little or no insulation is re< quired. maximum temperature; ?50F. approvals; Underwriters' Laboratories listed and Factory Mutual approved for % through 8-inch pipe. Complies with Federal Specification WW-H-171c (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: o Load ratings meet USAS Code requirements and are substantiated by laboratory test, e Clamps tightly to pipe, e Wide range of sizeB. o Rounded comers provide greater safety for per sonnel. ordering: Specify pipe size, figure number, name. loads e weights o dimensions (inches) pipe sira % % 1 . 1% l'/t 2 2% 3 m 4 5 0 B 10 % 12 5^14 16 18 20 24 maxrecent load, lb* {or sendee temperature 650r 7S0P 500 448 SOD 445 500 445 500 800 1040 445 715 930 1040 930 1040 830 1040 930 1040 1040 1615 930 930 1440 16X5 2480 2490 1440 2220 2220 2490 2490 6060 2220 2220 273D 3060 3060 2730 . 2730 wgt (approx) lb per 100 29 33 35 38 89 113 124 139 153 229 260 542 654 1392 1518 2050 2225 3156 3581 5312 B 1 1% i% % i% 2% 2% 2% 3% 3% 4 4% 6 7% 8% 8 10 XUS 12% 15 C % % 4 4 % % % % % u X % 1 1 1 1% IK i'/t 1% Based on the allowable chesses shown in the USAS Code for Pressure Piping. -D 1% 1% m m 3% 3% 3% m 4% 5% 7 8% 3% 10% 11% 13 14% 16% EF G H z % %*1 1% 4 %xl 1% % %*1 1% 4 %x 1 1% 4 %xl 2% % %Xl 1% 1% 1% 1% 24 2% 2% % %xl 2% % %*1 3% % %*1 3% 3.4 3% 3% H %xl% 4% 4% % %*1% 4% 5 % %xl% 5% 8% % %xl% 6% 7% % %r2 B% m % %*2 9% m % %x2% 10% 10% % %x2% 11% n% 1 %x2% 12% 12% 1% %x2% 13% 15% 1% %x3 16% I WA-tfEX 00X434 ITEM MO. B-39 heavy pipe clamp Jig. 216 TRAINING DETAILS PAGE 229 pipe clamps size tango:3 through 16 inch, material: Carbon steel, finish: Black. service: Recommended lor 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: Additional line can be suspended below clamp by attachment to bottom bolt. load ratings meet USAS Code requirements and are substantiated by laboratory test. Designed for heavy loads in temperature up to 75QF. Rounded comers provide greater safety for per sonnel. ordering: Specify pipe size, figure number, name. loads weights dimensions finches) maxrecom load, lb* for servlet temperature pipe he 850#F 7S0F wgt (approx) lb per 100 B Cp 0 3370 3% 3370 4 3S15 s 3515 6 4885 8 4865 3005 3005 3135 3135 4340 4340 417 458 604 700 1340 1570 2% 1 3% 1 4 4% 3% 1 4% 4'/.' 1 5% S l'A e% 6% m 7% 10 6010 5360 2450 12 8675 . 7740 4250 14 9120 8135 ' 5187 7% 8% 9 m 10% 8% i% 11% 18 9120 8135 8887 10% 12% * Boaod an the allowable stresses shown ia (ha USAS Codo for Pleasure Piping. w E F 6H 3% 3% 3% 4% 5% 6% 7% 8% 10 11 % % % %" 1 1 154 1% iK V/z % x2 %*2 %x2 -%x2 %*2% %*2% %*2% %*3 %*3% %*3% 3% 4% 4% 5% 6% 7% 8% 10% 11% 12% i j ^A-TEX 003,435 X % % % % % % % % % % TEXACO INC. PUGET' SOUND PLANT TRAINING DETAILS PAGE 230 DEPARTMENTS PIPE CLASSIFICATION PIPEFITTER (TRAINEE) DATEs JULY 1, 1970 ITEM NO. B-0 SUBJECTS PACK VALVES . When you are packing valves you must he sure to have the ri|ht 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 under packing ring to stop product leak and still let valve open and close. It helps to lubricate the packing while installing. ) WA-TEX 001436 TEXACO INC. PUGEff^goTO^FSANT TRAINING DETAILS PAGE 231 DEPARTMENTS PIPE CLASSIFICATION PIPEFITTER (TRAINEE) DATES JULY 1, 1970 " ITEM NO. B4l ~ SUBJECT? INSTALL AND REMOVE OHMART LEYEL~C0NTR0l3M : A, REMOVE The removal of Ohmart level controller 1b 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 decarbonising 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. WA-TEX 001437 TEXACO INC PAGE 233 TRAINING DETAILS DEPARTMENTS PIPE CLASSIFICATION; PIPEFITTER (TRAINEE) DATE; JULY I, 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. Pub 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. I WA-TEX 001439 ITJEM NO. B-42 TRAINING DETAILS PAGE 234 Special r>0# W.P. Self draining hydrant type valve, modified from manufacturer's a* standard fire hydrant to provide one I2l>'j flanged outlet nozzle or. the barrel. Valve to open against line pressure, working parts to be removable from grade. Balance of parts to be manufacturer's atanuvrJ, fire hydrant construction with suitable corrosion resistant materials, seals and gaskets. Valve-to be provided with handvueel'wkich is to |J counterclockwise to open. s U n 14 *0 |i Jo g 4" |g .-Sn 3H a2l J>..s& ll Nh ll I iP 11" HftNt>VJHE6L H.R OF APAVING UNS 4"5Ee 6 3 SHE OF IN LET* OUTLET FLGD. COMM. 411 6" " K10M.DIft.0F HYDRANT VALVE SEAT OPENING. 4* S" S'* PLfoD. OUTLET NOZZLE -F. i D. IZS^E ft S ft STD. -M4A'SNtlUSFAC1T1URERS STD. MOTES Ss i? "! al .s FLGD. INLET NO TELE F, D. H IZ5# ASA STD,. 1, "T" D1MEHS10M TO BE specified when ordering VALVE- ` 2, DIM'S A.BfcC TO BEfURtilSHEO BY VALVE SUPPLIER. ^ATZ-Vk'' *1 <3 3 S| sl II I If "0"" iff a gS 3V rn L 4" St (6" VALVE ITEM N2*L-1068 WA-TEX 001440 THIS dm, HAb bE'uW ADAPTED VROM TE.XA5 CO. VALVE NSy-SSOBJ THE TEXAS COMPANY ',; fuse; sound works 6400_k. APPROVED BY THE TEXAS CO. ... A ll-U-57 :4RCVtS3& AS NOTED A A wr. A ISSUED for. construction ISSUED FOR. APPROVAL . t m ^nb AV1AM HYDRANT TWVAlVE FOR WATER SERVICE '^TZu life. a ____ H.G. JL H. G, W^ .. DR H, -G. CH'K. SUP.W& SET l*H> date S-I4-S7 job no. 2 5-25 CH'K. OSURP. . DRAWING Ho. REV. ENG. CHIEF -ci -raci -a ITEM WO, B-42 (TRAINING DETAILS special 3elf draining valve, hydrant type, 2" valve cent v.-pcn'-n j, j ,,.o ci.a.i, wor. "ng pressure, bronze n<at, leather or rubber faced pi-- ,, suitable corrosion resistant materials, suitable seals, i'V handwheelT turn counterjloc?vis> to open, wording parts to be removable iron, grad-, vi.*u to op..n egairiut Iin.` pressure. Darling Vo.t,/n.& Mftrt:. Co. drawin/. tvimrer 1/i'T .cr,.equal. *w5A ll Is . -=nr.\ . ll CJfr Sg 88-?5 **o3* -P5I e9 Bs-8au IO" HAWOWHSEL 1* 1Z OR 2" OUTLET NOZZLE FEMALE STO. PIPE THD, si 8s fsi GROUND OR PAVlNCb LINE Is "T''D> MEW SION TO 13C SPECIFIED WHEN ORDERING VALVE. DIM'S A,0U TO 06' FURNISHED By VALVE SUPPLIER, - "I 1 5{ >?s l| OR 2 INLET NOZZLE - FEMALE STD. PIPE THREAD. a"B f-ia i* P'3 VALVE ITEM NO. L-I Q67 WA-TEX 001441 JlCTC : TH-'S OflAwidcS HAS SEEN ADAPTED FROM TEXAS 00. VALVE DWG. NO. V - S 5 I B I IU8\" iisir j V: s& t - , THE TEXAS COMPANY. . PUGET SOUND WORKS ' \0/ ' 6400 L APPROVED BY THE TEXAS CO. TUSISO-L'v 4-|-?7 Wx l/rt _. _ MffiED DIM'S AiS^C FR. VENDOR DJG. F.RtZ5a548-VJ8-W AA tJwhi iSSDeD PoR. CONSTRUCTION SOE ri.6. *<t -j SrT A Di-h-sy ISSUED for. APPROVAL 0R H G. CH'K. OR. ]vf SUP.ViTO DR. DATE < CORPORATION HYDRANT TYPE VALVE FOR WATER SERVICE USE HCH'K. ENG. 3-1O-S? JOB No. &C g^ CW Fy DR SUP DRAWING No. CHIEF ENG 50-EL-140 PtV l ITEM NO. B-42 TRAINING. DETAILS . PAGE 236 Special X5C$ W.P. Seif draining hydrant type. valve, modified from manufactu:re:*`a .standard h" nominal valve opening fire hydrant, to provide one I"' 250f ASA- Std. flanged pumper noacle and one I'-x/i;"' hoco aov.^ie on the barrel. Valve to opefa against line pressure, working parts to ue removable from grade. Balance of pixrts to be nu'inufactu"er'a s tandem fire hydrant construction with ouitabi-i.corrosion resistant material.:-, seals ana. gaskets. -Vu.ve to oe provided with handwheel wilier* in to mm counterciockwis-: to open, Similar to Darlinfj Mfg^Co. ;iwg. Ko. D-'.v.. or equal. 4" FUS'D. PUMPER MOZZLE MD.2SO*ASA STD, GROUND OR PAVING LINE 12" HANDWHEEL Z'fl STD. HOSE NOZZLE-CAPPED. THREAD TO BE NAT. STD. H0S6 THREADS ?N FPA) UNLESS OTHERWISE SPECIFIED. MANUFACTURERS STD. "T ' DlMEKlSHOM TO BE SPECIFIED WHEN ORDERING VALVE. Dim's, a.b t c ro be FURNISHED BY VALVE SUPPLIER. dim's B,C 4-* FL6D. INLET NOZTLE F. SO. 12S'*ASA STD. WA-TEX 001442 Valve item n2*l-io69 NOTE'- THIS pflAWiNG HAS BEEN aDAPIED FROM TEXAS CO. VALVE DWG. NO V- 8BOS2 THE TEXAS COMPANY PUGET SOUND WORKS : 6400-^k ' APPROVED BY THE TEXAS CO. 71*856-1 'v 4-j-g? 'fejJtT.. ftDPEP MlSC. 8lHS. PER VENDOR Pi|>6.F.P.g2y.46-S-28-7-; 4!Mrj issoso Foe. construct!U D3A-T2E2-g7 ISSUED FOR APPROVAL FIRE WATER MONITOR VALVE HYDRANT-TYPE ' TEXACO INC. PUGET SOUND PfiMW? TRAINING DETAILS PAGE 237 DEPARTMENT t PIPE CLASSIFICATIOifr^PIPEFITTER (TRAINEE) DATE: JULY 1, 1970 ITEM NO. B-43 SUBJECTS INSTALL EXPANSION JOINTS To install expansion joints, be sure flanges are lined up properly and to have the right gaskert 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. WA-TEX 001443 TEXACO INC. PUGET SQTffTD PLANT PAGE 238 TRAINING 'DETAILS DEPARTMENT? PIPE CLASSI-ElCATIOin *PIPEFITTER (TRAINEE) DATE; JULY 1, 1970 '" ITEM NO. B-44 SUBJECT? FLANGE AND UNFLANGE To flange and unflange equipment, have the right tools for the Job, know the right size bolts 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-241-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. WA-TEX 001444 TEXACO INC. puget' jsowm HiAST TRAINING DETAILS PAGE 239 DEPARTMENTS PIPE CLASSIFICATIOlfi~~PIPEFITTER (TRAINEE) BATES JULY 1, 19TO ITEM NO. B~45 SUBJECTS INSTALL EDUCTORS A. INSTALL" * When installing eductors, be sure all flange and union surfaces are clean, proper gaskets are used arid that flanges are lined up properly. The above points are important because a leak may cause loss of suction. See the following examples of oommonly used ejectors. J WA-TEX 001445 ITEM NO. 23-45 TRAINING DETAILS PAGE 240 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. JET PUBV1PS This bar stock stainless steel elector has butt-welding connections and Is used where special corrosion resistance Is desired. This special bar stock 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 Wt" x %" N.P.T. connections) bronze ejector ha3 male discharge and female suction on Inlet connections. Large cast bronze hydraulic elector with flanged connections for bilge water removal. Special stainless steel ejector with flanged discharge and screwed inlet and suction con nections for pumolne corrosive chemicals. I WA-TEX 001446 . ITEM NO. B-45 TRAINING DETAILS PAGE 241 GRAHAM SINGLE STAGE NON CONDENSING AIR EJECTOR VAPOR INLET, STEAM INLET TYPICAL STEAM NOZZLE DETAIL 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 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 Z STEAM CHEST 3 AIR CHAMBER 4 DIFFUSER 5 AIR CHAMBER GASKET 6 DIFFUSER. GASKET 7 STEAM VALVE 8 STEAM STRAINER . .. . GMC-104 GRAHAM MANUFACTURING GO., INC. 415 LEXINGTON AVE. i . Mrui K1 W ' m-TEX 001447 TRAINING DETAILS DEPARTMENTS PIPE classificationT^pipepitter (TRAINEE) DATES JULY 1, 1970 ITEM NO. B-46 SUBJECT; INSTALL TEMPORARY FIELD OTPS---------------------------------- When installing field pumps, get the right pump for the Job and the right equipment to haul the pump to the Job site. You oan get piping and fittings for suction, discharge and steam supply from pipe storage area south of the airstrip. It is best to hook up suction piping first and then the 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 001448 TEXACO INC. PUQETSOmlDTEftNT TRAINING DETAILS PAGE 243 DEPARTMENT: PIPE CLASSIPlCATrOffr^PIPEFITTER <TRAINEE) DATE: JULY 1, 1970 ' ITEM N0,, B-47 -- SUBJECT: INSTALL STEAM TRACING ar^iPi1 gNgfiTOiMgg" 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 he no added heat loss. Steam tracing should he trapped sufficiently to get maximum heat from ^efam ^tracing. i WA-TEX 001449 TEXACO INC, PAGE 244 TRAINING DETAILS DEPARTMENTS PIPE CLASSmCATIOfF^PXPEFITTER (TRAINEE) DATES JULY 1, 1970 ITEM NO. B"48 SUBJECT % MAKE PRESSURE TAPS A, REQUIREMENTS (1) WHEN PERMITTED - Where practical, operating line^ or equipment ' shal'Pbe emptied and freed of combustible gases and liquids before performing hot work. However, preaoure tapping may be performed In order to avoid loss of valuable operating time or expense for gas-freeing lines and equip ment when all of the conditions for the operation have been met, (2) WHERE NOT PERMITTED i'a) In vapor apace of atmospheric tankage. |b| On alloys requiring stress relieving of welds. i'cJ In hydrogen or hydrogen rich'service (because ' of tendency to leak through the packing glands5 (d) In systems with flanges rated over 300 # ASA. (e) No pressure tapping shall be authorised on wall thickness of less than'3/16"'.. (3) HOT WORK PERMIT FORM R-841 must be obtained from the operatl ng" d~epa rtment. "^i ''permit must be connte^iffned by the PLANT MANAGER or ASST. PLANT MANAGE!' Material to'`be''pressure 'Sapped 'must be "'hammer ueubeo by Inspection Department. Inspector on job must sign nermit and results of hammer test. Asst. Plant Managershould be notified one day In advance of pressure tap. Chief Engineer must Initial permit indicating no alloy Is Involved and meet3 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 -TBt and Inspection Department before starting work. %e) The pressure rating of the pressure tapping equipment shall be at least as great as the system being tapped. j WA-TEX 001450 \ ITEM HO. B46 TRASHING DETAILS PAGE 245 (f) Welders shall be instructed to apply a light bead of weld to start fcifch, gradually building up to required weld to prevent excessive heat, B. LIME 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. Ho pumping shall be permitted in or out of the tank, D. VESSEL TAPPING (l) Liquid in the vessel shall be at least two feet above the upper limit of the welding and tapping. Mo 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 (1) These pressure tap machines drill holes from 1" to 2" and 3n to 14" in any size or type of line or vessel. The drilling ^.operation may b done under pressure by using a valve between the machine and the line; The valve 1b 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 Sif' any attachment* valve dr fitting, subjected to pressure or -feggjge'fa. 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 1'" - 2". j WA-TEX 001451 \ ' *Oa B-48 TRAINING DETAILS PAGE 246 ` . ) Assemble Grill 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 'flanged* whichever the case may be). Make sure all connections : are tight and bleeder valve is closed. 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 comp^^ drilling operation if leak is slight, or completely retrfg#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 on end of feed indicator rod) and place it In packing nut hole. This 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 on feed tube before retraetI5g7 Leave Indicator rod location stationary which will locate position of $pdl in cut after packing is tightened and drilling r$$paed. Use "MARPAX" No. 2 WA-TEX 001452 ITEM N0,, B48 TRAINING DETAILS PAGE 247 (9-) RETRACTING BORING BAT? WHEN CUT IS COMPLETED - whan feed indicator md is aligned with feed tube groove, the out should be completed and boring bar may be retracted by using ratchet handle in counter-clockwise direct,ion. (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. j WA-TEX 001453 mu missmuia tempernipITEM NO. B-48 TRAINING DETAILS PAGE 248 tAPSmssde wkklf & mUf with ffcu. -f!h rawi/asHttl infs;-. .?. & h vms. V->* ? * o, eoic Hur- (.VTn*If<i i.'b .. ;, itx.<>/ 9v'k.I.,-*rrfo h*'>ir|v.^ WA-TEX 001454-,, ITEM NO. B-48 TRAINING DETAILS PAGE 249 THE' WIBSON-HiLLCO MODEL ^S TAPPING DIAGRAM . . * SKID MOUNTED, ENGINE DRIVEN HYDRAULIC PUMP WITH OIL RESERVOIR TANK 9 Relief volve protects system thru separate circuit. Extra large reservoir provides ' ' ample cooling. Mercury clutch between engine ^ ' & pump 'with flexible coupling '* assures easy starling and long engine life (engine and pump mounted on specially designed neoprene shock mounts). H||s* Hydraulic components assure Up) constant torque regardless of speed. HYDRAUUC POWER UNIT 0 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 FROM RELIEF VALVE DISCHARGE LINE TO TAPPING MACHINE REIUF VALVE FILLER CAP RETURN LINE FROM TAPPING MACHINE SUCTION LINE AIR MOTOR ATTACHMENT -saM'x1 Sr'Tv. i ***&}{*. 5ke!eh showing flow of com pressed crfr from air compressor to receiver to air motor through SO ft. or less of suitable air hose. Min. Compressor size: 105 GFM @ 90 PSI. (Furnished by Customer). .. . WITH NEW GEAR RATIO AND HIGH-SPEED POWER UNITS, - (AIR OR HYDRAUUC MOTOR) TAPPING TIME IS REDUCED .A . 4&2r_____________ ________ ______________________________ , , ^ ^4 . T,L- --I 1-I..inr._ . . i - --^ - 'fei ... , WA-TEX 001455 ITEM NO. B-48 TRAINING DETAILS PAGE 250 MACHINE IS RUGGED AND DEPENDABLE The WmSON-HILLCO hipping machine tuts hole in pipeline quickly and easily without shutdown or leakage STEP BY STEP TAPPING PROCEDURE measuring ooq J 8 LOWER-IN CRANK AIR MOTOR & ACCESSORIES {Hydraulic Rawer Optional) ';75' - TIMKEN RADIAL-THRUST BEARING WELDED STEEL CONSTRUCTION THROUGHOUT ' GEAR CASE 4'i.ASA 600# RING JOINT FLANGE OF TAPPING MACHINE ; BORING BAR RETRACTED---------------- EXTENDED SELF ADJUSTING MSH-PRESSUSE, HIGH-TEMPERATURE CHEVRON PACKING UL-. y ADAPTER t> FLANGE TAPPING VALVE CLOSED ------------------- OPEN "I 4 -- BRANCH CONNECTION PIPE LINE, TANK OR PRESSURE VESSEL CUTTER S PILOT TAPPING MACHINE MOUNTED ON ADAPTER FLANGE VALVE OPEN, SORIA'S SAP EXTENDED TAP COMPLETED, COUPON RETAINED ON PILOT DRILL 1. Weld side outlet to p i pe line. Side outlet may be Pipe Nip ple or Weldolet wish or with out reinforcement; or welded or bolted split tee,2 2. Mount topping valve on side opening. Round opening gate valves generally used. Plug valves may be used with special cutters. 3, Mount adopter Plrnrge oft tap ping machine, then :nsioit proper cutter. Attach tapping machine with adopter flange to tapping valve. 4. Valve open, iawer-in crank is rotated to extend boring bar until pilot drill touches pipe. 5. Tapping under pressure through the well without leakage. Coupon is retained on pilot drill by spring loaded balls. 6, Retract cutter with coupon, close valve and remove ma chine. THE NEW LONGER BORING-BAR TRAVEL (42" USABLE TRAVEL) RESULTS IN A WIDER RANGE OF PIPE AND TANK TAPS ... ~~ ' ' j WA-TEX 001456' TRAINING DETAILS PAGE 251 VyffflSOM_i-_Hs_lUs-CkO Slapsp;9-*-- to choose ho* MOOR 100 TAPS TO 2" Hand Operated 800F. <3 600 PSI ar 1200 PSI @ 100aP. MODEL 300 TAPS TO 4" Hand er Power Operated 400`F. (S' 200 PSI or 1000 PSI @ 100F. TYPICAL DRILLS & CUTTERS NEEDED TO COMPLETE VARIOUS SIZE TAPS (Model 660 Machine) WrnSon insertooth cutters for Mode! 660 tapping machine range in sizes 3" to 14" for pipe taps and up to 16" for tank taps. All cutters have tool steel cutting edges. Snsertlp pilots ate equipped with spring loaded stoel balls to bold cou pon ip cutter. INSERTIP PILOT Smmkk, spplksdim. s, hipping. mmhhuuL milk. PV drills (dsiAMpmsi $tft iappii$jp holm. ihjtDJugh. PLUG VJILVES The PV drill. Is a 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 PV DRILL SIZES FOR MODEL 660 TAPPING MACHINE 3" 4" 6" 8" For topping Through 8" Plug Volvo CARRYING CASE FOR TAPPING MACHINE SPECIAL COMPARTMENT FOR PILOTS HOLDERS, SMALL COTTERS, ETC. MACHINE IS HELD IN PLACE ITH BOOMER TYPE CLAMPS --if **'*' MODEL 1200 PIPE TAPS TO 24" TANK TAPS TO 30" Power Optraidd S00F. <" 500 PSI cr 1200 PSI <f? 100*F. STEEL PROTECTIVE HOOD CLAMPS TO SKID UNIT BASE PROVIDING A COMPACT CARRYING CASE ] WA-TEX 001457 1L HiWdDDd(sg^ddo Dcca ^UUIA* P. O, B O X 4 0 3 * TUtJ A 9 OKLAHOMA ITEM NO. B-^8 TRAINING DETAILS Atr motor w/2il gear reducer Clutch Hsndlc Minimum compressor requirements! 105 CFM @ 90 psi. (Furnished by customer) NOTE: Hydraulic power is recom mended for taps over 12" HYDRAULIC POWER gS|mptete self-contained IjUtver unit. No other source of power required. Hydraulic Power Unit 9 H.P. air cooled gasoline engine 20 gal. hydraulic fluid reservoir (SAE 10 W oil normally used for fluid.) Not furnished, e Hydraulic hose -- 50 ft, Diameter: 56" for pressure line %" for return line Hose connections equipped with best quality self sealing couplings ta prevent loss of hy draulic fluid and to keep system clean. PAGE 252 TYPICAL TAPPING SET-UP * WittSon Sandwich topping valve. Conventional goto volvo may be used. I wa-TEX 00X458 ITEM NO. B-48 TRAINING DETAILS PAGE 253 WlSon-Hflco Tapping Machines Models 660 li 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 @ moo f. Maximum operating temp., both models: ' 7000 F-, @ 700 psi Each machine factory tested to 2,176 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 boo lbs. 760 w/air motor 625 tbs. 660 w/hydraulic 535 lbs. . 760 w/hydraulic 660 lbs. Lengths: 660,6414" without measuring rod 11034" with rod 760,8814" without measuring rod 15814" with rod Cutters are available for standard pipe taps. Stopple Plugging Machine taps and Shortstopp5 Plugging Machine taps. Special cutters can be furnished for tanks and flat plate taps, . U. S. PATS. 2,679,173 - 2.097.39B WA-TEX 001459 ITEM NO. B-48 TRAINING DETAILS PAGE 254 For making connections to pipelines and plant piping safely and without shut down. Hand operated or air motor drive. Specifications! Boring bar travel: 24" Tank taps to 4", pipe taps to 6" Maximum operating pressure: 1,440 psi @ 100 F. Maximum operating temperature: 700 F. @ 700 psi Each machine factory tested to 2,175 ps! Power: Manual or air molar Feed: .005 per revolution Lower-in crank: 12 turns per inch Weights: Hand powered, 125 lbs. Air powered, 163'/a lbs, length: 42U" without measuring rod 70" with rod 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. Special cutters can be furnished for tanks and flat piate taps. ( WA-TEX 001460 l Wii, ITEM MO. B-48 TRAINING DETAILS PAGE 255 WKON SHORTCUT! DHULUK MCMIS T-8, T-12 & T-18 U.S. PATENT NO'S 3068725, 3068726 & PATENTS PENDING IN OTHER COUNTRIES ! WA-TEX 001461 ITEM NO. B-48 TRAINING DETAILS PAGE 256 Installation of Pig-lag Scraper Passage Indicator Shown below 1$ the proper cutter and drill, either of which may be used for drilling a hole for Pig-Sig ' installation. The proper valve adapter is also shown, " Cutter holder-- Pilot 5-206 Cutter Stock No. 5481-01 t%" igq Di-m pyj Drill Stock No. 5-193-01 Q Valve Adopter for Cutter or Drill . 706-U for mo on 2* threaded valve. Notes-- Cutter designed for wall thicknesses up to and including (For thicker wall pipe use drill.) Valve requirements: Min. thru bore 2". 2" Thread-O-Ring'9 Pfwg Holder A plug holder is used for setting Pig-Sig assembly with the T-10f. 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. 4i.,, M vSy- j.r`" , Thiead-O'Rinti is a i, D. Wi{'uin6,on. Inc, traderna/k for n eMcrn#lly, internally threaped pipe nipple. Hole Saws and Valve Adapts rs Hole saws are used with the T-101 for size on size taps. Stock No. 5485-01 Hole Saws >, {{ole Saw A: Diameter w-; Homri'iCutter Vsizeg-O.D. Hole Saw Holder-Plbi ; Stock - .' No. 1 *>* ' - 5-204 . 5-204 -,. 5-205 Hole Saw Stock No, 5-179-02 5-179-03 5-179-04 Valve Dimensions* Valve Sfza Min. Thru Sere Matt. Pace to Face Dimension 2" W 14%" 3" 3V." )414" 4" 12" Valve Adapters (threaded) `-`siio Stock No. "^'TVSC 705-15 Size 3" Stack No. 6-1303-01 Valve Adapters (flanged) Size Series Stock No. ' 2" 150# 6-1305-15 3" 150# 6-131845 A" 150#. . 6`-1'302-15 '' 2" 300# 64305-30 3" 300# 64318-30 4" 300# 6-1302-30 2" 600# 3" 600# 4" 600# thru bare diameters and maximum face to face dimensions for making taps thru Shortstopp itl ? i" mw*' *' * ' WA-TEX 001462/._L. ITEM WO, B-48 TRAINING DETAILS CHOICE OP FITTINGS THREAD-O-RIHG NIPPLE PAGE 257 THREAD-0*-RING PLUG CAN BE SUPPLIED WELDED TO SCARFED HIPPIE OR WELDOLET FITTING. HADE FROM STANDARD WELDING FLANGE OF SPECIFIED SERIES AND FACING. / SCARFED TO FIT SPECIFIED PIPE SIZE. MADE FROM SEAMLESS STEEL TUBING. PRESSURE RATING: Plugs are Installed against line pressure up to 1,000 PS I using VlmSON-HILLCO Tapping Machines* MADE FROM NAVAL BRASS WITH NEOPRENE O-BING INSTALLING TEST COUPON IN PIPELINE WITHOUT SHUTDOWN DRILL AND HOLDER 3. DRILL IS REPLACED BY PLUG HOLDER AND THREAD-O-RING PLUG. BLIND FLANGE 5, TAPPING.MACHINE REMOVED, VALVE RECOVERED AND BLIND FLANGE 111 PLACE. NOTE; COUPON IS RECOVERED.BY ABOVE PROCEDURE IN REVERSE. Threaded plugs are Installed and removed with the following WmSON-HlLLCO Tapping Machines only; Models loo, IQOB, iooc, 300 and 3o, Ltolitwl P. O. BOX AO TULSA 3, OKLAHOMA WA-TEX 001463 ITEM NO. B-48 Kt r TRAINING DETAILS PAGE 258 The Plidco Hot Tapping Saddle is an adaptation of the PJidco Split-Sleeve. It is used for hot taps where sur rounding conditions do hot permit the immediate in stallation 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 Rob. t. m. Write for Bulletin HT-700 PLIDCO HOT TAPPING SADDLE SPECIFICATIONS /-- Mein Pipe (Run) Ncmlrul Siza Branch Pipe Nominal Slid Inches z1 % 3 4 a 6 8 B 10 10 12 12 *12 14. 14 *14 16 16 `16 18 18 *"18 20 20 *20 22 22 *22 | 24 1 24 ! `24 1 26 g 26 1 `26 g 30 1 30 ! *30 Inches 1 thru 1 % 1 thru 2 1 thru 3 1 thru A 1 thru 4 5 and 6 1 thru 4 5 thru 8 1 thru 4 5 thru 10 1 thru 4 5 thru 10 12 1 thru 6 3 and 10 12 and 14 1 thru 6 8 and 10 12 thru 16 1 thru 6 18Band 10 12 thru 1 thru 6 S and 10 12 thru 20 1 thru 6 8 and 10 12 thru 22 1 thru 6 8 and 10 12 thru 24 1 thru 6 8 and 10 12 thru 26 1 thru 6 8 and 10 12 thru 30 Body Olmmlons Unctl) Dlom. Between of I.D. 0.0. Overall Langth End Packing Studs W B* JC> *D* Inches Incites Inches Ineho* inches 2>A 3% 8%. 2'/, 3V, 6 V* 4 6 a% 5 6 6% 7>/<r B'/, 9 7 '/a 8% 18 9% 10% 10 914 10%. 28 ll'/l 12% 10% IP/. lay. 18 13*/, 14% 10% 13 V, 14% 18 13*/, 14 V* 24 14 V, 16% 14 14 Vi 16% 18 14 V, 16% 24 16% 18% 14 16% 18% 28 16V* 18% 24 18 % 21 14 18% 21 15 1 8% 21 20 % 23 26 14 2D'4 23 15 20% 23 28 22% 25 14 22% 25 28 22% 25 24V* 21 24'/, 27 30 14 18 24% 27 32 26 V* 30 26 V* 30 14 18 26 V* 30 34 3030 V* 34% 14 % 34 V* 18 30 V* 34 V* 38 s% 5'A 5*4 SV. 3% 22 3*4 22 5% 12 5% 12 18 8 22 18 e 22 18 8 12 20 8 22 22 8 12 24 8 12 26 8 12 28 8 12 32 % % % % % % % */ 1 i i l 1 i% PA P/o 1% P/, 1*4 1*4 1% P4 PA pa PA PA PA 1% PA PA 1% PA P/r 1% PA PA PA * Not available from stock Length Branch Sidt Bars Approx. Shipping Woltht *El Jntftos Inchtt Pound, 2% 1 x 1 18 2% 1 xP/j 20 2% 1 X PA 28 3 PAxP/i 35 3 PAxl'A 4B 3 I%xl% 120 3*A 2 xl'A 114 3% 2 x PA 180 4 2% x2 M3 4 2% x2 225 4 2% x2 263 4 2% x 2 270 4 2% *2 360 4 3 X 2% 264 4 3 x 2% 340 4 3 x2% 454 4 3 x 2% 295 4 3 x2% 380 4 3 x 2% 505 4 4 x 2*A 360 4 4 x2% 465 4 4 x2JA 670 4 4 x 2'A 400 4 4 x2'A 515 4 4 x 2% 800 - 4 4 x3 485 4 4 x3 625 4 4 x3 1038 . d 4 X3 520 4 4 x3 670 4 4 x3 1885 4 5 x3 618 4 5 x3 795 4 5 x3 1500 4 5 x3 940 4 5 x3 1218 4 5 X 3 2550 / Larger sizes on application THE P>8P!S OEVgLOPMEiyT COMPAIUY 5350 W8St 130th Street Cleveland, Ohio 44142 Telephone: (Area Code 216) 267-1640 j Export Department: 17 Battery Place. Now York, New York 10004 Cable: WELDENDS-New York * WA-TBX 001464 TEXACO INC. PUGET SOUND PLANT PAGE 259 TRAINING DETAILS DEPARTMENT: PIPE , CLASSIFICATION! PIPEFITTER (TRAINEE) DATE: JULY X, 1970 ' ITEM NO. B-49 SUBJECT: DISMANTLE, REPAIR AND reassemble oxygen Lines AND EQUIPMENT ' a.SAFETY: To avoid Tiro 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 '' ' . b.ASSEMBLE: The system should be assembled without the use of any greased Joint compound. Gasket paste Is bdt to be Used on fcaskdts, 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 services these elements are not to be installed until final equipment assembly. Valves should be Installed* but without seats, gates, discs and other removeable parts. * c.HYDROSTATIC TESTING: Each section of the line should be ., subjected to a hydrostatic test, . '.using.clean, oil free water. The test pressure should be 15 times 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 Bhall be l.l times maximum operating pressure. When testing with nitrogen, 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. _ -~v . ' e.DEGREASING OXYGEN LINES: The system should be degreased by washing with trichlorethylene solvent followed by oil free hot water, then blown dry 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 / WA-TEX 001465 ITEM NO. B-49 TRAINING DETAILS PAGE 360 repacked with dry oil-free asbestos packing. ' 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 Acheson 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 (John3-Manville Chempac 2024.) . (2) Low pressure nitrogen (app. 75 lbs.) 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.REASSEMBLES When reassembling existing oxygen lines and equipment after repairs are made, wash all parts with Trlehlorethylene 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 nuts, 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. j WA-TEX 001466 t ?mTwEXrAmCOmXrHrCu. wr training DETAILS PAGE 261 DEPARTMENTS PIPE ,, CLASSIFICATION? PIPEFITTER (TRAINEE) DATES JULY 1, 19TO ITEM NO. B"50 ' SUBJECT? INSTALL PIPE CLAMPS A pipe damp Is used to repair a leak when the pipe line can't be blocked off or welding can't he done In the area. The pipe to be clamped must be cleaned as well as possible before putting the clamp over the hold It is Important that the clamp is centered over the hole and tightened evenly. ' WA-TEX 001467,