In the commercial, industrial, and manufacturing sectors, process piping is important. In this article, we familiarize you with essential aspects of process piping, learn how it differs from traditional plumbing, and delve into its contributions across food and beverage production.
Let’s start with the basics of process piping:
Process piping refers to the pipes, valves, fittings, and other components used to transport fluids in industrial facilities. Unlike plumbing systems in residential or commercial buildings, process piping is designed for conveying fluids at high temperatures and pressures. Process piping is a key component of many manufacturing operations, particularly in the chemical, oil and gas, food and beverage, and pharmaceutical industries.
Process piping systems must be carefully engineered to handle hazardous, volatile, or unsanitary fluids. Components are typically made from stainless steel or alloys to withstand corrosion. Valves and pumps regulate flow rates, while insulation maintains temperatures. Proper slope, support, and layout prevent buildup and clogging. Advanced materials allow process piping to meet rigorous standards.
While plumbing and process piping both convey liquids, they serve very different purposes. Plumbing handles safe drinking water, drainage, and sewage in homes, schools, and offices. It operates at low pressures and temperatures. Process piping manages industrial liquids and gases at extreme heat, flow, and pressure.
Process piping must withstand caustic acids, volatile solvents, or sanitizing agents. Piping contains specialized materials and components not found in plumbing systems. The design requirements also differ significantly, as process piping aims for optimal flow rates, heat transfer, and energy efficiency in production processes.
A process piping system contains many interconnected components working together:
Now that you have a clear understanding of what process piping is and its components, let’s examine how it’s used in the food and beverage industry:
From food processing plants to pharmaceutical production, process piping is used to safely transport liquids, gases, slurries, and powders from one point to another. The fabrication and installation of these critical systems requires expertise, planning, and precision.
The fabrication of process piping begins with the design drawings and material specifications provided by the engineering team. Piping components like straight pipes, elbows, tees, flanges, valves, and filters are brought into the fabrication shop. The lines are customized, cut to length, deburred, beveled, cleaned, and stacked according to the spool drawings.
Fitters assemble the piping spools by welding the pipes, fittings, and other components per the isometrics. The welds, materials, and fabrication process must conform to applicable codes and standards like ASME B31.3, ANSI B16.5, and AWS D1.1. Heat numbers are recorded, and material test reports are filed for traceability. Once assembled, the spools are checked against the isometrics and engineering models to ensure fit-up and dimensional accuracy.
The spools are then sent for visual, dye penetrate, radiographic, or ultrasonic inspections based on code requirements. Insulation and painting are applied before the spools are shipped to the installation site. Proper handling, loading, and transportation procedures are followed to prevent damage en route.
At the plant site, the piping spools are unloaded and stocked according to area layouts. The civil and structural works would have been completed by this stage and the piping supports, pipe racks, and hangers installed. The prefabricated piping spools are lifted using cranes or rigging equipment and aligned with connecting piping or equipment nozzles.
Fit-up gaps are measured, alignment corrections are made, and the joints are tack-welded. Permanent shop welds may also be completed at this stage if partial welds were done during fabrication for transportation purposes. Flange bolts are then tightened to connect equipment like valves, strainers, and pumps.
Supports are adjusted, expansion joints are aligned, and sloping drain lines are verified using tubing levels. Once aligned, the piping systems are permanently welded according to code requirements. Welds are tested as needed, followed by hydro testing, which involves filling the pipes with water pressurized to 1.5 times the design rating.
The piping systems are then flushed, cleaned, and dried before insulation. After insulation and final supports are installed, the completed piping systems undergo leak testing using air or the actual process medium. Any leaks found are repaired before handover for pre-commissioning.
Given the hazards of piping system failure, certified service providers are critical. They should have qualified personnel, ASME code stamps, in-house spool fabrication, and experienced welders certified for all necessary methods and materials. The provider should have accredited testing and inspection equipment and robust QA processes compliant with ASME B31.3 and local codes. Their installation crews need training and expertise in critical lifts, rigging, alignment, and setting prefabricated modules for high-temperature process piping.
For over 90 years, Champion Industrial has been the go-to HVAC, metal fabrication, plumbing and pipefitting, and maintenance provider for businesses throughout Northern and Central California. As members of the National Certified Pipe Welding Bureau and Mechanical Contractors Association of America, our certified welders and fabrication experts craft powerful and efficient process piping systems based on your needs. Contact us today to discuss your process piping project and receive a free quote.
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