A piping network carries steam, condensate, process fluids, and utilities between generation points and users. JBM engineers, fabricates, and installs complete networks from 15 to 200 NB, covering plant steam, condensate, clean steam, hygienic process, utility water, compressed air and nitrogen, CIP, thermic fluid, and vacuum service, in welded, flanged, and tri-clamp construction to ASME B31.1, B31.3, BPE, and IBR.
Line sizes are selected for velocity and pressure drop: 25–35 m/s for steam, 1.5–3 m/s for liquids. Routing follows a slope for drainage, with drip legs on steam mains and self-draining falls on hygienic lines. Joints are butt-welded, orbital-welded, flanged, or clamped to suit service. Supports, guides, anchors, and expansion loops absorb thermal movement, and every line is pressure tested, flushed, and tagged before handover.
Challenges
Thermal Expansion
Hot lines grow and overstress supports and equipment nozzles.
Dead Legs and Poor Drainage
Low points and long branches trap product and condensate.
Weld Quality
Inconsistent manual welds cause leaks and hygienic failures.
Energy Loss
Uninsulated steam and hot lines waste fuel and cause burn risk.
Congested Layouts
Clashing routes block access for operation and maintenance.
Solutions
- Stress Analysis + Loops: Loops, bellows, guides, and anchors placed per calculated movement.
- Slope and 2D Branch Rule: Drainable falls and branch lengths within 2D for hygienic lines.
- Orbital Welding + Inspection: Automatic welds with borescope and radiography records.
- Insulation and Cladding: Surface held below 55°C; heat loss reduced by up to 90%.
- 3D Modelling and Rack Design: Clash-free routing with access corridors and tagged lines.
Applications
- Pharmaceutical: Clean steam, WFI, CIP, and process transfer lines.
- Food & Beverage: Product transfer, steam, and chilled water networks.
- Chemical: Thermic fluid, solvent, vacuum, and nitrogen lines.
- Utilities: Boiler house, air compressor, and cooling tower distribution.
Types & Configurations
| Type | Code | Material & Joint | Pressure / Temp. | Design Code | Typical Use |
|---|---|---|---|---|---|
| By Service | |||||
| Steam (LP / MP / HP) | ST | CS A106 Gr.B seamless, butt or socket weld | LP ≤3.5, MP ≤10.5, HP ≤17.5 bar; 210°C | ASME B31.1 / IBR | Boiler to users |
| Condensate Return | CD | CS A106 Gr.B Sch 80 or SS304 | ≤10 bar; 180°C | ASME B31.1 | Trap discharge return |
| Clean Steam | CS | SS316L tube, orbital weld, Ra ≤0.6 µm | ≤6 bar; 165°C | ASME BPE | SIP, humidification |
| Process (Hygienic) | PR | SS316L tube, orbital weld, electropolish option | ≤10 bar; 150°C | ASME BPE / 3-A | Product transfer |
| Utility Water (CHW / CW / HW) | UW | CS, SS304, PPR, or HDPE | ≤10 bar; 5–95°C | ASME B31.3 | Cooling and heating water |
| Compressed Air & Nitrogen | AN | SS304, GI, or aluminium | ≤10 bar; ambient | ASME B31.3 | Instrument and process gas |
| CIP Supply & Return | CIP | SS316L tube, orbital weld, 1:100 fall | ≤6 bar; 90°C | ASME BPE | Cleaning circuits |
| Thermic Fluid | TF | CS A106 Gr.B seamless, spiral wound gaskets | ≤10 bar; 300°C | ASME B31.3 | Hot oil heating |
| Vacuum | VC | SS304 / SS316L, welded or O-ring flanges | FV to 1 mbar | ASME B31.3 | Dryers, reactors, distillation |
| By Construction | |||||
| Welded (Butt / Orbital) | -BW | B16.9 fittings, TIG root, orbital for tubes | Full line rating | ASME B31.3 | All services |
| Flanged | -FL | B16.5 flanges with suitable gaskets | 150# / 300# | ASME B16.5 | Equipment and maintenance breaks |
| Tri-Clamp Hygienic | -TC | Ferrule, clamp, and EPDM or PTFE gasket | ≤10 bar; 150°C | ASME BPE / DIN 32676 | Removable hygienic joints |
| Pre-Insulated / Jacketed | -INS | Mineral wool or PUF with cladding, or jacketed pipe | −20 to 250°C | CINI / ASTM C585 | Heat retention, viscous products |
| Supports, Racks & Expansion Loops | -SUP | MS / SS supports, guides, anchors, loops, bellows | Per stress analysis | MSS SP-58 | Thermal movement and routing |
Pipe Size Data: 15 to 200 NB
| Size | OD [mm] | Wall Sch 10S [mm] | Wall Sch 40 [mm] | Steam Cap. [kg/h] | Water Flow [m³/h] | Span Water [m] | Span Steam [m] | Wt. Sch 40 [kg/m] | Hygienic Tube OD [mm] |
|---|---|---|---|---|---|---|---|---|---|
| 15 NB | 21.3 | 2.11 | 2.77 | 74 | 1.4 | 1.8 | 2.1 | 1.27 | 12.7 |
| 20 NB | 26.7 | 2.11 | 2.87 | 130 | 2.5 | 2.0 | 2.4 | 1.69 | 19.05 |
| 25 NB | 33.4 | 2.77 | 3.38 | 210 | 4.0 | 2.1 | 2.7 | 2.50 | 25.4 |
| 40 NB | 48.3 | 2.77 | 3.68 | 490 | 9.5 | 2.7 | 3.4 | 4.05 | 38.1 |
| 50 NB | 60.3 | 2.77 | 3.91 | 810 | 16 | 3.0 | 4.0 | 5.44 | 50.8 |
| 80 NB | 88.9 | 3.05 | 5.49 | 1,800 | 34 | 3.7 | 4.6 | 11.29 | 76.2 |
| 100 NB | 114.3 | 3.05 | 6.02 | 3,100 | 59 | 4.3 | 5.2 | 16.07 | 101.6 |
| 150 NB | 168.3 | 3.40 | 7.11 | 7,000 | 134 | 5.2 | 6.4 | 28.26 | 152.4 |
| 200 NB | 219.1 | 3.76 | 8.18 | 12,100 | 232 | 5.8 | 7.3 | 42.55 | N/A |