piping materials lhk
TRANSCRIPT
PIPING MATERIALS
INTRODUCTION
Piping materials are of many types. The specific material to suit a design requirement is chosen on the basis of certain key factors.
FACTORS AFFECTING SELECTION OF PIPING MATERIALS
• Mechanical properties – tensile, yield, creep, rupture, fatigue and impact
• Performance requirements and material reliability• Safety• Environmental conditions• Availability• Resistance to erosion and corrosion• Economic factors
VITAL CHARACTERISTICS REQUIRED Toughness
Creep StrengthDuctility
Good surface finishHardness
CLASSIFICATION OF PIPING MATERIALS
O T H E R S P E C IA L A L L O YS
S T A IN L E S S S T E E L
A L L O Y S T E E L
C A R B O N S T E E L
C A S T IR O N
F E R R O U S
L E A D A N D IT S A L L O YS
N IC K E L A N D IT S A L L O YS
A L U M IN IU M & IT S A L L O YS
C O P P E R & IT S A L L O YS
N O N -F E R R O U S
M E T A L L IC
C E M E N T
C E R A M IC
G L A S S
L D P E
P T F E
H D P E
P V C
N O N -M E T A L L IC
F R P P P L IN E D
M S G L A S S L IN E D
M S C E R A M IC L IN E D
M S L E A D L IN E D
M S P T F E , M S P V DF
M S R U B B E R L IN E D
L IN E D
P IP IN G M A T E R IA LS
COMMONLY USED PIPING MATERIALS LOW CARBON STEEL, LOW ALLOY STEEL AND STAINLESS STEELS
(used for high temperature services)
WROUGHT IRON, CAST IRON, DUCTILE IRON, COPPER, BRASS, ALUMINIUM AND ITS ALLOYS AND NICKEL STEEL
OTHER PLASTICS MATERIALS
(PVC, polythene, polypropylene, asbestos cement, GR pipes, concrete, glass, rubber and some newer plastics)
TEMPERATURE LIMITATION OF PIPING MATERIALS
SI NO
MATERIAL MAX WORKING TEMP OC
REMARKS
1 Carbon Steel Yield stress decreases beyond this temp
A106 GrB 427
API 5L GrB 230
2 Alloy Steel -do-
A335 GrP11 570
A335 GrP22 600
A335 GrP91 650
3 Stainless Steel From –220 OC to 538 OC
A312 GrTP304 -200 to 500
A312 GrTP316 -200 to 538
4 Aluminium 175 Loses strength beyond this temp
5 Titanium 400 -do-
6 Thermoplastics 260 Melts beyond this temp
7 Thermosetting plastics
260 Some epoxies can be used upto 290 OC
8 Concrete 290 Cannot be used for temp intensive services
9 Rubber Room Temp -do-
MATERIAL PROPERTIESMATERIAL YIELD STRENGTH (Mpa) UTS (MPa)Carbon Steels 260-1300 500-880
Cast Irons 220-1030 400-200
Low Alloy Steel 500-1980 680-2400
Mild Steel 220 430
Stainless Steel, austenitic 286-500 760-1280
Stainless Steel, ferritic 240-400 500-800
Nickel and its alloys 200-1600 400-2000
Titanium and its alloys 180-1320 300-1400
Copper 60 400
Cooper Alloys 60-960 250-1000
Brasses and Bronzes 70-640 230-890
Aluminium 40 200
Aluminium Alloys 100-627 300-700
Lead and its alloys 11-55 14-70
Tin and its alloys 7-45 14-60
Polypropylene 19-36 33-36
Polyurethene 26-31 58
Polyethylene HD 20-30 37
Polyethylene LD 6-20 20
FERROUS MATERIALS
CARBON STEELS
Is an alloy of Iron and Carbon
Contains 0.1 % to 1.5 % of Carbon
Based on Carbon Content it can be classified into
1. Mild steel - 0.05 % - 0.30 %
2. Medium Carbon steel – 0.30 % - 0.70 %
3. High carbon Steel – 0.70 % - 1.5 %
4. It can withstand upto to a temperature of 450 C
General chemical composition of CS is C - 0.07, 1.56 %, Mn – 1.6 %,
Si – 0.6 %, S – 0.1%, P – 0.1%.
CARBON STEEL – MATERIAL COMPOSITION
C Mn Si P SA106 GrB(1/2”-14”)
API 5L GrB(1/2”-14”)A53 GrB(1/2”-14”)
A105 (S.W.)(1/2”-1½”)
A216GrWCB2” & above
0.04 0.045CS castings suitable for high Temp services 0.3 1 0.6
0.035 0.035
Forged CS for ambient and high Temp services 0.35 0.9 0.35 0.05 0.05
MATERIAL DESCRIPTION CHEMICAL COMPOSTION
Seamless, CS pipe for low Temp services (Galv) 0.3 0.9 0.15 - 04
0.035
ERW ( E=0.85), CS pipe, Seamless 0.27 1.15 - 0.04 0.05
Seamless, CS pipe for high Temp & Pr services 0.3 0.29 - 1.06 0.1 0.035
ALLOY STEELS
• Adding of Alloying elements to improve the characteristics of the material is termed as Alloy Steel.
• Commonly used Alloying elements are Silicon, Chromium, Nickel, Molybdenum, Manganese, Vanadium, Titanium, Boron, Aluminium, Cobalt and Tungsten.
• WHAT ARE THE EFFECTS OF ALLOYING?
PURPOSE OF ALLOYING
1. Improved Corrosion resistance 2. Better Hardenability 3. Improved Machinability High or low temperature Stability Ductility Toughness 4. Better Wear resistance
INFLUENCE OF ALLOYING ELEMENTSAlloying Advantage Disadvantage
Aluminium Resistance to heat and oxidation(2 - 5 %) Improves scale resistance
Imparts strength Increases wear resistance (carbides) Corrosion resistance Hardness & Strength If above 5% corrosion resistance is improved even at high temp
Manganese Increases tensile strength & machinability Improves hardenability
Molybdenum High temp strength & impact resistance(0.15 – 0.6 %) Corrosion resistance especially to chloride solutions
MachinabilityNickel Decreases decomposition of austenite
(upto 5%) Increases resistance to oxidation at high temp Decreases critical temperature Prevents precipitaion of Cromium Carbides Imparts strength Wear resistance Abrasion resistance Increases red hardness (hot working) Powerful deoxidiser, forms strong carbides Wear resistance & strength Causes fine grain structure
Increases brittleness
ChromiumMachinability,
weldability
Vanadium
Machinability
Titanium
Tungsten
LOW ALLOY STEEL – MATERIAL COMPOSITION
C Mn Si Cr Mo
0.05 - 0.15 0.3 - 0.6 0.5 1.9 - 2.6 0.87 - 1.13 HP, superheated and hot reheat Steam
0.08 - 0.12 0.3 - 0.6 0.2 - 0.5 8 - 9.5 0.85 - 1.05 Superheated steam piping system
Pipe fitting alloy steel for moderate and elevated Temp
0.05 - 0.15 0.3 - 0.6 0.5 1.9 - 2.6 0.87 - 1.13 High Temp services
Alloy steel castings for Pr containing parts suitable for high Temp services
0.18 0.4 - 0.7 0.6 2 - 2.75 0.9 - 1.2 Valves for AS pipes
Ferritic alloy steel pipe for high Temp services
DESCRIPTION CHEMICAL COMPOSTION SERVICE
STAINLESS STEEL
Adding 11.5 % or greater chromium in iron,changes the microstructure and based on that its varieties are obtained.
Posses greater percentage of chromium which forms a chromium oxide film exposed to air that prevents chemical attack of moist air on the material surface
Nickel retains the austenitic structure of steel Greater resistance to corrosion than all types of steels Classified into three types based on its micro structure 1. Austenitic stainless steel 2. Ferritic stainless steel 3. Martensitic stainless steel
STAINLESS STEEL – MATERIAL COMPOSITION
C Mn Cr Mo Ni
A312Gr.TP316L(1/2”-14”)
A403 Gr.WP304
A351Gr.CF8A182
Gr.F304
(2” & above)
8 - 11
Forged fittings
Castings
A312 GrTP304
2-Mar 11 - 14 Corrosive process service
SERVICE
18-20 - 8 - 11Wrought austenitic stainless steel pipe fittings 0.08 2
MATERIAL DESCRIPTION CHEMICAL COMPOSTION
8 - 11 Hydrocarbons, chemicals, etc.
Welded & seamless austenitic stainless steel0.27 1.15 16-18
-
0.04 2 18-20 -
Valve castings
0.08 2 18-20 - 8 - 11 Flanges
0.08 1.5 18-21
NON-FERROUS MATERIALS
COPPER AND ITS ALLOYS
• Used when heat and electric conductivity are important• Theraml conductivity is high• Alloys are brasses, Bronzes (Cu-Sn) and Cupronickels (Cu-Ni)• Upto 20% Zn in Brass gives good corrosion resistance• Bronzes display good strength with corrsion resistance• Cupronickels have highest corrosion resistance among Cu alloys• Cupronickels are used for heat exchanger tubing
NICKEL AND ITS ALLOYS
• Easy machinability and weldability• Chloromet and Hastelloy are widely used other than Monel 400• Not resistant to oxidising environments• Monel 400 is used to handle dilute sulphuric acid and
hydrochloric acid• Alkalis and sea water do not affect Nickel
ALUMINIUM AND ITS ALLOYS
• Good thermal conductivity• Most workable metal• Highly resistant to atmospheric conditions, industrial fumes,
fresh brackish or salt water• Not resistant to corrosion• Loses strength rapidly at 1750C.
TITANIUM
• Strong and medium weight• Titanium Oxide is formed which prevents corrosion• Resistant to Nitric acid of all concentrations except fuming
nitric acid• Welding requires inert atmosphere• Loses strength above 4000C• Provides good resistance to hydrochloric acid when alloyed
with 30% Molybdenum• Not affected by impingement and crevice corrosion
COMMON NON-FERROUS PIPING MATERIALS (METALS)ASTM Des. DESCRIPTION SERVICES
SB42 Seamless Cu pipes Heat exchanger services
SB43 Seamless red brass pipes Moderate corrosion resistance
SB75 Seamless Cu tubes Heat exchanger tubing
SB161 Ni seamless pipes & tubes Alkaline solution, sea water
SB165 Ni-Cu alloy, seamless pipes & tubes Dilute sulphuric acid
SB167 Ni-Cr-Fe alloy for seamless pipes & tubes Hydro fluoric acids
SB171 Ni-Cr-Fe alloy for condenser tube plates Condenser tubing
SB210 Al alloy drawn seamless tubes Cryogenic
SB241 Al alloy extruded tubes & seamless pipes Cryogenic and low temp
SB337 Seamless and welded Ti & Ti alloy pipes Nitric acid & sea water
SB444 Ni-Cr-Mo-Columbium alloy, seamless pipes & tubes
High concentration acid
SB564 Ni alloy forgings Forged pipe fittings
SB690 Fe-Ni-Cr-Mo alloys, seamless pipes & tubes
Wear resistant services
NON-FERROUS MATERIALS COMPOSITIONASTM
DesSi Cu Al Ni
(Co)Pb Fe Zn Mn Ti P C Cr Others
SB43 - 84.6-86
- - 0.5 max
0.5 max
Rem. - - - - -
SB75 - 99.9min
- - - - - - - 0.015-0.45
- -
SB161 0.35max
0.25max
- 99 min
- 0.4 max
- 0.35 max
- - 0.15 max
-
SB165 0.52-3
0.3-0.5
0-2.4 45-72 - 6-25 - 0.5-1.5
0.05-0.1
0.02 max
0.05-
0.25
14-29
SB171 - 58-62 6-11 - 0.07-0.25
0.06-0.4
0.2-1 1-1.5 0.1-0.2
- - - Sn
SB241 0.2-0.6
0.05-0.4
- - - 0.35-0.7
0.05-0.25
0.03-1.5
0.05-0.2
- - 0.05-0.25
SB444 0.5max
- 0.4 max
58 - 5 max - 0.5 max
- 0.015 max
0.1 max
20-23
Cb, Ta, Co, Mo
SB564 0.05-1
0.2-40
0.1-0.5
20-99 - 0.2-50 - 1-3 0.1-2 0.04 max
- 0.5-35
Mo
SB690 1 max
0.75 max
- 23.5-25.5
- Rem. - 2 max
- 0.04 - 20-22
Mo, N
NON-METALLIC PIPES
COMMONLY USED NON-METALLIC PIPING MATERIALS
• Plastics – Thermoplastics and Thermosetting plastics• Concrete• Ceramic• Asbestos-Cement• Glass• Rubber
THERMOPLASTICS
POLYVINYL CHLORIDE (PVC)
• Tough and exceptionally resistant to chemical attack• Rigid unplasticized Polyvinyl Chloride is thermoplastic material• Pipes are manufactured by extrusion• Fittings, flanges and valves are manufactured by injection
moulding
TYPES OF PVC
There are three types of PVC pipes,
Type-I, “normal-impact” grade
Type-II, “high-impact” grade
Type-IV, newer grade
PVC MATERIAL PROPERTIES
PROPERTIES TYPE – I TYPE – II TYPE - IVHydrostatic design
pressure2000 psi 1000 psi 1600 psi
Temperature 160 OF - -
Grades available PVC 1120, PVC 1220
PVC, 2110, PVC 212, PVC 2116
PVC 4116
ADVANTAGES OF PVC PIPES
• No physical or little deterioration when exposed to direct sunlight, unlike other plastics
• Does not support combustion• No scales are formed over smooth inside surface
APPLICATIONS OF PVC
• Extensively used in highly corrosive application involving acids, alkalis, salt solution, alsohols and many chemical
• In oil fields as it can carry sour crude oil to which PVC is inert and paraffin built-up is minimum
• Salt-water disposal in oil fields• Gas transmission service• Cold water line in Industry as it is non-toxic and doesn’t add
any odour or taste to water• For vent piping for removal of acid fumes and corrosive gases
TETRAFLUROETHYLENE (TEFLON)
• Unaffected by alkalis and acids except flourines and chlorines, molten metals at elevated temperatures (260 0C max)
• TFE + Chlorine = CTFE, which is highly resistant to corrosion by acids and alkalis up to 180 0C
• TFE components can be prepared only by powder metallurgy
POLYETHYLENE (PE)
• Produced from hydrocarbons and ethylene under high temperature and extremely high temperature pressure
• Types – Low, Medium and High Density• HDPE is not very flexible as LDPE• 2% Carbon black is added to increase weather resistance
APPLICATIONS OF PE
• HDPE is used in jet wells and farm sprinklers• Salt water disposal lines• Chemical waste lines• Gas gathering systems• Conduit for power and telephone cables
ACRYLONITRILE-BUTADIENE-STYRENE (ABS)
• It produced by injection or compression moulding• Exhibit good toughness and tensile strength
APPLICATIONS OF PE
• Service of inorganic acids, bases and salts• Sewage piping• Crude oil and gas piping
THERMOSETTING PLASTICS
Generally produced by centrifugal casting, hand lay-up moulding and filament winding. Major resins are Epoxy and Polyester resins and generally reinforced with glass or blue asbestos fibre.
EPOXY
• Used in transportation of acids, neutral or basic salt solutions, waste process water and sewage
• Used in paper industries for pulp stock wastes and dyes• It resists fouling, salt atmosphere and marine organism• Used in food and beverage industry
CONCRETE PIPES
CONCRETE PIPING MATERIALS
• Types – reinforced and non-reinforced• Some non-reinforced concrete pipe material specifications are
ASTM C14, AASHO M86, ASTM C412, etc.• Non-reinforced pipe sizes vary from 12” to 24”• Some reinforced concrete pipe material specifications are
ASTM C76, AASHO M170, SS-P-375, etc.• Used for sewage and industrial waste, storm waste, culverts,
water supply
ASBESTOS-CEMENT PIPES
• Not used very commonly• Some standard material specification are ASTM C296, AWWA
C400, SS-P-331, etc.• Used for drains and industrial waste
PIPE LININGS
COMMONLY USED LINING MATERIALS
• Rubber• Plastic• Lead• Glass• Epoxy resin• Synthetic resin
RUBBER LINED PIPES
• Natural and Synthetic rubber linings are used to counteract corrosion
• Generally used in the temperature range of –20 OC to 50 OC• Commonly used natural rubbers are soft rubber, semi-hard and
hard rubbers• Commonly used synthetic rubbers are Polychloroprene-
Neoprene, Butyl rubber, Nitrile rubber and Thiokol• Cannot be used for strongly oxidising conditions or halogenated
carbon
PLASTIC LINING
• PTFE and PVC are important lining materials• Used for chemical resistance, corrosion protection, resist
abrasion, non-toxic and smooth bore reduces friction• PTFE is chemically inert and used from –270 OC to 260 OC• Polyvinyl flouride, fluoroethylene propylene and polypropylene
can be added to enhance the range of PTFE• PVC provides tough and heavy-duty finish resistant to most acid
and marine growth
LEAD LININGS
• Lead lining is useful for most corrosive fluids and sulphuric acid below 80% concentration
• Should not be used for nitric acid, hydrochloric acids, hydrofluoric acids, organic acids and alkalis
• Can be alloyed to improve mechanical properties
GLASS LININGS
• Glass enamel (glass like) inorganic compositions are used as linings
• Bonded to mild steel by fusion on metal surface above 750 OC• Provide good resistance against acid attack and abrasion• Cheap alternative in many situations• Temperature range of –20 OC to 250 OC
EPOXY RESIN LININGS
• Good resistance to alkalis and most acids except strongly oxidising ones
• Good resistance to abrasion by suspended particles due to glossy nature of lining
• Used mostly in natural gas pipe lines
SYNTHETIC RESIN LININGS
• Sprayed phenol formaldehyde can be used when expected corrosion is less
• Cannot be used above 80 OC• Because of sterile and non-tainting properties it is used in food
processing industries• Mostly used to line welded steel vessels
LINED PIPES SAMPLES
PIPING MATERIAL SPECIFICATION
What is a Material Specification?
A Piping Material Specification is an engineering specification that contains requirements for the selection of materials to be used in the construction and fabrication for all process and utility piping.
FEATURES OF A MATERIAL SPECIFICATION
• Material of construction, end construction, end connections and wall thicknesses for various ranges
• Individual line class of the piping materials• Codes and standards relevant to the pipes and fittings of the
specified material class• Line class coding system• Pressure-Temperature ratings for various fittings and limiting
sizes of fittings• Other general notes and design criteria as applicable to the
material class
CLASS SERVICE INDEX – IDEA STANDARDSSI NO CLASS MATERIAL MAX P
(kg/cm2)T RANGE
(OC)SERVICE
1 A1A CS 20 -29 to 300 Fuel oil, nitrogen liquid, fuel gas, NaOH, brine, steam tracing
2 A1AR CS 20 -29 to 300 Steam condensate, BFW
3 A1B CS 20 -45 to 400 Hydrocarbons, catalyst solutions, lube oil, flare, flue gas, caustic, hot
nitrogen
4 A21A 304 SS 19.33 -29 to 300 Pure water(pump seal cooling) WPF, additive solutions, seal oil, antifoam,
carbonate, brine II
5 A21B SS 19.33 -29 to 150 Demin. Water, other process
6 A37A Aluminium 1.4 100 Pneumatic conveying
7 B1C CS - - Chlorine vapour, chlorine liquid
8 B1EH CS 52 -29 to 260 Hydrocarbons for HDPE only (Dupont B1E)
9 D21A 304 SS 101.25 -200 Liquid ethylene (Cryogenic)
10 S5A CS polypropylene
lined
10.55 -29 to 80 Chemical sewer, regeneration wastes (H2SO4 and NaOH)
SOME MATERIAL COMPARISONS
GENERAL DESIGN CONSIDERATIONS
• Seamless pipes are mostly preferred in power piping, butt welded may also be used
• API 5L pipes are not permitted by IBR for design pr.>20 kgcm2 and temp>260 OC
• Most projects require multinational specification
• Economy precedes the choice of code for material specification, after design requirements
THANK YOU
FOR YOUR PATIENCE