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In-Service Inspectors Pressure Equipment

Senior In-Service Inspectors Pressure Equipment

Lesson No 7

MATERIALS
In-service Inspectors

Contents
Subject Page

Ferrous materials 3
Carbon or unalloyed steel 3
Low alloy steels 4
Stainless steels 4
Copper alloys 5
Nickle alloys 6
Pressure parts 8
Assignment 10

Lesson 7 Materials
The most important materials used for the construction of pressure equipment in the
processing industry can be classified under the following headings:
1. Ferrous
2. Non ferrous
Steels and other ferrous metals dominate the industry and most of this section will
concentrate on these. Non ferrous metals will be covered in somewhat less detail. Non
metallic materials play only a minor role in boiler and pressure vessel construction at this
stage, and are not covered.

1. Ferrous Materials

Generally speaking, ferrous materials are classified as:

Carbon or unalloyed steels

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Low and medium alloyed steels

Stainless steels

Carbon or unalloyed steel

By far the most commonly used metals in the processing industry is carbon steel, which
contains mainly iron and small amounts of carbon, silicon, manganese, phosphorous and
sulphur. Carbon influences the mechanical properties of the material to a large extent; it
increases the tensile strength and hardness, reduces elongation and has unfavourable
effects on weldability.

Steel of the above type is known as unalloyed steel. Unalloyed steels can be further
subdivided according to Table 1.

Table 1: carbon content of typical carbon steel types

Typical carbon content %
Structural Steels 0.05 0.20
Steels for boilers and pressure vessels 0.15 0.35
Steels for machined parts 0.20 0.45
Tool Steels 0.40 1.10

In order to improve its properties, elements like nickel, chromium, molybdenum etc are
added to the steel. The types of steel thus obtained are called alloyed steel. The influence
of the various elements added to the steel in small percentages as indicated is illustrated in
Table 2. Greater amounts of alloying elements may have a different influence from that
indicated.
Table 2
Influence on
Alloying elements in Yield Tensile Elon- Impact Creep Weldability
steel Strength Strength gation Value Strength
C up to 0.9% >> >> << << > <<
Mn up to 1.8% >> >> < > > <
Si up to 0.5% > > < > > <
Ni up to 2% >> >> < >> > <
Cr up to 1.5% >> >> < < > <
Mo up to 0.5% > > < < >> <
>> Strongly Increasing << Strongly Decreasing
> Slightly Increasing < Slightly Decreasing

Steels are normally specified according to various national or international standards. The
most commonly standards specified are:
AS Australian Standards
AS/NZS Australia/New Zealand Standards
ASTM American Standard for Testing and materials
BS British Standards
SAE Society of Automotive Engineers
DIN German Standards
EN European Norm
JIS Japanese Steel Standard

A comparison list of standard specifications is given in Table 4 at the end of this chapter. It
would be worthwhile for the course participants to make themselves familiar with the most
common specifications used in their plant locations, and the inherent differences between the
different products, eg. ASTM A-106 Pipe Specification, ASTM A105 Flange Specification,

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(seamless pipe specification forging). A study of each specification will show that the
mechanical properties of different grades of steel can be significantly different. Therefore,
when specifying a 'grade of material' the service and fabrication constraints (eg. Amine,
caustic, H2S environments), post weld heat treatments to be applied, weldability and welding
expertise available all have to be taken into account. Not only during the initial design stage,
but just as importantly, during any subsequent repairs or modifications.

Low Alloy Steels

Low alloy steels have small amounts of alloys such as chromium, nickel and molybdenum,
generally added to improve mechanical properties. Apart from the influence of alloying
elements on the mechanical properties of steel, certain elements have a marked effect on
the corrosion resistance of the alloyed material. The most important element in this respect
is chromium, which increases the resistance to attack at high temperatures by oxygen,
hydrogen and sulphur. The addition of molybdenum enhances creep resistance properties.
Typically Chrome-Molly alloyed steels which are generally used are listed:
1%Cr. 0.5%Mo
1.25% Cr. 0.5%Mo
2.25%Cr. 1%Mo
5%Cr. 0.5%Mo

the low alloy grades of steel are primarily used in high temperature and hot hydrogen
service. What was said above in relation to the correct choice of material selection is
certainly more applicable where alloy materials are involved. The margin of error in these
applications is very much reduced, and the consequence of failure are potentially more
devastating.

Stainless Steels
Stainless steels are widely used in the oil and gas, as well as in the chemical and paper
manufacturing industries. The generic name stainless tells refers to a family of alloy steels
developed from a basic composition of iron, manganese and carbon. The range of steels
vary from the plain chromium variety to those containing up to six alloying elements in
addition to the usual impurities (tramp elements). The best known are the Austentic or 300
series which cannot be hardened by heat treatment. They contain chromium and nickel and
often other alloys as well. The Ferritic grades are cheapest, but show lower corrosion
resistance than the Austenitic. Martenstic also have relatively poor corrosion resistance, but
can be hardened by heat treatment. The newer duplex grades show good general corrosion
resistance to stress, corrosion cracking, but are expensive.

Table 3 lists the chemical composition for stainless steel grades commonly used. Each
grade of steel is specified for specific services based on the corrosion resistance and cost.
The task of specifying high alloy steels should not be taken too lightly if satisfactory service is
to be obtained from these relatively expensive alloys. A detailed knowledge is required of all
the process operating conditions, both during service and those that can occur during
shutdowns of the unit, or during changes in operational modes (for example, due to catalyst
regeneration or catalyst changes).

Table 3: Chemical Composition of some common stainless steels

Austenitic Stainless Steels-Composition
UNS Common C Cr. Mn Mo N Ni S Other
Name
S 30400 304SS 0.08max 18-20 2.0max 8-10.5 0.030max
S3100 310SS 0.25max 24-26 2.0max 19-22 0.030max
S 31600 316SS 0.08max 16-18 2.0max 2.0-3.0 10-14 0.030max
S32100 321SS 0.08max 17-19 2.0max 9-12 0.030max Ti 5x C. min

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Martensitic Stainless Steel-Composition

UNS Common C Cr. Mn Mo Ni P S Si
Name
S40300 403SS 0.15 11.5-13.0 1.0max 0.040max 0.030max 0.50max
S4100 410SS 0.15 11.5-13.5 1.0max 0.40max 0.030max 1.0max
S41600 416SS 0.15 12.0-14.0 1.25max 0.60max 0.15max 1.0max
S4200 420SS 0.15 12.0-14.0 1.0max 0.40max 0.030max 1.0max
Ferritic Stainless Steels-Composition
UNS Common C Cr. Mn Mo N Ni S Other
Name
S40500 S405SS 0.08max 11.5-14.5 1.0max
S43000 S430 0.08 16.0-18.0 1.0max 0.045 Al .010-0.30
Duplex Stainless Steels-Composition
UNS Common C Cr. Cu Mn Mo N Ni S
Name
S31500 3 RE-60 0.030max 24.0-26.0 2.0max 2.5-3.0 0.14-0.20 5.5-6.5 0.030
S31803 SAF 2205 0.030max 21.0-23.0 2.0max 2.5-3.5 0.08-0.20 4.5-6.5 0.030
S32304 SAF 2304 0.030max 21.5-24.5 0.05-0.06 2.5max 0.05-0.06 0.05-0.20 3.0-5.5 0.040max

Mechanical properties for each grade can be found in ASTM Standards handbooks and from
information sheets supplied by the steel maker of supplier. Particular attention should be
paid ensuring the correct material and welding consumables (by colour coding and strict
issue control) are used throughout the entire circuit. In many applications, Positive Alloy
Material Identification Procedures (PAMI) are incorporated as part of the quality control
acceptance test steps. The inadvertent use of incorrect grades has been known to occur, as
has the substitution of carbon steel in lieu of alloy steel components.

Non Ferrous Metals

Only some of the most important and common alloys of copper and nickel will be discussed.

Copper Alloys

The best known copper alloys are the bronze and brass which are used in wrought and cast
forms. According to the ASTM specifications, copper base alloys containing alloying
elements other than zinc or in sufficiently large amounts to be predominant over zinc are
termed as bronze. All copper alloys containing an acceptable amount of zinc are
designated as brass. Brass with a high tensile strength is often wrongly described as
bronze, although this material by definition should be called brass.

The copper-tin alloys are the best known representatives of the bronze group. Their
resistance to corrosion increases with the tin content. Adding small amounts of zinc
improves the castability, but reduces the corrosion resistance. The tin-bronze most used
contains 80%Cu, 10% Al, 5%, Ni, 3%Fe plus other residual elements, which is used, for
instance, for parts of sea water condensers and coolers for cooling water pumps.

Nickel added to copper in quantities of up to 30% gives another sea-water-resistant alloy

Cupro-Nickel. This alloy is sometimes preferred in steam condensers with sea water as a
coolant. In many applications this material (nominal composition 76% Cu, 22%Zn, 2% Al
plus minimum 0.02% As) is the preferred choice due to its better resistance to tube end
erosion. Arsenic (As) is added to this material in order to prevent dezincification.

Nickel Alloys

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The range of nickel alloys is quite extensive and specific grades find application where
resistance to corrosive environments and high temperatures, while other grades are resistant
to a wide range of acids. In this section, the tree common nickel alloys will be discussed.
(The Nickel Development Institute can provide detailed information on the applicability of
individual alloys.)

Monel 400 (65%Ni, 32% Cu) is a strong, weldable alloy resistant to corrosion by flowing sea
water, sulphuric, hydrochloric and phosphoric acids. It retains its strength and toughness up[
to 4500C. Typical applications include valves and pumps, heat exchangers, marine fixtures
and fittings. Monel 500 (an age hardenable alloy) combines the corrosion resistance of alloy
400 with increased strength and hardness. The mechanical properties can be further
enhanced by cold working prior to precipitation hardening.

Inconel 625 (61% Ni, 21.5% Cr, 2.5% Fe) maintains its high strength from cryogenic
temperatures to 11000C, and has excellent fatigue strength. It is resistant to most corrosives
and is virtually immune to chloride-ion stress cracking.

Incoloy 825 (42% Ni, 21.5% Cr, 2% Cu, 30% Fe) is used in aggressively corrosive
environments as this alloy resists oxidising and reducing acids. It is also resistant to pitting
and intergranular attack. It has exceptional resistance to corrosion by sulphuric and
phosphoric acid solutions and sea water. Typical applications are heat exchanger tubing and
phosphoric acid evaporators.

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Table 4: Common standards for ferrous metals unalloyed for pressure applications
AS ASTM BS Application
Plate
A-283-C 4360: Gr 43A Structural steel for storage tanks & non-pressure
retaining parts.
A-285-C 1501: Low strength killed or semi-killed pressure vessel
151Gr.400B steel.
1548-7- A-515-Gr. 1501: 161 Gr Carbon steel plates (semi killed) low/medium
430 55/60 400-130B strength for pressure retaining parts.
A-515-70 1501-224 Gr C-Mn (semi killed) medium strength tube sheets.
430/90
A-229 1501-211 C-Mn steel plates high strength for pressure-
retaining parts.
A 516 Gr 1501-224 Gr Fine grained C-Mn steel for pressure retaining
55/60 400A/B parts and low temperature service.
1548-7- A-516Gr 1501-224 Fine grained C-Mn steel for pressure retaining
460/490 65/70 Gr 430A/B, parts and low temperature service
460A/B
Products
A-214 Electric resistance welded tubes for unfired heat
exchanger equipment.
A-179 3602-CFS 410 Seamless cold drawn tubes for heat transfer
equipment.
A-178 3059-1 ERW Electric resistance welded steel tubes for boilers
320 and superheaters.
A-226 3059-2 ERW Electric resistance welded steel tubes (semi killed)
440 for boilers and superheaters
A192 3059-2 S Seamless steel tubes (semi killed) for boilers and
2.440 superheaters.
A-106 Gr 3602-HFS 410 Seamless C-Mn steel pipe for seamless shells of
A/B pressure vessels and welded on nozzles and for
welded furnace coils.
A-333 Gr 3603 HFS 410 Seamless fine grained C-Mn steel pipe for process
6 LT 50 lines at low service temperature.
A-234 1640-WPB Carbon steel butt weld fittings 9semi killed) for
WPB general use.
A-420 1640 WPO LO Carbon steel butt weld fittings 9semi killed) for low
WPL 6 temperature service.
A-105 1503-221- Carbon steel forgings (semi killed) for tube sheets
430/221-490 flanges and other retaining parts.
A-350 LF2 1503-224-430 Carbon steel forgings (Si-Al killed) for steel sheets,
LT flanges, fittings, valves and other pressure
retaining parts.
Castings
A-48 No. 1452 Gr. Pump impeller and some castings
30 or 40 220/260

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ASSIGNMENT

1. Describe how you would test ferritic steels for resistance to brittle fracture.

2. There is an unrecorded Material Data (MD) auxiliary heavy-duty steam pipe

connecting a steam receiver.
What procedures are to be taken to obtain the metal composition.
Testing requirements prior to commission pipe for use.

3. Austenitic stainless steel (S304) is to be used in a heater exchange.

Explain the advantages using S304.
Give the composition.
State the mechanical and physical properties
Working temperature range.
.

4. What is Creep?

5. List two ways (2) in which the additions of alloying elements reduce creep.

6. Name two (2) alloying elements found in ferritic stainless steel.

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