PIPING MATERIAL

MODULAR FABRICATION YARD PIPING MODULE PART II

INTRODUCTION
Piping Materials can be classified as
   

Metals (ferrous) : CS, SS, Alloy Steel Metals (non-ferrous) : Cupro Nickel, Al Non-metals : PVC, cement, glass Materials are selected based on their mechanical and metallurgical properties. Mechanical properties: strength, ductility, hardness, brittleness, toughness Metallurgical properties: Chemical composition, weldability

CARBON STEEL
Low Carbon Steel : C < 0.15% Condenser Tubes : SA 179 Weldability : Excellent : 0.15% < C < 0.30% Pipes : SA 106 GR B Weldability: Good

Mild Steel

CARBON STEEL
Medium Carbon Steel : 0.3% < C < 0.5% Machinery Parts Weldability: Fair High Carbon Steel : 0.5% < C < 1% Dies & punch, Tools Weldability: Poor  Steel : Carbon < 2%  Cast Iron : Carbon > 2%

Weldability  As Carbon % increases , weldability decreases  Effect of carbon & other elements on the weldability of carbon steels can be estimated by equating them to an equivalent amount of carbon.


Carbon Equivalent: Ceq = C + Mn/6 + Cr + Mo+ V + Cu + Ni 5 15 Killed Steel During Steel making process oxygen present is removed by adding Silica (De oxidizing agent).

ALLOY STEEL


Addition of elements such as Cromium, Nickel, Molybdenum, Manganese, Silicon along with heat treatment improves the properties of steels such as mechanical strength, corrosion resistance, toughness Steel is a ferrous alloy having main constituent Iron and other alloying elements / Impurities like Carbon, Manganese, Phosphorus, Sulfur, Silicon, Chromium, Nickel, Molybdenum

ALLOY STEEL
Solid solubility in ferrous alloys : Interstitial solid solution : Carbon with Iron forms interstitial solid solution (Carbon steel) Substitutional solid solution : Cromium and Nickel with iron forms Substitutional solid solution (Stainless steel) Low alloy steels : Alloying elements < 5% High alloy steels : Alloying elements > 5%.

STAINLESS STEEL


Alloy of iron with Cromium content more than 11% and less than 30% and other alloying elements Nickel, Molybdenum etc is called stainless steel. Stainless steel has excellent resistant to corrosion. Stainless steel becomes corrosion resistant (passive) because of formation of un-reactive film which adheres tightly to the surface of metal. This can be chromium oxide (Cr2O3) film that acts as a barrier protecting metal against corrosion.

EFFECT OF ALLOYING ELEMENTS

Chromium Nickel : Increases resistance to Oxidation. : Increases resistance to mineral acid, produces tightly adhering high temperature oxides. Molybdenum: Increases resistance to chloride. Copper : Increases resistance to sulphuric acid. Titanium : Stabilize carbides to prevent formation of chromium carbide Niobium : Stabilize carbides to prevent formation of chromium carbide

THE EFFE T OF ALLOY NG ELEMENTS ON THE PROPERT ES OF STEEL

MACHINABILITY

RESISTANCE TO WEAR

FORGEABILITY

HIGH TEMPERATURE STABLITY

COOLING RATE

IMPACT VALUE

ELONGATION

YIELD POINT

CARBIDE FORMATION

ELASTICITY

STRENGTH

ALLOYING ELEMENT

HARDNESS

Silicon Manganese in perlit.steels Manganese in austenit.steels. Chromium Nickel in perlit.steels Nickel in austennit.steels Aluminum Tungsten Vanadium Cobalt Molybdenum Copper Sulphur Phosphorous

=Increase

=Decrease

= constant

- = not characteristic or unknown

Several arrows =more intensive effect

SCALING

STAINLESS STEEL
Classification based on 1. Alloying Constituents 2. Metallurgical Microstructure 3. Degree of sensitization

STAINLESS STEEL
Alloying constituents 200 Series : Cr. Ni - Mn group ( Mn replaces a portion of Ni) : Cr - Ni group : Straight Chromium Group ( Cr < 30%)

300 Series 400 Series

STAINLESS STEEL
Metallurgical microstructure. Austenitic SS: Alloy of Cr, Ni, Fe Non Magnetic High Corrosion resistance at temp up to 1500F Hardenable by cold working Crystallographic form-Face centered Cubic lattice (fine grain structure) Possess high impact strength at low temp Ex: Type 304, 304L,316,316L

STAINLESS STEEL
Ferritic SS:  Alloy of Cr, Fe  Magnetic  Non Hardenable by heat treatment  Crystallographic form- Body centered cubic lattice (coarse grain structure)  For marine application. (10.5% Cr alloy with no nickel)  Contains high carbon, therefore brittle & relatively poor corrosion resistance  Has resistance to chlorides stress corrosion cracking  Ex: Type 409, 430, 439

STAINLESS STEEL
Martensitic SS.  High hardness (carbon added to the alloy)  Corrosion resistant  Heat treatable to high hardness level  Crystallographic form-distorted lattice  Type 410,420.

STAINLESS STEEL
Precipitation Hardened SS  Magnetic  Heat treatable to high strength.  Weldable and corrosion resistant similar to type 304  Ex:-17-7PH, 17-4PH

STAINLESS STEEL
Duplex SS
    

Contain both Austenite & Ferrite in microstructure. Ni (4 to 7%). When ferrite- Resistant to chloride stress corrosion cracking. When Austenite-Sensation to chloride stress corrosion cracking. High strength, Good corrosion resistance Ex: Alloy 2205, Alloy 255

STAINLESS STEEL
3. Degree of sensitization of grain boundaries GROUP 1 SS grade 304,316,309,310. They are susceptible to sensitization. (During welding, flame cutting)

STAINLESS STEEL
GROUP 2
 Stabilized stainless steel type 321 &347  Grain boundaries sensitization eliminated by alloying elements like Titanium or Columbium. (Because Titanium or Columbium forms carbides first).  Columbium (Type 347) is stronger stabilizing agent than Ti (Type 321), Hence Type 347 is superior to 321

STAINLESS STEEL
GROUP 3
 Extra low carbon stainless steel Type 304L, 316L  Can be stress relieved, welded & cooled slowly without significantly increasing their susceptibility to IGC.

R I

AIN
U ( I) Y ( I) (%) a

Y
DU U F HARDN A ICI Y 29 000 000 29 000 000 28 000 000 28 000 000 80 R 75 R 80 R 75 R

UN N

1) A s e c Type 304 Type 304L Type 316 Type 316 L 2) Fe c Type 430 Type 439 Type 409 3) D ex lloy 2205 70 o lus lloy 255 a e s c Type 410 Type 420 Type 440L ec a 17 7 H 17 4 H Cus o 455

30 400 30 403 31 600 31 603

75 000 70 000 75 000 70 000

30 000 25 000 30 000 25 000

30 35 30 35

43 000 43 035 40 900

60 000 60 000 55 000

30 000 30 000 30 000

20 20 20

29 000 000 29 000 000 29 000 000

85 R 90 R 85 R

31 805 32 950 32 550

90 000 90 000 1 10 000

65 000 70 000 80 000

25 20 15

29 000 000 29 000 000 30 500 000

30 RC 30 RC 32 RC

4)

41 000 42 000 44 050

1 90 000 1 50 000 2 40 000 2 00 000 2 80 000 2 70 000

15 5 2

29 000 000 29 000 000 29 000 000

41 RC 55 RC 60 RC

5)

17 700 17 400 45 500

2 10 000 1 90 000 1 90 000 1 70 000 2 30 000 2 20 000

5 8 10

32 500 000 28 000 000 29 000 000

48 RC 45 RC 48 RC

ASTM / ASME Nomenclature



Materials are listed based on their known chemical composition, manufacturing processes, mechanical strength etc, in different codes i.e,ASTM, ASME, DIN, MSS etc, and common UNS number ASTM Standard gives various details of materials like manufacturing process, Grades, Chemical Composition, and Mechanical Properties. ASME Code accepts the ASTM materials with some additional specified properties.

ASTM / ASME Nomenclature

SA 312 TP 304 S : ASME approved Material A : Ferrous 312 : Manufacturing Process No. TP : Tubular Product 304 : Grade SA 234 GR WPB S : ASME approved Material A : Ferrous 234 : Manufacturing Process No. GR : Grade. WP : Wrought Product B : Grade

ASTM / ASME Nomenclature



SA 350 LF 2 SA 216 WCB SA 335 P 11 SA 182 Gr F11 SA 351 Gr CF 8 SA 351 Gr CF 3 SA 351 Gr CF 8M SA 351 Gr CF 3M

: Low Temperature Forging Grade 2 : Weldable Casting Grade B : Pipe Grade 11 : Forging Grade 11 : Centrifugal Cast, Carbon % - 0.08% : Centrifugal Cast, Carbon % - 0.03% : Centrifugal Cast, Carbon % - 0.08%, Mo : Centrifugal Cast, Carbon % - 0.03%, Mo

CORROSION


Corrosion is the tendency of any metal to return to its most stable thermodynamic state i.e. state with most negative free energy formation. . More simply stated, it is a chemical reaction of metal with environment to form an oxide, carbonate, sulphate or other stable compound. Corrosion is broadly classified into two categories: temperature and below)  High temperature corrosion (corrosion at elevated temperature including molten metal.)

 Low temperature corrosion (corrosion at room

CORROSION
Classification :

General or uniform corrosion.  Localized Corrosion



Inter granular corrosion (IGC) Pitting corrosion crevice corrosion Stress corrosion cracking Micro biological influenced corrosion.

INTER GRANULAR CORROSION



During Welding:- ( at Temp. 800-1600 F ), Carbon molecules diffuse to grain boundary & precipitate out of solid solution as chromium carbide at the grain boundaries. This result in the depletion of chromium content in the thin envelope surrounding each grain, Hence Stainless Steel becomes susceptible to Inter Granular Corrosion & is said to be sensitized. Corrosion property of sensitized steel can be restored by desensitization i.e. heat above 1600 F, & rapid cooling. Testing Standard: IGC Practice A/B/C/D/E

SULPHIDE STRESS CORROSION CRACKING



 

A cracking process that requires simultaneous action of corrodant and sustained tensile stress. Testing Standard: NACE TM- 01/77 Reporting of test result: Curve shall be reported as per NACE-TM-01-77 for various stress level between 72%and 90% of SMYS. Acceptance Criteria: At 72 % SMYS, time of failure shall not be less than 720 hrs.

HYDROGEN INDUCED CRACKING



Hydrogen induced cracking (HIC) is also known as cold cracking, delayed cracking or under bead cracking HIC occurs in piping or vessel as a result of hydrogen pick up in service It occurs in steels during steel manufacturing, during fabrication, and in service. It occurs as a result of welding, the cracks are sited either in HAZ of parent material or in the weld metal it self. Testing Standard: NACE TM- 02/84

NACE
NACE: National Association of Corrosion Engineers  NACE Standard gives chemical composition, Manufacture, Fabrication & testing Requirements for Steels intended to be used for Sour Service environment Sour service Requirements  Steel shall be manufactured by Basic Oxygen Process or Electric arc furnace  Steel to be Killed & fine grained  Materials shall be in Normalized Condition  Nickel % limited to < 1%  Carbon content< 0 .23%  Carbon Equivalent < 0.43%  Hardness < 22 HRC  Sulpher content< 0.002%

Material Selection Criteria

Service media
      Corrosive-sea water, H2S, Ammonia Non Corrosive Cryogenic Low temperature Medium temperature High temperature Low pressure High pressure Material specification Additional requirements Cost Availability Weldability Manufacturability

Temperature

Pressure
 

Standard
 

Economy
   

Material Selection for Temperature

SERVICE TEMPERATURE F)

PLATE

PIPE

FORGING

PRESSURE BOLTING

C R O G E N I C T E M P
(-425) (-321)

SA 240 types 304, 304L, 347

SA 312 types 304,304L, 347

SA 182 grades F304, F304L, F347

Bolts: SA 320 gr. B8 strain. Hardened Nuts: SA 194 gr.8 (S5 SA 20)

SA 240 types 304, 340L, 316, 316L SA 353 (-320) (-151)

SA 312 types 304, 304L, 316, 316L

SA 182 grades F304, F304L, F316

Material Selection for Temperature (Continued)

SERVICE TEMPERATURE (F) (-150) (-76)

PLATE

PIPE

FORGING

PRESSURE BOLTING

SA 203 GR.D OR E

SA 333 GR.3

SA 350 GR. LF3

L O W

(-75) (-51)

SA 203 GR.A OR B

SA 333 GR.3

SA 350 GR. LF3

BOLTS: SA 320 GR.L7 NUTS: SA 194 GR.4

T E M P E R A T U R E

(-50) (-21)

SA 516 ALL GRADES IMPACT TESTED

SA 333 GR.1

(-20) (+4)

SA 516 ALL GRADES OVER 1 IN. THICK IMPACT TESTED SA 53 (SEAMLESS) OR SA 106

SA 350 GR. LF1 OR LF2

(+5) (+32)

SA 516 ALL GRADES OVER 1 IN. THICK IMPACT TESTED

BOLTS: SA 193 GR.B7 NUTS: SA 194 GR.2H

Material Selection for Temperature (Continued)

SERVICE TEMPERATURE (F)

PLATE

PIPE

FORGING

PRESSURE BOLTING

I N T E R M E D I A T E T E M P

(+33) (+60)

SA 285 GR.C, IN. THK. MAX. SA 515 GR.55, 60, 65, 1.5IN. THK. MAX. SA 516 ALL GRADES, ALL THK.

(+61) (+775)

SA 285 GR.C, IN. THK. MAX. SA 515 GR.55, 60, 65, 1.5IN. THK. MAX. SA 516 ALL GRADES, ALL THK. SA 204 GR.B ALL

SA 53 (SEAM LESS) OR SA 106

SA 181 GR.I OR II SA 105 GR.I OR 11

Bolts: SA 193 gr. B7 Nuts: SA 194 gr. 2H

Material Selection for Temperature (Continued)

SERVICE TEMPERATURE (F)
(+776) (+875) E L E V A T E D

PLATE

PIPE

FORGING

PRESSURE BOLTING

SA 204 GR.B OR C

SA 335 GR.P1

SA GR.F1

182 BOLTS: SA 193 GR.L7 NUTS: SA 194 GR.2H

(+876) (+1000)

SA 387 GR.11 CL1 SA 387 GR.12 CL.1

SA 335 P11 SA 335 P12

SA 182 GR. F11 SA 182 GR. F12

T E M P E R A T U R E

(+1000) (+1100)

SA 387 GR.22 CL1

SA 335 P22 SA 182 GR.22

SA 193 GR.B5 SA 194 GR.3

(+1100) (+1500)

SA 240 T PES 304, 316, 321, 347, 347PREFERED

SA 312 T PES 304H, 316H, 312, 347H

SA 182 GRADES 304H, 316H, 321H, 347H

SA 193 GR.B8 SA 194 GR.8

ABOVE +1500

T PE STAINLESS INCOLO

310

GROUPING OF MATERIALS
Base Metal P1 P3, P4,P5 P6, P7 P8 P9 P10, P11 Type : Carbon Steel : Alloy Steel : Ferritic & Martensitic Steel : Austenitic Stainless Steel : Nickel Steel : Quenched & Tempered Steel

MATERIAL AND ITS SPECIFICATIONS

DESCRI I CS AS SS DSS

PIPE

A 106 R B

A 335 R P11

A 312 TP 316

A 790 U

31803

BW ITTI

A 234 R WPB

A 234 R WP 11

A 403 WP 316

A 815 U

31803

R ED FLANGES/ FITTINGS FASTNERS

A 105

A 182 GR F11

A 182 GR F 316

A 182 GR F 51 UNS S 31803 A 453 GR 660 L A

A 193 GR B7/ A 194 GR 2H A 516 GR 70

A 193 GR B16/ A 194 GR 2H A 387 GR 11

A 193 GR B7 / A 194 GR 2H A 240 GR 316

PLATES

A 240 UNS S 31803

THANK YOU