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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.
MACHINABILITY
RESISTANCE TO WEAR
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
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.
60,000 30,000 60,000 30,000 55,000 30,000 90,000 65,000 90,000 70,000 1,10,000 80,000 1,90,000 1,50,000 2,40,000 2,00,000 2,80,000 2,70,000 2,10,000 1,90,000 1,90,000 1,70,000 2,30,000 2,20,000
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.
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: Low temperature corrosion (corrosion at room temperature and below) High temperature corrosion (corrosion at elevated temperature including molten metal.)
CORROSION
Classification :
Inter granular corrosion (IGC) Pitting corrosion crevice corrosion Stress corrosion cracking
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
A cracking process that requires simultaneous action of corrodant and sustained tensile stress. NACE MR-0175 standard presents metallic material requirements for resistance to sulfide stress cracking(SSC) for petroleum production,drilling,gathering,flowline equipment, and field processing facilities to be used in hydrogen sulfide (H2S)-bearing hydrocarbon services. 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 (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%
Temperature
Pressure
Standard
Economy
Cost Availability Weldability Manufacturability
PLATE
PIPE
FORGING
PRESSURE BOLTING
C R Y O G E N I C T E M P
Bolts: SA 320 gr. B8 strain. Hardened Nuts: SA 194 gr.8 (S5 SA 20)
PLATE
PIPE
FORGING
PRESSURE BOLTING
SA 203 GR.D OR E
SA 333 GR.3
L O W
(-75) (-51)
SA 203 GR.A OR B
SA 333 GR.3
T E M P E R A T U R E
(-50) (-21)
SA 333 GR.1
(-20) (+4)
SA 516 ALL GRADES OVER 1 IN. THICK IMPACT TESTED SA 53 (SEAMLESS) OR SA 106
(+5) (+32)
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
PLATE
PIPE
FORGING
PRESSURE BOLTING
SA 204 GR.B OR C
SA 335 GR.P1
SA GR.F1
(+876) (+1000)
T E M P E R A T U R E
(+1000) (+1100)
SA 335 P22
SA 182 GR.22
(+1100) (+1500)
ABOVE +1500
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