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PIPING MATERIALMODULAR FABRICATION YARD
PIPING MODULE PART II
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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
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CARBON STEEL
Low Carbon Steel : C < 0.15%
Condenser Tubes : SA 179
Weldability : Excellent
Mild Steel : 0.15% < C < 0.30%
Pipes : SA 106 GR BWeldability: Good
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CARBON STEEL
Medium Carbon Steel : 0.3% < C < 0.5%
Machinery Parts
Weldability: FairHigh Carbon Steel : 0.5% < C < 1%
Dies & punch, Tools
Weldability: Poor
Steel : Carbon < 2%
Cast Iron : Carbon > 2%
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Weldability
As Carbon % increases , weldability decreases Effect of carbon & other elements on the weldability of
carbon steels can be estimated by equating them to anequivalent 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 removedby adding Silica (De oxidizing agent).
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ALLOY STEEL
Addition of elements such as Cromium, Nickel,Molybdenum, Manganese, Silicon along with heattreatment improves the properties of steels suchas mechanical strength, corrosion resistance,
toughness
Steel is a ferrous alloy having main constituentIron and other alloying elements / Impurities like
Carbon, Manganese, Phosphorus, Sulfur, Silicon,Chromium, Nickel, Molybdenum
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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%.
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STAINLESS STEEL
Alloy of iron with Cromium content more than11% and less than 30% and other alloying
elements Nickel, Molybdenum etc is called
stainless steel.
Stainless steel has excellent resistant tocorrosion.
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.
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EFFECT OF ALLOYING ELEMENTS
Chromium : Increases resistance to Oxidation.
Nickel : 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
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ALLOYING
ELEMENT
HARDNESS
STRENGTH
YIELDPOINT
ELONGATION
IMPACTVALUE
ELASTICITY
HIGH
TEMPERATURE
STABLITY
COOLINGRATE
CARBIDE
FORMATION
RESISTANCETO
WEAR
FORGEABILITY
MACHINABILITY
SCALING
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
THE EFFE T OF ALLOY NG ELEMENTS ON THE PROPERT ES OF STEEL
=Increase =Decrease = constant - = not characteristic or unknown Several arrows =more intensive effect
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STAINLESS STEEL
Classification based on
1. Alloying Constituents
2. Metallurgical Microstructure
3. Degree of sensitization
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STAINLESS STEEL
Alloying constituents
200 Series : Cr. Ni - Mn group
( Mn replaces a portion of Ni)
300 Series : Cr - Ni group
400 Series : Straight Chromium Group
( Cr < 30%)
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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
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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
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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.
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STAINLESS STEEL
Precipitation Hardened SS Magnetic
Heat treatable to high strength.
Weldable and corrosion resistant similar to type304
Ex:-17-7PH, 17-4PH
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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 corrosioncracking.
High strength, Good corrosion resistance
Ex: Alloy 2205, Alloy 255
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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)
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STAINLESS STEEL
GROUP 2
Stabilized stainless steel type 321 &347
Grain boundaries sensitization eliminated by alloyingelements 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
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STAINLESS STEEL
GROUP 3
Extra low carbon stainless steel Type 304L, 316L
Can be stress relieved, welded & cooled slowly withoutsignificantly increasing their susceptibility to IGC.
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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.
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ASTM / ASME Nomenclature
SA 312 TP 304S : ASME approved Material
A : Ferrous
312 : Manufacturing Process No.
TP : Tubular Product304 : Grade
SA 234 GR WPB
S : ASME approved Material
A : Ferrous
234 : Manufacturing Process No.
GR : Grade.
WP : Wrought Product
B : Grade
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ASTM / ASME Nomenclature
SA 350 LF 2 : Low Temperature Forging Grade 2
SA 216 WCB : Weldable Casting Grade B
SA 335 P 11 : Pipe Grade 11
SA 182 Gr F11 : Forging Grade 11
SA 351 Gr CF 8 : Centrifugal Cast, Carbon % - 0.08%
SA 351 Gr CF 3 : Centrifugal Cast, Carbon % - 0.03%
SA 351 Gr CF 8M : Centrifugal Cast, Carbon % - 0.08%, Mo
SA 351 Gr CF 3M : Centrifugal Cast, Carbon % - 0.03%, Mo
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CORROSION
Corrosion is the tendency of any metal to return to its moststable thermodynamic state i.e. state with most negativefree energy formation. . More simply stated, it is a chemicalreaction 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 roomtemperature and below)
High temperature corrosion (corrosion at elevatedtemperature including molten metal.)
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CORROSION
Classification :
General or uniform corrosion.
Localized Corrosion
Inter granular corrosion (IGC)
Pitting corrosion
crevice corrosion
Stress corrosion crackingMicro biological influenced corrosion.
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INTER GRANULAR CORROSION
During Welding:- ( at Temp. 800-1600 F ), Carbonmolecules diffuse to grain boundary & precipitateout of solid solution as chromium carbide at thegrain boundaries. This result in the depletion of
chromium content in the thin envelopesurrounding each grain, Hence Stainless Steelbecomes susceptible to Inter Granular Corrosion& is said to be sensitized.
Corrosion property of sensitized steel can berestored by desensitization i.e. heat above 1600F, & rapid cooling.
Testing Standard: IGC Practice A/B/C/D/E
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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 asper 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.
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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
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NACENACE: National Association ofCorrosion 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 arcfurnace
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%
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Material Selection CriteriaService media
Corrosive-sea water, H2S, Ammonia
Non CorrosiveTemperature
Cryogenic
Low temperature
Medium temperature
High temperature
Pressure Low pressure
High pressure
Standard Material specification
Additional requirements
Economy Cost
Availability
Weldability
Manufacturability
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Material Selection for Temperature
SERVICE
TEMPERATURE F)PLATE PIPE FORGING
PRESSURE
BOLTING
C
R
O
GENI
C
T
EM
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. HardenedNuts: SA 194 gr.8
(S5 SA 20)
(-320) (-151)
SA 240 types 304,
340L, 316, 316L
SA 353
SA 312 types
304, 304L, 316,
316L
SA 182 grades
F304, F304L,
F316
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Material Selection for Temperature (Continued)
SERVICETEMPERATURE (F)
PLATE PIPE FORGINGPRESSURE
BOLTING
L
O
W
T
E
M
P
E
R
A
T
U
R
E
(-150) (-76) SA 203 GR.D OR E SA 333 GR.3 SA 350 GR.
LF3
BOLTS: SA 320
GR.L7
NUTS: SA 194
GR.4
(-75) (-51) SA 203 GR.A OR B SA 333 GR.3 SA 350 GR.
LF3
(-50) (-21) SA 516 ALL
GRADES IMPACT
TESTED
SA 333 GR.1
SA 350 GR.LF1 OR LF2
(-20) (+4) SA 516 ALL
GRADES OVER 1 IN.
THICK IMPACTTESTED
SA 53
(SEAMLESS) OR
SA 106
BOLTS: SA 193
GR.B7
NUTS: SA 194
GR.2H(+5) (+32) SA 516 ALL
GRADES OVER 1 IN.
THICK IMPACT
TESTED
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Material Selection for Temperature (Continued)
SERVICETEMPERATURE (F)
PLATE PIPE FORGING PRESSUREBOLTING
I
NT
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
.
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
(+61) (+775)
SA 285 GR.C, IN.
THK. MAX.
SA 515 GR.55, 60,
65, 1.5IN. TH
K. MAX.SA 516 ALL
GRADES, ALL THK.
SA 204 GR.B ALL
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Material Selection for Temperature (Continued)
SERVICETEMPERATURE (F)
PLATE PIPE FORGINGPRESSURE
BOLTING
E
L
E
V
A
T
ED
T
E
M
P
E
R
AT
U
R
E
(+776) (+875) SA 204 GR.B OR C SA 335 GR.P1 SA 182
GR.F1
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
(+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
GRADES304H, 316H,
321H, 347H
SA 193 GR.B8SA 194 GR.8
ABOVE +1500 T PE 310
STAINLESS
INCOLO
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GROUPING OF MATERIALS
Base Metal TypeP1 : Carbon Steel
P3, P4,P5 : Alloy Steel
P6, P7 : Ferritic & Martensitic SteelP8 : Austenitic Stainless Steel
P9 : Nickel Steel
P10, P11 : Quenched & Tempered Steel
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MATERIAL AND ITS SPECIFICATIONS
DESCRI I CS AS SS DSS
PIPE A 106 R B A335 RP11 A312 TP 316 A 790 U 31803
BW ITTI A234 R WPB A234 R WP 11 A403 WP 316 A815 U 31803
R ED
FLANGES/
FITTINGS
A105 A182 GRF11 A182 GRF 316 A182 GRF 51
UNSS 31803
FASTNERS A193 GR B7/
A194 GR 2H
A 193 GR B16/
A194 GR 2H
A193 GR B7 /
A 194 GR 2H
A453 GR 660 LA
PLATES A 516 GR 70 A 387 GR 11 A 240 GR 316 A240 UNSS 31803
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THANK YOU