ch01_ppts_callister7em

7/29/2019 ch01_ppts_callister7em

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Chapter 1 -

Materials and equipment Design

PETR 350DESCRIPTION

This is a multidisciplinary course aimed at: study of the materials selection process for

equipment used in gas and oil operations

Corrosion mechanisms and inhibition methods

Codes, standards and applicable specificationspresented along with their applications

1


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Chapter 1 -

Learning Objectives

Learners will: become familiar with metals used in equipment in

the oil and gas sector

understand the differences in properties between

carbon steels, stainless steels, alloys andsuperalloys

know and understand the primary corrosionmechanisms and the conditions under which theyoccur

become familiar with codes , standards andspecifications as applied to oil and gas industryequipment

2


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Chapter 1 -

recognize the criticality of material failures inequipment performance

This course will provide the learner with thetechnical aspects of metallic and non-metallicmaterials and their properties.

Material selection criteria and applicationsspecific to the oil and gas industry will becovered.

The course will include equipment designconsiderations along with codes, standards and

specifications utilized in the oil and gas industry.Corrosion mechanisms and mitigation techniqueswill be covered.

3


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Chapter 1 -

Resource Material

References: Specifications CSA for pipeline

SpecificationsAPI for drill pipe, tubing andcasing

Chemical Engineering Design and Analysis,Duncan, T. Michael

Journal of Petroleum Technology

Oil and Gas Journal

Introduction to the Canadian Natural GasIndustry, Canadian Energy Research Institute

Energy Research Institute

4


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Chapter 1 - 5

LECTURES

Lecturer: Ahmed Yusuf

Time: Sunday 8.00 9.30 am8.00 9.30 am

Location: B1 G02

Activities: Present new material

Announce reading and homework

Take Final Exam*


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Chapter 1 - 6

Purpose:

Discuss homework, quizzes, exams

Hand back graded quizzes, exams

Discuss concepts from lecture

Instructor:

Times and Places:Sun.

Tue.

10:00 - 12.00 noon

10:00 - 12.00 noon


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Chapter 1 - 7

Purpose: To learn more about materials by relatinglecture material with observations. Also to learn to properlyformulate and write engineering reports and proposals.

Instructor: Sondus

Location: B4

LABORATORY SECTIONS


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Chapter 1 - 8

TEACHING ASSISTANTS

Teaching Assistants will

participate in tutorial sessions,

have office hours to help you with course material

and problem sets.

NameEng. Sondus

Office_ XXX

Tel.X-XXXX

E-mail_____


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Chapter 1 - 9

Required text: Materials Science and Engineering: An Introduction

W.D. Callister, Jr., 7th edition, John Wiley and Sons,Inc. (2007).

COURSE MATERIALS

Optional Material:

Chemistry Books

Physical Metallurgy Books


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Chapter 1 - 10

GRADING

Assignments in-tutorial 10%

Laboratory Reports 10%

Based on core homework problems

Midterm #1 30%

Tentatively scheduled for:Material covered:

Final 50%

Tentatively scheduled for:Material covered:


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Chapter 1 - 11

READING SCHEDULE

Week

123456

78

910

Topic

General Intro; Atomic BondingCrystalline Structure; Imperfections

Diffusion; Mechanical PropertiesStrengthening Mechanisms; Failure

Phase DiagramsKinetics & Phase Transformations

Processing & Applications of MetalsStruc., Prop., Proc., Applic. of CeramicsStruc., Prop. of Polymers; Composites

Corrosion; Elec. & Thermal Prop.Magnetic & Optical Prop.

Materials Selection; Econ. & Envir. Issues

Chapter

1,23,45,67,89

1011

12,1315,16

17,18,19*20*,21*22*,23*

Lectures: will highlight important portions of each chapter.*These chapters available at website www.wiley.com/college/callister.


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Chapter 1 - 12

Chapter 1 - Introduction

What is materials science? Why should we know about it?

Materials drive our society

Stone Age Bronze Age

Iron Age

Now?

Silicon Age? Polymer Age?


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Chapter 1 - 13

Example Hip Implant

With age or certain illnesses joints deteriorate.

Particularly those with large loads (such as hip).

Adapted from Fig. 22.25, Callister 7e.


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Chapter 1 - 14

Example Hip Implant

Requirements

mechanical

strength (manycycles)

good lubricity

biocompatibility



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Chapter 1 - 15

Example Hip Implant



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Chapter 1 - 16

Hip Implant

Key problems to overcome

fixation agent to holdacetabular cup

cup lubrication material

femoral stem fixing agent(glue)

must avoid any debris in cup

Adapted from chapter-opening photograph,Chapter 22, Callister 7e.

FemoralStem

Ball

AcetabularCup and Liner


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Chapter 1 - 17

Example Develop New Types ofPolymers

Commodity plastics large volume ca. $0.50 / lbEx. PolyethylenePolypropylenePolystyreneetc.

Engineering Resins small volume > $1.00 / lbEx. Polycarbonate

NylonPolysulfoneetc.

Can polypropylene be upgraded to properties (and price) nearthose of engineering resins?


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Chapter 1 - 18

ex: hardness vs structure of steel Properties depend on structure

Data obtained from Figs. 10.30(a)and 10.32 with 4 wt% C composition,and from Fig. 11.14 and associateddiscussion, Callister 7e.Micrographs adapted from (a) Fig.10.19; (b) Fig. 9.30;(c) Fig. 10.33;and (d) Fig. 10.21, Callister 7e.

ex: structure vs cooling rate of steel Processing can change structure

Structure, Processing, & Properties

H

ardness(BH

N)

Cooling Rate (C/s)

100

2 00

3 00

4 00

5 00

6 00

0.01 0.1 1 10 100 1000

(d)

30mm(c)

4mm

(b)

30mm

(a)

30mm


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Chapter 1 - 19

Types of Materials Metals:

Strong, ductile high thermal & electrical conductivity

opaque, reflective.

Polymers/plastics: Covalent bonding sharing of es

Soft, ductile, low strength, low density thermal & electrical insulators

Optically translucent or transparent.

Ceramics: ionic bonding (refractory) compounds of metallic

& non-metallic elements (oxides, carbides, nitrides, sulfides) Brittle, glassy, elastic

non-conducting (insulators)


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Chapter 1 - 20

1. Pick Application Determine required Properties

2. Properties Identify candidate Material(s)3. Material Identify required Processing

Processing: changes structureand overall shapeex: casting, sintering, vapor deposition, doping

forming, joining, annealing.

Properties: mechanical, electrical, thermal,magnetic, optical, deteriorative.

Material: structure, composition.

The Materials Selection Process


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Chapter 1 - 21

ELECTRICAL

Electrical Resistivity of Copper:

Adding impurity atoms to Cu increases resistivity. Deforming Cu increases resistivity.

Adapted from Fig. 18.8, Callister 7e.(Fig. 18.8 adapted from: J.O. Linde,Ann Physik5, 219 (1932); andC.A. Wert and R.M. Thomson,Physics of Solids, 2nd edition,McGraw-Hill Company, New York,1970.)

T(C)-200 -100 0

1

2

3

4

5

6

Resistiv

ity,r

(10-8O

hm-m)

0


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Chapter 1 - 22

THERMAL Space Shuttle Tiles:

--Silica fiber insulation

offers low heat conduction.

Thermal Conductivityof Copper:

--It decreases whenyou add zinc!

Adapted fromFig. 19.4W, Callister6e. (Courtesy ofLockheed AerospaceCeramics Systems,Sunnyvale, CA)(Note: "W" denotes fig.

is on CD-ROM.)

Adapted from Fig. 19.4, Callister 7e.(Fig. 19.4 is adapted from Metals Handbook:Properties and Selection: Nonferrous alloys andPure Metals, Vol. 2, 9th ed., H. Baker,(Managing Editor), American Society for Metals,1979, p. 315.)

Composition (wt% Zinc)

ThermalCondu

ctivity

(W/m-K)

400

300200

100

00 10 20 30 40

100mm

Adapted from chapter-opening photograph,Chapter 19, Callister 7e.(Courtesy of LockheedMissiles and SpaceCompany, Inc.)


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Chapter 1 - 23

MAGNETIC Magnetic Permeability

vs. Composition:--Adding 3 atomic % Si

makes Fe a betterrecording medium!

Adapted from C.R. Barrett, W.D. Nix, andA.S. Tetelman, The Principles ofEngineering Materials, Fig. 1-7(a), p. 9,1973. Electronically reproducedby permission of Pearson Education, Inc.,Upper Saddle River, New Jersey.

Fig. 20.23, Callister 7e.(Fig. 20.23 is from J.U. Lemke, MRS Bulletin,Vol. XV, No. 3, p. 31, 1990.)

Magnetic Storage:

--Recording mediumis magnetized byrecording head.

Magnetic Field

Magnetization Fe+3%Si

Fe


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Chapter 1 - 24

Transmittance:

--Aluminum oxide may be transparent, translucent, oropaque depending on the material structure.

Adapted from Fig. 1.2,Callister 7e.(Specimen preparation,P.A. Lessing; photo by S.Tanner.)

single crystalpolycrystal:low porosity

polycrystal:high porosity

OPTICAL


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Chapter 1 - 25

DETERIORATIVE Stress & Saltwater...

--causes cracks!

Adapted from chapter-opening photograph,Chapter 17, Callister 7e.(from Marine Corrosion, Causes, andPrevention, John Wiley and Sons, Inc., 1975.) 4mm

--material:7150-T651 Al "alloy"(Zn,Cu,Mg,Zr)

Adapted from Fig. 11.26,Callister 7e. (Fig. 11.26 provided courtesy of G.H.

Narayanan and A.G. Miller, Boeing CommercialAirplane Company.)

Heat treatment: slows

crack speed in salt water!

Adapted from Fig. 11.20(b), R.W. Hertzberg, "Deformation andFracture Mechanics of Engineering Materials" (4th ed.), p. 505, JohnWiley and Sons, 1996. (Original source: Markus O. Speidel, BrownBoveri Co.)

held at160C for 1 hrbefore testing

increasing loadcrac

kspeed(m/s)

as-is

10-10

10-8

Alloy 7178 tested insaturated aqueous NaCl

solution at 23C


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Chapter 1 - 26

Use the right material for the job.

Understand the relation between properties,

structure, and processing.

Recognize new design opportunities offeredby materials selection.

Course Goals:

SUMMARY

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