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Stainless Steel in Plumbing

Systems for Buildings and Industry

Pravin Goel Presentation to ADG, CPWD, Chandigarh

10th April, 2013

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• Stainless Steel is an Alloy of Iron with

minimum 10.5 % Chromium

• Chromium forms a layer of Oxide which is

– Very Thin

– Passive

– Impervious

– Self Forming instantly on damage

What is Stainless Steel?

Stainless

Steel

Passive CrO Film

Steel / GI

Rust

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Self Repairing surface

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Important Properties

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• Aesthetics

• Hygiene, Anti-Bacterial

• High Level of Clean-

ability

• High Strength to

Weight Ratio

• Fire Resistant

• High Temperature

Resistant

• Excellent Fabrication

properties

• Excellent Impact

resistance

• Long Maintenance

Free Life

• Cryogenic (Sub Zero)

Properties

• Different Finishes

Important Properties

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High Resistance to Corrosion

• Suitable even for

environments

like coastal area.

Extremely Severe

Severe

Moderate

Mild

Negligible Corrosion map of India

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Fire Rating

High Strength at High

Temperature

Minimum structural

deformation

Retains half the room

temperature strength at 500°C

No painting required, not

prone to fire

Fire testing: Darchem Engineering, NiDI

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Stainless Steel Plumbing Systems

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Competing Plumbing Materials in India

GI Galvanized Iron

PVC Polyvinyl chloride

(variants : cPVC, uPVC)

PPR Polypropylene Random

Copolymer

Cu Copper

Composites Metal – Aluminum/ Steel

lined with PVC

Stainless Steel 304, 316, 444

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Global References

Taipei Financial Center Petronas Towers, Malaysia Aurora Residential Towers,

Australia

304 stainless steel pipes and Press Fitting Couplings are used in the Petronas towers,

the tallest buildings in the world, to accommodate High Pressures and Vibration.

Similarly, Taipai Financial Center and Aurora Towers have used these stainless steel

piping system for Fire protection and Hot and Cold Water Supply

Source: High pressure Urban water Distribution Nickel Vol20, number

2, March 2005

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Global References

Lightweight Bridge to carry drinking water in Tokyo.

Source: Peter Cutler, NiDI, JSSA, Nickel Magazine Mar2005

• Lightweight bridges are used to

carry potable water and

pedestrians across river spans

up to 632 m in Japan

• 85% Type 304

• 10% Type 316

• Some 2205 near the coast

• No repainting

• 40% cheaper over 30 years

• First one built: 1983

• Max pipe diameter: 0.8 m

• There are now ~3000 such

bridges in Japan

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• Raw water handing in Meltur Dam,

Cauvery River

• First stainless steel raw water pipe in

India (1998)

• 300 mm x 3 mm grade 304 stainless steel replaced 900 mm x 13 mm cast iron

• Lightweight meant easy installation in

hilly country

• >50 year life expected (2 replace-

ments of cast iron in that time)

• Smooth bore meant sustained low

pumping costs

• LCC analysis: 60% saving over 50

years

Mettur Dam, Tamil Nadu

Source: Peter Cutler, NiDI

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Why Fire Sprinklers Fail?

Newly constructed HDIL Building on fire

18th Nov, 2010

3 persons Killed

Fire in “Bombay House” Tata group HQs

Feb 09, 2011,

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Application in Fire Fighting Systems

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• Cost Effective grade for

Sprinkler system

• Low Nickel Grades 439 or J4

• Cost of pipe competitive with

Tata “C” Class

– About 30% cheaper than SS

304 pipes

• Fittings of 304 grade

• Estimated installed cost

similar to Tata “C” class

pipes.

Special Grade for Fire Sprinklers

Advantages SS Sprinkler System: fast and reliable assembly of the system

without using an open fire,

resistance to high pressure – up to 16 bar,

low flow resistance in pipes and fittings,

low weight of pipes and fittings,

mechanical strength,

very good look of the system,

function of signalisation of not ready-pressed

connections.

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Corrosion Resistance:

Ferritic vs Austenitic

Source: Ferritic Solutions by ISSF

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Salt Spray Test Comparison

Source: Salt Spray Test and its use in ranking stainless

steel- ISSF, May 2008

In Salt spray Test Chloride concentration specified (3%)is hundred times more

than in drinking water (0.025%) and even more than in Sea Water (1.8%)

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• Tests by JSSA on SS Piping

systems (joined by

mechanical coupling)

– Good & air tight

– Do not leak

• 21 storey high rise building

constructed

– Between 1st & 4th Floor, system

was designed to simulate

Earthquake shocks on 5th to 21st

Floor

• Source: Nickel Magazine, Volume 23,

• No. 4, October 2008 Issue

Earthquake Resistance

• The tests were part of a broad, 3-year

program designed to expand the use of long-

lasting stainless steel in residential high-rise

piping systems throughout Japan

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Applications in Hospitals

Corrosion of copper pipe-work in

domestic hot and cold water services

in Hospitals in many areas of

Scotland, where water is soft and

contains high levels of sediment, has

led to increasing use of stainless steel

SS Pressfit System can be pressure tested up to 25 Bar

Source: Bright Future for SS Plumbing, Association of Plumbing and Heating contractors

Erosion in Copper Pipes

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• ANSI Std. – NSF 51 – 2002

– Stainless Steel with min Cr 16% is

recommended for food contact

• European Std. for Food Compatibility

– Stainless Steel with min Cr 13 % recommended

for food contact

• ISSDA recommends SS Plumbing with SS

grades with min 16 % Cr

Food Grade Compatibility

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• No general corrosion so no need for corrosion

allowance

• No Threading required, hence thinner – 1/3rd the

weight of GI pipe

• No need for protective coating

• No need to control water chemistry

• Water purity is maintained

• Lightweight

• Easy to Install

• Equipment is durable with Low Life Cycle Cost

SS Plumbing

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Approvals to use stainless steels

• National approvals in EU Member States will

be replaced by European Acceptance Scheme

• USA:

– specified grades approved for public water supply

without restriction under ANSI/NSF 61

– approved under International Building Code

– approved under International Residential Code

• National approvals in Australia/New Zealand,

China, Malaysia

• India .....

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• 2008 Uniform Plumbing Code – India

– Page No. 119, Clause 605.11

– Galvanised Iron:

• Water Pipes & Fittings made of galvanised

iron shall not be recommended in piping

systems used to convey potable water

Plumbing Code – India

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• Pipe – SS Grade (AISI 304/ 316L or J4

grades)

• Fittings – Innovative Press Fit Design (AISI

304 / 316L grade)

– Sealing Ring

: EPDM

• Press fitting Tools

– Manual / Hydraulic

– Battery Operated

Product – Press Fit Technology

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• Providing and fixing Stainless Steel Grade either AISI 316L or AISI 304 grade

pipes confirming to JIS 3448, JWWA G 116, complete with "Press-Fit" Type

joining system with V-Profile (double crimping), EPDM O-ring for Hot and Cold

water supply (brand “J-Press") capable to withstand temperature upto 110

degree centigrade, such as sockets, bends, elbows, tees, reducers, unions,

flanges, etc. necessary adapters for SS / GI/ Copper and CP fittings, jointing,

sundries, cutting holes in walls/ floors/ slabs and making good complete.

MAKE: J-PRESS

OD Thk

1/2" 15.88 x 0.8 Outer dia pipe

3/4" 22.22 x 1.0 Outer dia pipe

1" 28.56 x 1.0 Outer dia pipe

1.25" 34.0 x 1.2 Outer dia pipe

1.5" 42.7 x 1.2 Outer dia pipe

2" 48.6 x 1.2 Outer dia pipe

Specifications of SS Pipes (for tender)

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Element Unit 304 316L 439 J4 (204)

Ni % 8 – 10.5 10 -14 0.5 1 – 2

Cr % 17.5 –

19.5

16 – 18 17-19 15 – 16.5

C % (max) 0.08 0.08 0.03 0.10

Mn % (max) 2 2 1.0 8.5 – 10

Mo % - 2 – 3

Cu % - 1.5 - 2.0

Si % (max) < 1

P % (max) < 0.045

S % (max) < 0.030

Fe % Balance

Composition of Various Grades

UTS Mpa 515 485 415 650

YS Mpa 205 170 220 325

Hardness HRB (max) 92 95 92 100

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Introducing “V” Profile

Pressing at 3-locations, in front of, on top, and behind the sealing ring

makes joint gas and water-tight.

The latest and foolproof Double Compression pipe fittings

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Press Fitting with V-Profile

Latest V-profile Fittings

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Grooved Piping for Large

Diameter pipes

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What is Grooved Piping System

• A Fast, Clean and Errorfree way to join

Pipes

– No Welding

– No Threading

– No Flanging

• The Joints are

Removable

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Types of Grooved Fittings

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Couplings

• Couplings are used

to join the Grooved

pipes and fittings.

• Couplings consists

of Gaskets to give a

Pressure-Tight pipe

system

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Components of Grooved System

Housing Nut & Bolts Gasket

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Grooves

• Grooves are rolled

or cut at the ends of

the pipes

• Fittings, Valves and

other components

are manufactured

with the same

grooves

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Tests and Studies

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Leakage Rate experience (Japan)

Relationship between Ratio of Stainless Steel piping to leakage rate

Source : JSSA

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• If a pipe has been used for a long time, on condition that the same

water power slope, rate of flow will be gradually reduced due to

increase of surface roughness caused by corrosion.

• According to Kohl Brooke and White, the surface roughness of a pipe

increases in proportion to T (years in use).

ε = ε0 ＋ αＴ

(α constant = 0.06 ～ 2.1mm per year)

Surface Roughness

Source : JSSA, The Society of Heating, Air-Conditioning and Sanitary

Engineers manual <the 13th edition> 121?122 pages.

Flow Qty comparison

(l/min)

SS Carbon Steel

Pipe size

=32 Su,

R=45

At Design

• l/min

C=150 C=100

101 49

After some time

• l/min

C=150 C=80

101 39

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Demolition waste

During operation

During

construction

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Durability Tests in Japan

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Effect of water velocity on corrosion rate

http://www.nickelinstitute.org/index.cfm/ci_id/3080/la_id/1/document/1/re_id/0

Copper

Mild steel

Stainless steel Co

rro

sio

n r

ate

(m

py)

Flow rate (ft/sec)

0 4 8 12 16 20

0

32 28 24

0.003

0.006

0.012

0.009

0.018

0.015

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• The use of SS for general service allows one to

select a smaller dia pipe for a given flow volume

vis a vis Carbon Steel pipes

• eg. 200A for v=3.5 m/s, 7000 l/min is equivalent to

300A, v= 2.0 m/s, 7000 l/min in Carbon Steel

pipes

Savings – Use Lower Dia in SS Piping

Design Manual for SS Plumbing (page 49)

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Test Reports

Pressure Test

• Design for

25kgf/cm2

• Tested upto

95Kgf/cm2

without any

deformation

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• Test for Joint Strength - Tensile

Strength - 3500N before joint slip

Test Report - UTS

SS GI Copper PPR

Material Tensile

Strength (Mpa)

>520 >290 >210 >49

Comparative Strength

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Easy to install

Easy to use in Difficult areas

Time taken :

About 8 hrs against 2-3 days for

GI& Copper (1/3rd time). Expected to

come down further to 4-5 hrs.

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Life Cycle Cost

Initial Installed Costs

+

Costs over the life of the structure

• Materials • Fabrication • Installation

• Maintenance • Replacement • Disruption

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Estimated Cost of a Bathroom

Per Toilet (Internal): GI Rate GI Total SS Rate Discount SS Total

Usage C Class Cost 304 Price Cost

Pipe – Hot+Cold (m) 22 125.10 2752 162.47 146.22 3217 Elbow 15 25.40 381 79.34 71.41 1071 Tee 10 36.50 365 145.21 130.69 1307 Coupling 15 21.00 315 56.00 50.40 756 Threaded Adapter 8 21.00 168 233.95 210.55 1684 Material Cost/ Toilet 3981 8035 Labor Cost 8000 7000

Total Cost of Plumbing in a bathroom 11,981 15,035 100% 125%

Cost Comparison

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Cost GI SS

• Material Cost 3,500 8,000

• Labor Cost 8,000 7,000

• Total Cost 11,000 15,000

• Average Life 10 years 50 years

• Replacement 4 times Nil

– Avg. Cost of Replacement 20,000 0

– Avg. Cost of interiors 30,000 0

Total Cost (4 times) 200,000 0

• Repair Cost 8,000 0

• Total Lifecycle Costs 219,000 15,000

Life Cycle Costs

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Lifecycle costs

Built in 1972 with CS rebar;

corrosion began 2 years later.

first cost £28 million

By 1989, amount spent on repair. £45 million

By 2010, estimated amount that

would be spent on repair.

£120 million

Total amount that would be

spent by 2010

£165 million; (nearly 6

times the original cost !)

Additional first-cost of SS rebar

in critical locations (selective

use)

£3.4 million; (only 12%

increase in initial cost ).

Midlands Link Viaduct, UK

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Summary Comparison Parameter GI PPR cPVC Copper SS Remarks

Corrosion Resistance * 5* 5* **** 5* 304 Grade SS

Hygiene * *** *** **** 5* Recommended for Food and Pharma equipment

Maintenance Free Life * *** ** *** 5* No need of replacement

Enhances Building Life * *** *** **** 5* No leakage, hence no damage to building

Strength of Pipes **** ** * *** 5* SS is the strongest Material

Ease of Installation ** ** *** ** 5* Fast installation with Low Skill worker

Earthquake Proof *** ** ** *** 5* Withstands the vibrations and shocks due to its ductile nature

Cleanability * ** ** **** 5* No deposit buildup due to smooth surface

Food Grade * ** ** **** 5* Meets all food grade standards

High temperature Application *** * * **** 5* Retains strength at high temperature

Low Temperature Application *** * * *** 5* Is not brittle at low temperature, unlike plastics or GI

Fire Resistant **** * * *** 5* Withstands High temperature.

Experience of Usage 5* * * 5* 5* Worldwide usage experinence of 30-40 years

Outside Painting Required * **** **** **** 5* No need of painting

Deposition of Algae ** * * *** 5* Smooth surface prevents algae buildup

Blockage Problem * ** ** **** 5* No deposit buildup hence no blockage

Damage due to Drilling **** ** * **** 5* Strongest material doesn't get damaged due to drilling

High Flow Rate of Water ** *** *** *** 5* Smooth and Wear resistant at High Flow rate

Low Roughness (less scaling) * *** *** **** 5* Smooth surface prevents deposition

Usage in Public Building * * * ** 5* Strong material not easily damaged

Wear Resistant * * * * 5* Not effected by sand or high flow rate

Joint Assurance System *** * * ** 5* No Welding or Solution joining. Permanent Mechanical Joint

Saves Pumping Energy * *** *** **** 5* Smooth surface need less electricity

Water Quality affect * **** **** **** 5* No change in water quality during storage

Pressure Rating *** ** * *** 5* Highest pressure rating of 25 bar

Joint Strength ** * * ** 5* Press fit joint has foolproof and high strength joint

Application Range *** ** ** **** 5* Used for Air, Water and Many Gases

Less conduiting (Jhiri) reqmt ** * * *** 5* As Pipe dia is less

High Wall Strength *** * * *** 5* Less Brick cutting for piping retains its strength

Saving in Labor Cost * **** **** ** 5* Fast installation with Low Skill worker

Saving in Installation Time * *** *** ** 5* Fast to install (approx 1/3rd time of GI piping)

Application in High Rise Buildings *** ** ** **** 5* Not affected by Vibration and Maintenance

Cost *** 5* 5* * ** Slightly more than GI and others

Low Diameter possible * * * **** 5* High flow rates allow for use of low diameter

Life Cycle cost * *** *** **** 5* Lowest lifecycle cost

Total 5 * 1 2 2 1 34 Highest Rating in most parameters

Scale : 1 Poor, 5- Best

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A Big Builder, Mumbai

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• Chennai Airport

• Ambedkar Hospital, Noida

• Crowne Plaza, Rohini

• Indus Hotel, Sahadhara

• AIIMS, Delhi

• Sugdha Hospital, Hisar

• Jindal Hospital, Hisar

• Govind Nursing Home, Hisar

• Heritage Hotel, Gwalior

• Houses – Punjabi Bagh,

Pitampura, Vasant Vihar,

Shanti Niketan, etc

• Farm Houses, Delhi

• Military Engineer Services

• Factories

• DLF- Magnolia, Golf Course,

Gurgaon

• Jindal Guest House, Delhi

• Sony Bakery, Delhi

• Orbit Flat, Mumbai

• Jalandhar

• Chandigarh

• Panchkula

• Ambala

• Haveli, Jalandhar

Some Major Users of SS PressFit Technology

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Thank You

For more details please contact

PRAVIN GOEL

+91 8800304400,

pravingoel@outlook.com

P-20,FF, Uppals Southend, Sohna Road, Gurgaon

JSteelSystems@gmail.com

752, Sector 10, Panchkula