Piping Materials Final

8/22/2019 Piping Materials Final

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PIPING MATERIALS

B. A. Bhanvase


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- Challenge of choosing the correct piping materials of construction!!

- The Piping Material Engineer, the individual responsible for the

selection and the specifying of piping material for process facilities.

-A piping material engineers role is driven by codes, standards,

technical data, and catalogued information.


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- What is a PIPING MATERIAL ENGINEER?

- This individual can be employed by either the EPC (engineering,

procurement, and construction) contractor or the operator/end user.

- The individual responsible for creating the project piping classes and the

numerous piping specifications necessary to fabricate, test, insulate, and

paint the piping systems.


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The Piping Material Engineers Responsibilities

Develop the project piping classes for all process and utility services.

Write specifications for fabrication, shop and field testing, insulation, and

painting.

Create and maintain all data sheets for process and utility valves.

Create a list of piping specials, such as hoses and hose couplings, steam

traps, interlocks. Create and maintain data sheets for these piping special (SP) items.

Assemble a piping material requisition with all additional documents.

Review offers from vendors and create a technical bid evaluation.

Make a technical recommendation.

After placement of a purchase order, review and approve documentation

from vendors related to piping components.When required, visit the vendors premises to attend kickoff meetings, the

testing of piping components, or clarification meetings.

Co-operate with the following departments: Piping Design and Stress, Process,

Instrumentation, Vessels, Mechanical, Structural, Procurement, Material

Control.


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Experience

- Strong areas should include piping design layout and process

requirements.

- Familiar areas should include the following:

Corrosion

Welding

Piping stress

Static equipment

Rotating equipment

Instruments


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The Piping Material Engineers Activities

(1) Development of the project piping classes

(2) Writing specifications for fabrication, shop and field testing, insulation,

and painting

(3) Creating all data sheets for process and utility valves

(4) Creating a list of piping specials and data sheets

(5) Assembling piping material requisition with all additional documents

(6) Reviewing offers from vendors and create a technical bid evaluation

(7) After placement of a purchase order, reviewing and approving

documentation related to all piping components

(8) Vendor visits(9) Bids for new projects


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Development of the project piping

classes

All process plants have of two types of principal piping system: Process pining systems

Utility piping system

Process piping systems can be further divided into primary process, which isthe main process flow and secondary process, which applies to the variousrecycling systems.

Utility piping systems are no less important. They are there to support theprimary process, falling into three groups: Support Instrument air, cooling water, steam

Maintenance plant air, nitrogen

Protection foam and firewater

Piping Classes: Each piping system is allocated a piping class, which listsall the components required to construct the piping. A pipe class includesthe following: Process design conditions

Corrosion allowance

Lists of piping components

Special assemblies

Support notes


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Writing specifications for fabrication, shop

and field testing, insulation, and painting

It is pointless to specify the correct materials of

construction is the pipe is fabricated and erected by poor

qualified labor, using bad construction methods and

inadequate testing inspection, insulation and painting.

The piping material engineer is responsible for writing

project narratives covering these various activities to

guarantee that they meet industry standards and clients

requirements.


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Creating all data sheets for process and

utility valves

All valves used within a process plant must have a

dedicated valve data sheet (VDS).

This document is passport for the component.

It details the size ranges, pressure rating, designtemperature, material of construction, testing and

inspection procedures .

This VDS is essential for the efficient procurementand the possible future maintenance of the valve


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Creating a list of piping specials

and data sheets

A piping system generally comprises common

components such as pipe, fittings and valves.

However, less common piping items may berequired, such as strainers, hoses and hose

couplings, steam traps.

This second group, calledpiping specials, must

carry an SP number as an identifying tag.


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Assembling piping material requisition

with all additional documents

When all the piping specifications have been defined

and initial quantities identified by the Material Take-off

Group, the piping material engineer is responsible for

assembling the requisition packages.


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Materials

-Selection of material for piping depends on its compatibility with

the fluid, the environment and services.

-Making a quality component (material) is very important for whichwe add key ingredients (alloys) to the base element (iron).

-Each alloying element brings a unique and valuable characteristic to

the component mix.


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Material Classification

Pipe Material

Metals Non-Metals

Non-Ferrous Ferrous Non-Plastic(Concrete)

Plastic

Ni Alloys

Cu Alloys

Al Alloys

Iron

Steel

High Alloy (SS)

Medium Alloy (Cr-Mo)

Carbon

Cast Iron

Wrought Iron

Thermoplastic,Thermosetting,Fiber Reinforcement

Gray Cast, Ductile,White, Malleable

High C

Medium CLow C


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Ferrous Pipe

[A] IRON:

(a) Wrought Iron: crushed iron melted with addition of (charcoal + crushed

limestone).

- used for making bars, tubes, slabs and plates.

(b) Cast Iron: includes series of (Fe+C) alloys with C in excess of 1.7 (wt %).

- generally includes [2% C, 1% Si OR 3% C, 1.5% Si].

- has very good flow characteristics, hence suited for casting.

- On the basis of %C Cast Iron can be classified as:

# Gray Cast Iron# Ductile Iron

# White Iron# Malleable Iron


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# Gray Cast Iron: produced by slow cooling of the iron with large proportion

of Graphite flakes.- used for machinery pedestals and engine blocks (ASTM A 395,

ASTM A 439, ASTM A 536, ASTM A 571).

# Ductile Iron: produced by rapid cooling of melt iron with large proportion of

Graphite Spherical Nodules.

- suited for shock applications with ductility (ASTM A 395,ASTM A 439, ASTM A 536,ASTM A 571).

- specially used for culvert pipe.

# White Iron: carbon is in the form of cementite(Fe3C)

- It is a hard material which fractures easily.

# Malleable Iron: White cast iron has been annealed with large proportion

of graphite and Cementite to form malleable iron.

- It is ductile as well as having a good hardness.

ASTM American Society for Testing and Materials

API American Petroleum Institute


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[B] STEEL: alloys of Fe + C, containing less than 1.7% C.

(a) Carbon Steel: It is most common pipe material in the power, chemical,

process, hydrocarbon, and pipeline industries.

- Carbon steel specifications commonly used in steam, water

or air service includes (ASTM A106, ASTM A 53).

- Commonly used steel for pipelines is (API 5 L).

(b) Alloy Steel: ( low alloy steel contains less than 5% total alloys(ASM))

- Alloy steel contains( 0.3% chromium, 0.3% nickel,

0.08% molybdenum (Mo) (ASTM A 941).

- Commonly used in high temperature service.

- Used in high pressure steam lines in power plants,

heat exchangers, and furnace tubes and chemical plants.- Specifications for commonely used low alloy steels are

(ASTM A 335 P2),( ASTM A 335 P12),(ASTM A 335 P11),

( ASTM A 335 P3b), (ASTM A 335 P22),(ASTM A 335 P 21),

(ASTM A 335 P5 to P9).


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(c) High Alloy Steel: contains over 10% of Cr.

- common example is SS with chromium contentis (ASTM A 941).

- Ferrite alloy steel like (ASTM A 405) and (ASTM A 430) is

used for high temperature service.

- (ASTM A 316),(ASTM A 304) are more resistant to sea

waters, chloride, and sulphur hence useful for under

water pipeline.

- (ASTM A 304L) and (ASTM A 316L) is useful in

decreasing the precipitation of inter granular carbides

and corrosion.

- Forgings are made up of (ASTM A 105),(ASTM A 181)

and (ASTM A 182) carbon steels.

- Plate materials in the piping systems is made of

(ASTM A 570) for carbon steel and (ASTM A 240) for SS.


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Non-Ferrous Pipe

[A] Al Alloys: Al reacts with oxygen to form corrosive resistant, protective

oxide layer hence used.

- Mechanical properties are useful up to temperature 300 degree F.

[B] Ni Alloys: Ni is ductile material having high strength and good corrosion

resistant.- Ni alloys are useful in the corrosive and high temp applications.

- Alloys such as:

Hastelloy: (ASTM B 282) , (ASTM C 276)] used for pipe

Construction.

Monel: (ASTM B 165)- used for construction of seamless pipe.

(ASTM B 164)- Used for construction of flange.(ASTM B 366) - Used for construction of fittings.

Inconel: (ASTM B167)- Used for construction of seamless pipe.

(ASTM B 166)- Used for construction of flanges.

(ASTM B 366)- Used for construction of fittings.


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[C] Cu Alloys: Copper alloys are made by alloying copper, bronze and brass.

- they are corrosion resistant in water hence used for makingpipes.

- commonly used copper alloy for tubing is (ASTM B 88).


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Role of elements to improve material property

Carbon (C) increase strength and hardness, at the cost of reduced

ductility.

Manganese (Mn) - deoxidizes and desulfarised steel. It traps sulphur

impurities, avoiding brittle iron sulphides, improves hot - workability

and refines grain.

If Mn/C > 3 , manganese improves impact toughness.

Mn > 0.8 tends to harden steel.

Silicon (Si) is deoxidizer that capture dissolved oxygen and avoids .

porosity- improve castability.

Chromium (Cr) increase resistance to abrasion and wear, also

improve resistance to high temperature hydrogen attach and to coatwith graphite.

Molybdenum (Mo)- enhances creep resistance and high temperature

strength.

- improves resistance to pitting corrosion in many environment.


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Nickel (Ni) causes a significant improvement in fracture toughness

and fatigue resistance.

Aluminum (Al) improves the deoxidization achieved with silicon.

Copper (Cu) - scavengers sulfur and improves atmosphere

corrosion.

Vanadium (V) - improves a steel resistance to hydrogen attach at

high temperature.

Phosphorous (P) increase the ultimate strength of steel .


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Selecting process piping materials

Is the alloy available in the size and thickness required?

Is it the most economical choice?

Should it be specified as seamless or welded?

Is it suitable for the maximum anticipated operating temperature or will

long-term exposure to these temperatures cause its mechanical properties

to deteriorate?

Will it require special welding or heat treatment requirements?


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PROPERTIES CONSIDERED WHEN SELECTING MATERIALS

Machinability

Components may be formed by removing metal "chips" by mechanical

deformation.

This process is referred to as machining.

Machinabilitydescribes how a metal reacts to mechanical deformation

by removing chips, with respect to the amount of metal effectively

removed and the surface finish attainable.


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Formability

Components may be formed by processes such as rolling or bending,which may cause some parts of the metal to expand more than others.

Formabilityof a material is its ability to withstand peripheral expansion without

failure or the capacity of the material to be too manufactured into the final

required shape.

Ductility

Ductilityis the plastic response to tensile force. Plastic response, or plasticity,

is particularly important when a material is to be formed by causing the

material to flow during the manufacture of a component.

It also becomes important in components that are subject to tension andcompression, at every temperature between the lowest service temperature

and the highest service temperature.


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Stability

Stabilityof a material refers to its mechanical and chemical inertness underthe conditions to which it will be subjected.

Some of these environments, such as high temperatures, high acid, high

radiation, and high pressure, can be considered extreme and harsh;

therefore, the stability of the materials selected for service in these areas is

a major consideration.

Availability

The availabilityof a material used in the construction of nuclear plants refers

to the ease with which a material can be obtained and its cost.

Fabricability

Fabricabilityis a measure of the ease with which a material can be worked

and made into desirable shapes and forms.


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Heat TransferGood heat transfer properties are desirable from the fuel boundary to the

coolant in order that the heat produced will be efficiently transferred.

Cost

A major portion of the cost is for plant material; therefore, cost is an

important factor in the selection of plant materials.

Mechanical Strength

Mechanical strength plays an important role in selecting reactor materials.

In case of nuclear reactors, high mechanical strength is desirable because of

its possible degradation due to radiation damage and the need to contain theradioactive liquids and fuel.


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Detailed description of selection the proper material

Selecting the Proper Plastic Piping MaterialTo select the proper plastic piping material, conditions of service for the liquid to be

handled and the suitability of the materials for those service conditions must be known.

Listed is a summary and example of selecting the proper plastic piping material.

Service Conditions Check List

Type of Application

Type of Fluid(s)

Working Pressure (min/max)

Working Temperature (min/max)

Velocity (max)

Specific GravityViscosity

Particulates

Piping Size Range

Above- or Below-ground Installation

Interior/Exterior Exposure

Specific Code Agencies/Approvals


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TIPS for Material Selection

Chemical Compatibility

Pressure/Temperature Compatibility

Piping Size and Product Availability

Piping System Joining Method

Price Comparability


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Date post:	08-Aug-2018
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Piping Materials Final

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