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Module 2 Notes

The document discusses the properties and selection criteria for piping materials, focusing on mechanical, chemical, and physical properties, as well as corrosion resistance. It outlines various corrosion mechanisms and the types of materials suitable for different environments, including metals and non-metals. Additionally, it emphasizes the importance of factors such as temperature, pressure, and external conditions in determining the appropriate piping material for specific applications.

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Mitali Maske
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6 views25 pages

Module 2 Notes

The document discusses the properties and selection criteria for piping materials, focusing on mechanical, chemical, and physical properties, as well as corrosion resistance. It outlines various corrosion mechanisms and the types of materials suitable for different environments, including metals and non-metals. Additionally, it emphasizes the importance of factors such as temperature, pressure, and external conditions in determining the appropriate piping material for specific applications.

Uploaded by

Mitali Maske
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
~ “A gle NOL-O7 | ) av Chawihy Ane pee SA hee tn PSN Stas deter Here, - 2% deed * HES L LID nce, Pade : 6) fepletn te Tye 3 Ron = CARMIHE phase 2? de shicmatcaiueletsataced dee deraleltiel _—— CF AAR RR rests 28 deg, 93 roy, 24d 24 seer eS) Tepes Fifi Byam emi GH) hod ave STL sqatrgds of protecting obers a avound UW oNerqround Piping Ser Cerrelion: | Bran, Y e a6) Dvcust The Snaporlert Feathers TH ASC seleclion | mredktd oF Sonvhrurcttn of pipe: | 2D ory. Gemloin Drepervtet OF told gryctosdion Y het 7) Salutedion pruburads | py dta, 24 see: Q-1) SvpleSn pipe coustiy ed tratetedt otal 74 poy oe . : se Fntutediion % toh Properties of piping material 1. Mechanical Properties ‘Strength: Piping material strength is usually determined by codes like ‘ASME B31. It is based on yield strength and tensile strength at specific temperatures. Allowable stresses consider creep and rupture properties when materials operate in the creep range. ‘Toughness: Defined as the ability to absorb energy or resist impact, often critical for ductile materials like steel. Brittle behavior can occur at low temperatures or under specific conditions. “Modulus of Elasticity (Young's Modulus): Represents the material's ability to deform elastically under stress, measured via standardized tension tests. +2. Chemical Properties - Piping materials, especially metals, are affected by their elemental composition. Alloying elements are added to improve properties like ‘strength, ductility, and corrosion resistance. For example: « Interstitial Alloys: Smaller atoms like carbon fit into spaces in the lattice, enhancing strength. » Substitutional Alloys: Larger atoms replace lattice atoms, affecting material hardness and ductility. ¢3. Physical Properties - Thermal Conductivity: Important for heat transfer applications. - Thermal Expansion: Influences pipe integrity un’ temperature variations. YZ 2 - Density/Specific Gravity: Affects material handli, igt considerations. +4. Corrosion and Environmental Resistance Materials must resist internal and external corrosion. Common issues include: . Reaction with process fluids. . Environmental effects like UV exposure, soil corrosion, and atmospheric conditions. + Corrosion-resistant materials or coatings (e.g., stainless steel or lined pipes) are used to extend service life. +5. Fabricability and Installation . Weldability: Ease of joining materials using welding techniques. Formability: Ability to bend or form without cracking, crucial for custom piping designs. Workability: Related to installation ease, influenced by material ductility and hardness. *6. Service-Specific Properties . Creep Resistance: Ability to withstand deformation under prolonged high-temperature exposure. . Abrasion Resistance: Essential for materials handling solid-laden fluids. . Fatigue Resistance: Ability to endure cyclic loads without failure ae ea 7 l600 __ ae 1493°%C : oS ‘TE Oy 01022} [Link]¢ Ine Goo “tA Shows Gly Cet eR DINE ce >| moe yg C4 Pred by Aforre exe Cammditet posite ~ feac : oe ~ 6742 #H—____oy rveronsallsseacacs all 1. —_ t La: o og 2 3 e ony, a Compos‘tsen (wt), ‘ 2 fe > | Oustenste will depend Upen ¢ 7. 2F CUE less ten inGresse temp : Fos ougtewre ch jy 01022 A Temp. is obme 727°C Deonlite pee 227% iStenp. where reew, 76 G 22 Corben acted | may © 210224 pe sjeoponed wopog ‘uoyenvdard aay itor Anny cmene sins moe a pm 21206 mmo i steal Tron - Iron carbide Diograrm > 1 re) = ego Sra + C7, Cle OC1) — AT wwe a heat oe Fe fam Notuve Us inte roof Be bed tobse Bcc. BU Hard bet vepace Pag were ‘ais mead of Cagioen Fr Ee 6 ogre Lqvains 528 Cooamse goin S F22) neve Temp. 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Hy fv) Peso. + nite of fevdta + comentide + Forms ot eutetold point - @ odsicar Pdirs a) Cutectotd fornt + 0-46'l+ coho ) * F2TC ° + puatenits > poudts + Comentite (Peartt ») Gubect’c polrt —? + 4-3°/; cauban + etc + Uqutd — Austenite + Comenthle 0) Peritectte paint —? *0°18% casoan 21a © seed hes 0 27- & + qaid 4 Foust — Rustedte _oxd. Cait tran nad 2“ keg le Caner = ae = Piping Materials for Corrosion Resistance Corrosion isa significant concern in piping systems as it can compromise the structural integrity and safety of the system. Selecting corosion-resistant ‘matertals depends on the fluids chemical composition, temperature, pressure, and environmental conditions (e.g., marine or industrial atmospheres). 41. Corrosion Mechanisms 1. General Corrosion © Uniform thinning of the matertal. © Caused by acids, alkalis, or seawater exposure, Pitting Corrosion ‘© Localized attacks forming pts. ‘© Common in chlride-contatning environments. 3. Crevice Corrosion ‘© Occurs in shielded areas where stagnant ui collects © Accelerated by chlorides. 4. Galvanic Corrosion ‘© Arises when two dissimilar metals ae in contact in an electrointe. 5. Stress Corosion Cracking (SCC) ‘© Caused by tensile stress and a corrosive environment. ‘© Often occurs in chlorides or caustic environments. 6. Erosion-Corrosion ‘© Combination of mechanical wear and chemical attack. ‘9 Occurs in high-velocity fluids or abrasive environments. 2. Corrosion-Resistant Piping Materials Metals Stainless Steel + Grades: 304, 316, 317, 321, 347, Duplex (e.., 2205), Super Duplex. + Applications: General-purpose piping, food and beverage, chemical processing. + Corrosion Resistance: ‘© Excellent resistance to general, pitting, and crevice corrosion. ‘© 316/316L is superior in chloride environments dv to ‘molybdenum content. ‘© Duplex and Super Duplex have enhanced SCC and pitting resistance. + Limitations: Susceptible to chloride stress cracking under high stress Nickel Alloys + Examples: Inconel (Alloy 600,625), Monel (Alloy 400), Hastelloy (C22, a7, Applications: Harsh chemical environments, marine systems, and high: temperature applications. EE EEE EEE EPEE EP Eer ree Corrosion Resistance: ‘2 Exceptional resistance to axidizing and reducing agents ‘2 Resistant to pitting, SCC, and crevice corresion. Limitations: High cost. Copper and Copper Alloys Examples: Copper, Brass, Bronze + Applications: Water systems, HVAC, marine applications. + Corrosion Resistance: ‘> Natural resistance to biofouling and corrosion in water systems. Limitations: Limited resistance to highly acidic or alkaline environments. Titanium + Applications: Desalination plants, offshore applications, and chemical industries. Corrosion Resistance: ‘> Excellent resistance in chloride-tich environments, seawater, ‘and oxidizing agents. Limitations: High cost and fabrication dificult. ‘Aluminum and Aluminum Alloys + Applications: Lightweight structures, low-pressure systems, Corrosion Resistance: ‘© Good resistance to oxidation and mild environments. + Limftations: Not suitable for highly acidic or alkaline condition. 2.2 Non-Metals ‘Thermoplastics Examples: PYC, CPVC, HDPE, PYDF, PTFE (Teflon). + Applications: Chemical transport, water systems, and corrosive fluid. Corrosion Resistance: ‘> Immune to most chemical attacks (acids, alkalis, solvents), 12 PYC and CPVC are widely used for acidic and mild ‘environments, 2 PVDF and PTFE are suttabe for highly agressive chemicals. Limitations: Lower temperature and pressure limits compared to metals ‘Thermosetting Plastics (FRP) Examples: Fiber Reinforced Plastics, Epoxy-coated pipes. Applications: Corosive chemical processing, storage tanks. + Corrosion Resistance: ©. Excellent in acidic and alkane environments. Limitations: Brittle and less durable under mechanical stress, Rubber and Elastomers + Examples: Neoprene, EPDM, Viton. + Applications: Flexible joints, seals in corrosive environments. Corrosion Resistance: ‘> Resists specific chemicals, such as acid or bases. oem ‘al v4 INV eamerteat it iat Corrosion Protection 1. Protective Coatings / Painting © Epoxy coatings * Polyurethane paints ¢ Zinc-rich primers ¢ Prevents moisture/oxygen contact with float) 2. Galvanization Pe Orer Vine R Co RTL aales * Common for structural and utility piping 3. Insulation with Weather Barrier * For insulated hot/cold lines * Prevents CUI (Corrosion Under Insulation) 4. Use of Corrosion-Resistant Materials ( + Reply to ChatGPT gd ® X = O a 4. Use of Corrosion-Resistant Materials OSes C1) ¢ FRP / GRE pipes * Alloy steels 5. Corrosion Inhibitors ¢ Added internally to fluid ¢ Used when internal corrosion is concern 6. Proper Drainage / Design * Avoid water traps and stagnant zones * Slope lines for drainage 7. Regular Inspection & Maintenance * Thickness monitoring * Visual inspection bd Se ells Underground Piping Corrosion Protection 1. External Coating / Wrapping * Coal tar enamel * Fusion bonded epoxy (FBE) ¢ 3-layer polyethylene coating * Tape wrapping / bituminous coatings 2. Cathodic Protection (Very Important) Makes pipe the cathode so it does not corrode. ats BSC reward att] © Magnesium/Zinc anodes attached to pipe * Impressed Curre! ) hodic Protection (ICCP) ce Lede ee ee * Stainless steel for special cases ral ered ices OM rete) * Protects internal surface if transported fluid is corrosive 5. Proper Backfilling ¢ Use clean sand/non-corrosive soil * Remove rocks/debris that damage coating 6. Electrical Isolation * Isolation joints/flanges prevent stray current corrosion 7. Monitoring & Inspection © CP potential surveys * Holiday testing of Ry ing * Intelligent pigging for buried pipelines Piping Materials for Various Temperature and Pressure to agri is nin commer and SOE ORAS es ene neon ersoesseca tee se tice, and ergy. The lectn depend on see factor cl the Tube spores, enpertre ree, deviant cron Below i a detalled analysis, 1, Factors Influencing Piping Material Selection 1. Temperature + Low-Temperature Conditions: Below freezing (0 oF 32°F) to cryogenic levels (196°C or -320°F for LNG ystems), + Moderate-Temnperature Conditions: Ranges between ambient temperatures (upto 120°C or 50°F) + High-Temperature Conditions: Ranges from 120°C to 650°C (e8., steam systems). + Ultra-ighTemperatures: Above 650°C, typically for specialized ‘pplicattons ike gas turbines or supercritical steam plans 2. Pressure + Low Pressure: Below 150 ps. + Medium Pressure: Between 150 ps and 600 pst. + High Pressure: Above 600 psi, up to thousands of ps in specialized systems, 3. Fluld Characteristics * Corosiveness(e.., acidic or alkaline fds. + Toxdtty or fammabiity, Viscosity and phase (gas, ul, o slurry). 4. External Conitions Environmental exposure (¢.., marine environments, underground system) + Thermal cyting and mechanical stress. 2. Common Piping Materials 1. Metals + Carbon Steet © Applications: Widely used in land gas, water, and steam systems 1 Temperature Range: 29°C to 427°C (-20°F to 600°) © Pressure Rating: Suitable for mectum to high-pressure systems. © Advantages: Cost-effective, ood mechanical strength, 1 Limitations: Prone to corrosion in aggresive environments Unless coated or ined, + Staines Steet ‘© Applications: Chemical processing, food, and pharmaceutical indutres, 1 Temperature Range: 200°C to 800°C (-328°F to 1472°F), 1 Pressure Rating: Suitable for high-pressure ystems. ‘© Advantages: Excellent corrosion resistance, hyzlenlc properties ‘© Limitations: Higher cost than carbon see Pressure Rating: Suttable fr high-pressure systems. ‘Advantages: Excellent corrosion resistance, hygienic properties. Limitations: Higher cost than carbon steel + Alloy Steets ‘Applications: High-temperature steam and pressure systems. ‘Temperature Range: Up to 650°C (1200"F), ‘Advantages: Enhanced mechanical strength and temperature resistance. Limitations: Expensive and less ductile. + Copper and Copper Alloys Applications: HVA, refrigeration, and potable water systems. “Temperature Range: 200°C to 250'C (-328°F to 482°F). Pressure Rating: Suttable for low to moderate pressure Advantages: Excellent thermal conductivity, corasion resistance. Limitations: High cost and lower mechanical strength, + Nickel Alloys (eg, Inconel, Monel) ‘Applications: Extreme environments, such as chemical plants and marine systems. ‘Temperature Range: Upto 1000°C (1832°F). ‘Advantages: Exceptional resistance to corrosion, oxidation, and high temperatures. Limitations: Very expensive. 2.2 Non-Metals + Thermoplastic. + Thermosetting Plastics (. +» PVC, CPYC, HOPE, PP) Applications: Water distribution, chemical transport, drainage systems, Temperature Range: -40°C to 90°C (-40"F to 194°F), depending onthe plastic. Pressure Rating: Typically low to moderate. ‘Advantages: Lightweight, corrsion-reistant, cost-effective, Limitations: Poor performance under high temperature and pressure. FRP) Aplications: Corrosive environments n chemical industries. Temperature Range: Upto 200°C (32°F) Pressure Rating: Low to moderate, ‘Advantages: Strong and durable with excellent chemical resstance. Umitations: Britle and dificult to repatr + Rubber and Elastomers ‘Applications: Low-pressure systems for flexible connections, “Temperature Range: -40°C to 120°C (40'F to 248°F). Advantages: Flexible and resstant to abrasion and some chemicals Limitations: Limited temperature and pressure resistance Hot Insulation Material Properties (Used for steam lines, hot oil lines, boilers, furnaces) 1. Low Thermal Conductivity ° Minimizes heat loss from hot surface. Pree a eC Ley © Must withstand elevated operating temperatures without degrading. 3. Thermal Shock Resistance © Should tolerate rapid heating/cooling cycles. 4. Good Mechanical Strength © Resists crushing and deformation under load. 5. Dimensional Stability © Maintains shape at high temperature. Mm Cea lms © Maintains shape at high temperature. 6. Non-combustibility / Fire Resistance © Should not burn easily. 7. Low Density / Lightweight © Reduces structural load. rR OUTST Cd ° Should not react with pipe/equipment ilaicleom 9. Durability / Weather Resistance ° For outdoor service. 10. Personnel Protection Capability * Keeps outer surface temperature safe to touch. Typical hot insulation materials: mineral wool, glass wool, ca Ny silicate, ceramic Si eYs) we OCR ST ELT n VET Car) an ed ke) Y= eK (Used for refrigeration, chilled water, cryogenic lines) 1. Very Low Thermal Conductivity CM lmel- Tm emer) (RCN Cte 2. Low Water Absorption ° Must resist moisture uptake. 3. Closed-Cell Structure eC CML MRC Lem LALO CMa eA) elt Li ete) © Reduces condensation/icing. 5. Dimensional Stability at Low Temperature © Should not shrink/crack when cold. 6. Flexibility / Contraction Resistance © Handles thermal contraction of cold nininn ce High Vapor Barrier Performance © Reduces condensation/icing. Dimensional Stability at Low Temperature ° Should not shrink/crack when cold. aye Nel tele OC) ° Handles thermal contraction of cold piping. Ree am meet a PX (Tem Orel) eRe LU) ° Supports cladding/jacketing loads. Chemical Resistance 10. Resistance to Fungal/Microbial Growth ¢ Important in moist environments. Typical cold insulatiommaterials: PUF, PIR, elastomeric foam, ce! Mar glass, phenolic biey: |) @Muciurina! 1. Pipe Coating Pipe coating is the application of a protective layer on the external or internal surface of pipes to protect them from corrosion, erosion, chemicals, weather, and mechanical CercTaarclelcw LeU lee Relea meer L ttl] * Prevent corrosion/rusting * Increase pipe life * Protect against moisture and chemicals * Reduce friction in internal flow (for internal coatings) * Improve appearance/identification Common Pipe Coating Materials * Fusion Bonded Epoxy (FBE) — corrosion-resistant coating for buried pipelines corrosion-resistant coating for buried pipelines * Coal Tar Epoxy — used for underground/ underwater pipes * Bituminous/Asphalt Coating — economical corrosion protection * Polyethylene (PE) Coating / 3LPE - excellent underground protection * Polypropylene (PP) Coating / 3LPP — high-temperature service * Galvanizing (Zinc Coating) — protects steel from rusting * Cement Mortar Lining — internal coating for water pipelines © Rubber Lining — for abrasive/corrosive SI casa le * PTFE / Teflon Coating — for highly corrosive chemicals ¢ Paint Systems — primer + intermediate + top coat for atmospheric exposure ye YM Lt Cet) Pipe insulation is the covering of pipes with insulating material to reduce heat transfer between the pipe and surroundings. Purpose of Pipe Insulation ¢ Minimize heat loss/gain * Maintain process temperature ¢ Prevent freezing of fluids © Protect personnel from hot surfaces * Reduce condensation/sweating on cold pipes ¢ Improve energy efficiency aR RUSE) * Hot Insulation — for hot fluid lines to reduce heat loss * Cold Insulation - for chilled/cryogenic lines to prevent heat gain/condensation Common Pipe Insulation Materials © Mineral Wool / Rock Wool — hot insulation * Glass Wool / Fiberglass — thermal/ acoustic insulation * Calcium Silicate — high-temperature insulation ° Ceramic Fiber — very high temperature ¢ Polyurethane Foam (PUF) - cold insulation ¢ Phenolic Foam — low thermal conductivity ° Nitrile Rubber / Elastomeric Foam — HVAC/chilled water lines ¢ Expanded Polystyrene (EPS) — cold insulation ° Perlite — cryogenic insulation ° Foam Glass — moisture-resistant cold insulation a

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