B31.3 Process Piping Course - 03 Materials-libre

ASME B31.3 Process Piping Course

3. Materials

ASME B31.3 Process Piping Charles Becht IV, PhD, PE Don Frikken, PE Instructors BECHT ENGINEERING COMPANY, INC.

Materials -

1

Piping Development Process 1. Establish applicable system standard(s) 2. Establish design conditions 3. Make overall piping material decisions ̇ ̇ ̇

Pressure Class Reliability Materials of construction

4. Fine tune piping material decisions ̇ ̇ ̇

Materials Determine wall thicknesses Valves

5. Establish preliminary piping system layout & support configuration 6. Perform flexibility analysis 7. Finalize layout and bill of materials 8. Fabricate and install 9. Examine and test

BECHT ENGINEERING COMPANY, INC.

Materials -

2

ASME B31.3 Process Piping Course

3. Materials

3. Materials

ÜStrength of Materials ÜBases for Design Stresses ÜB31.3 Material Requirements ̇ ̇ ̇ ̇

Listed and Unlisted Materials Temperature Limits Toughness Requirements Fluid Service Requirements

ÜDeterioration in Service BECHT ENGINEERING COMPANY, INC.

Materials -

3

The Material in This Section is Addressed by B31.3 in: Chapter II - Design Chapter III - Materials Appendix A - Allowable Stresses & Quality Factors – Metals Appendix F - Precautionary Considerations

BECHT ENGINEERING COMPANY, INC.

Materials -

4

ASME B31.3 Process Piping Course

3. Materials

Strength of Materials

ÜStress ÜStrain ÜStress-Strain Diagram ̇ Elastic Modulus ̇ Yield Strength ̇ Ultimate Strength

ÜCreep ÜFatigue ÜBrittle versus Ductile Behavior BECHT ENGINEERING COMPANY, INC.

Materials -

5

Strength of Materials Stress (S): force (F) divided by area (A) over which force acts, pounds force/inch2 (psi), Pascals (Newtons/meter2) Strain (ε): change in length (ΔL) divided by the original length (L) F L BECHT ENGINEERING COMPANY, INC.

ΔL Materials -

6

ASME B31.3 Process Piping Course

3. Materials

Stress

Strength of Materials ST = Tensile Strength

SY = Yield Strength E = Elastic Modulus = Stress/Strain

Typical Carbon Steel

Strain

BECHT ENGINEERING COMPANY, INC.

Materials -

7

Stress

Strength of Materials ST = Tensile Strength SY = Yield Strength Proportional Limit 0.2% offset

Typical Stainless Steel

BECHT ENGINEERING COMPANY, INC.

Strain Materials -

8

ASME B31.3 Process Piping Course

3. Materials

Strength of Materials Creep: progressive permanent deformation of material subjected to constant stress, AKA time dependent behavior. Creep is of concern for

̇ Carbon steels above ~700ºF (~370ºC) ̇ Stainless steels above ~950ºF (~510ºC) ̇ Aluminum alloys above ~300ºF (~150ºC)

BECHT ENGINEERING COMPANY, INC.

Materials -

9

Strain

Strength of Materials Primary

Secondary

Tertiary

Rupture Creep Rate (strain/unit time)

Typical Creep Curve

Time BECHT ENGINEERING COMPANY, INC.

Materials -

10

ASME B31.3 Process Piping Course

3. Materials

Strength of Materials

Minimum Stress to Rupture, 316 SS Fig I-14.6B, ASME B&PV Code, Section III, Division 1 - NH

BECHT ENGINEERING COMPANY, INC.

Materials -

11

Strength of Materials

Stress

Fatigue failure: a failure which results from a repetitive load lower than that required to cause failure on a single application

Number of Cycles

BECHT ENGINEERING COMPANY, INC.

Materials -

12

ASME B31.3 Process Piping Course

3. Materials

Strength of Materials Brittle failure:

Ductile deformation:

BECHT ENGINEERING COMPANY, INC.

Materials -

13

Materials -

14

Brittle failure:

Stress

Strength of Materials Toughness

Ductile failure:

Stress

Strain

Toughness

BECHT ENGINEERING COMPANY, INC.

Strain

ASME B31.3 Process Piping Course

3. Materials

Strength of Materials Measuring Toughness using a Charpy impact test

W H1 -H2

Pendulum

H1

H2

Charpy Impact Test Cv = W(H1 - H2) Specimens tested at 40, 100 and 212ºF (4, 38 and 100ºC)

= Energy Absorbed

BECHT ENGINEERING COMPANY, INC.

Materials -

15

Strength of Materials

Ductile to Brittle Transition for a Carbon Steel BECHT ENGINEERING COMPANY, INC. Materials - 16

ASME B31.3 Process Piping Course

Ü Ü Ü Ü

3. Materials

Bases for Design Stresses Most Materials Bolting Gray Iron Malleable Iron

BECHT ENGINEERING COMPANY, INC.

Materials -

17

Bases for Design Stresses Most Materials – (materials other than gray iron, malleable iron and bolting) below the creep range, the lowest of (302.3.2) ̇ ̇ ̇ ̇

1/3 of specified minimum tensile strength (ST) 1/3 of tensile strength at temperature 2/3 of specified minimum yield strength (SY) 2/3 of yield strength at temperature; except for austenitic stainless steels and nickel alloys with similar behavior, 90% of yield strength at temperature

BECHT ENGINEERING COMPANY, INC.

Materials -

18

ASME B31.3 Process Piping Course

3. Materials

Bases for Design Stresses Most Materials – additional bases in the creep range, the lowest of (302.3.2)

̇ 100% of the average stress for a creep rate of 0.01% per 1000 hours ̇ 67% of the average stress for rupture at the end of 100,000 hours ̇ 80% of the minimum stress for rupture at the end of 100,000 hours

BECHT ENGINEERING COMPANY, INC.

Materials -

19

Bases for Design Stresses ASTM A106 Grade B Carbon Steel (US Customary Units) 25.00

Stress, ksi

20.00 15.00

2/3 of Yield 1/3 of Tensile

10.00

Allowable

5.00 0.00 0

200

400

600

800

1000

Temperature, F

BECHT ENGINEERING COMPANY, INC.

Materials -

20

ASME B31.3 Process Piping Course

3. Materials

Bases for Design Stresses ASTM A106 Grade B Carbon Steel (Metric Units) 180.0 160.0

Stress, MPa

140.0 120.0 2/3 Yield

100.0

1/3 Tensile

80.0

Allowable

60.0 40.0 20.0 0.0 0

100

200

300

400

500

Temperature, C

BECHT ENGINEERING COMPANY, INC.

Materials -

21

Bases for Design Stresses ASTM A312 Gr TP316 Stainless Steel (US Customary Units) 30.00

Stress, ksi

25.00 20.00

2/3 Yield 90% Yield 1/3 Tensile Allowable

15.00 10.00 5.00 0.00 0

200

400

600

800

1000

Temperature, F

BECHT ENGINEERING COMPANY, INC.

Materials -

22

ASME B31.3 Process Piping Course

3. Materials

Bases for Design Stresses ASTM A312 Gr TP316 Stainless Steel (Metric Units) 200.0 180.0

Stress, MPa

160.0 140.0 120.0

2/3 Yield

100.0

90% Yield

80.0

1/3 Ultimate

60.0

Allowable

40.0 20.0 0.0 0

100

200

300

400

500

Temperature, C

BECHT ENGINEERING COMPANY, INC.

Materials -

23

Bases for Design Stresses Additional Notes

̇ For structural grade materials, design stresses are 0.92 times the value determined for most materials (302.3.2) ̇ Stress values above 2/3 SY are not recommended for flanged joints and other components in which slight deformation can cause leakage or malfunction (302.3.2) ̇ Design stresses for temperatures below the minimum are the same as at the minimum

BECHT ENGINEERING COMPANY, INC.

Materials -

24

ASME B31.3 Process Piping Course

3. Materials

Bases for Design Stresses Bolting – below the creep range, the lowest of (302.3.2) ̇ 1/4 of specified minimum tensile strength (ST); if properties are enhanced by heat treatment or strain hardening, 1/5 ST ̇ 1/4 of tensile strength at temperature ̇ 2/3 of specified minimum yield strength (SY); if properties are enhanced by heat treatment or strain hardening, 1/4 SY ̇ 2/3 of yield strength at temperature

BECHT ENGINEERING COMPANY, INC.

Materials -

25

Bases for Design Stresses Bolting – additional bases in the creep range, the lowest of (302.3.2)

̇ 100% of the average stress for a creep rate of 0.01% per 1000 hours ̇ 67% of the average stress for rupture at the end of 100,000 hours ̇ 80% of the minimum stress for rupture at the end of 100,000 hours

BECHT ENGINEERING COMPANY, INC.

Materials -

26

ASME B31.3 Process Piping Course

3. Materials

Bases for Design Stresses Gray Iron – the lowest of (302.3.2)

̇ 1/10 of specified minimum tensile strength (ST) ̇ 1/10 of tensile strength at temperature

BECHT ENGINEERING COMPANY, INC.

Materials -

27

Bases for Design Stresses Malleable Iron – the lowest of (302.3.2)

̇ 1/5 of specified minimum tensile strength (ST) ̇ 1/5 of tensile strength at temperature

BECHT ENGINEERING COMPANY, INC.

Materials -

28

ASME B31.3 Process Piping Course

3. Materials

B31.3 Material Requirements

ÜListed and Unlisted Materials ÜTemperature Limits ÜImpact Test Methods & Acceptance ÜToughness Requirements ÜFluid Service Requirements

BECHT ENGINEERING COMPANY, INC.

Materials -

29

Listed and Unlisted Materials

Ü Listed Material: a material that conforms to a specification in Appendix A or to a standard in Table 326.1 – may be used (323.1.1)

Ü Unlisted Material: a material that is not so listed – may be used under certain conditions (323.1.2) Ü Unknown Material: may not be used (323.1.3)

BECHT ENGINEERING COMPANY, INC.

Materials -

30

ASME B31.3 Process Piping Course

3. Materials

Listed and Unlisted Materials An unlisted material may be used if (323.1.2) Ü It conforms to a published specification covering chemistry, mechanical properties, method of manufacture, heat treatment, and quality control Ü Otherwise meets the requirements of the Code Ü Allowable stresses are determined in accordance with Code bases, and Ü Qualified for service…all temperatures (323.2.3) BECHT ENGINEERING COMPANY, INC.

Materials -

31

Temperature Limits Listed materials may be used above the maximum described in the Code if (323.2.1)

̇ There is no prohibition in the Code ̇ The designer verifies serviceability of the material, considering the quality of mechanical property data used to determine allowable stresses and resistance of the material to deleterious effects in the planned fluid service (323.2.4)

BECHT ENGINEERING COMPANY, INC.

Materials -

32

ASME B31.3 Process Piping Course

3. Materials

Temperature Limits Listed materials may be used within the temperature range described in the Code if (323.2.2)

̇ The base metal, weld deposits and heat affected zone (HAZ) are qualified in accordance with Column A of Table 323.2.2.

BECHT ENGINEERING COMPANY, INC.

Materials -

33

Table 323.2.2 Requirements for Low Temperature Toughness Tests

e2 g a p See

1

nt. e m pple u s e of th

BECHT ENGINEERING COMPANY, INC.

Materials -

34

ASME B31.3 Process Piping Course

3. Materials

Temperature Limits Listed materials may be used below the minimum described in the Code if (323.2.2)

̇ There is no prohibition in the Code ̇ The base metal, weld deposits and heat affected zone (HAZ) are qualified in accordance with Column B of Table 323.2.2.

BECHT ENGINEERING COMPANY, INC.

Materials -

35

Carbon Steel Lower Temperature Limits Ü Most carbon steels have a letter designation in the column for minimum temperature in Appendix A Ü See page 26 of the supplement ̇ Note “Min. Temp.” column ̇ Read Appendix A note 7 ̇ Read Appendix A note 4 & see page 27

Ü For those that do, the minimum temperature is defined by Figure 323.2.2A BECHT ENGINEERING COMPANY, INC.

Materials -

36

ASME B31.3 Process Piping Course

3. Materials

Figure 323.2.2A Minimum Temperatures without Impact Testing for Carbon Steel

nt. e m pple u s the f o e 23 g a p See

BECHT ENGINEERING COMPANY, INC.

Materials -

37

Carbon Steel Lower Temperature Limits Ü Impact testing is not required down to -55ºF (-48ºC) if stress ratio does not exceed the value defined by Figure 323.2.2B Ü Impact testing is not required down to -155ºF (-104ºC) if stress ratio does not exceed 0.3

BECHT ENGINEERING COMPANY, INC.

Materials -

38

ASME B31.3 Process Piping Course

3. Materials

Fig.323.2.2B Reduction in Minimum Design Temperature w/o Impact Testing

See page 24 of the supplement. BECHT ENGINEERING COMPANY, INC.

Materials -

39

Carbon Steel Lower Temperature Limits Fig.323.2.2B provides a further basis for use of carbon steel without impact testing. If used: ̇ Hydrotesting is required ̇ Safeguarding is required for components with wall thicknesses greater than ½ in. (13 mm)

Stress Ratio is the largest of

̇ Nominal pressure stress / S ̇ Pressure / pressure rating ̇ Combined longitudinal stress / S

BECHT ENGINEERING COMPANY, INC.

Materials -

40

ASME B31.3 Process Piping Course

3. Materials

Carbon Steel Lower Temperature Limits Design Pressure: 650 psig NPS (45 bar) (DN) Design Temperature: 1 735°F (390°C). Pipe material is ASTM A53 (25) Gr B seamless. 4 (100) What options are available 12 to deal with expected (300) ambient temperatures down to -30°F (-34°C)? 30 (750) BECHT ENGINEERING COMPANY, INC.

Nominal Stress WT Ratio in (mm)

0.178 (4.52)

0.71

0.237 (6.02) 0.500 (12.70) 1.000 (25.40)

0.74 0.86 0.97 Materials -

41

Impact Test Methods and Acceptance Ü Impact testing is done in accordance with ASTM A370 Ü Each set of impact test specimens consists of 3 bars Ü Impact test temperature:

̇ For full size (10 mm square) Charpy V-notch specimens, the design minimum temperature ̇ For subsize specimens smaller than 8 mm, below the design minimum temperature

[323.3]

BECHT ENGINEERING COMPANY, INC.

Materials -

42

ASME B31.3 Process Piping Course

3. Materials

Impact Test Methods and Acceptance Ü Acceptance criteria

̇ Most steels, based on energy absorbed per Table 323.3.5 ̇ For high strength steels, including bolting, based on minimum lateral expansion of 0.015 in. (0.38 mm) opposite the notch

Ü Retest of a second set of three specimens is permitted under certain conditions. [323.3]

BECHT ENGINEERING COMPANY, INC.

Materials -

43

Fluid Service Requirements (323.4.2)

Ü Ductile Iron

̇ generally limited to temperature range of -20ºF to 650ºF (-29ºC to 343ºC) and B16.42 ratings ̇ welding is not permitted

BECHT ENGINEERING COMPANY, INC.

Materials -

44

ASME B31.3 Process Piping Course

3. Materials

Fluid Service Requirements (323.4.2)

Ü Other Cast Irons

̇ may not be used under severe cyclic conditions ̇ may be used for other services if safeguarded for heat, thermal and mechanical shock, and abuse ̇ may not be used in above ground flammable service above 300ºF (149ºC) or above 400 psi (2760 kPa)

BECHT ENGINEERING COMPANY, INC.

Materials -

45

Fluid Service Requirements (323.4.2)

Ü Gray Iron

̇ may not be used in flammable service above 150 psi (1035 kPa) ̇ may not be used in other services above 400 psi (2760 kPa)

Ü Malleable Iron

̇ may not be used outside -20ºF to 650ºF (-29ºC to 343ºC)

Ü High Silicon Iron

̇ may not be used in flammable service

BECHT ENGINEERING COMPANY, INC.

Materials -

46

ASME B31.3 Process Piping Course

3. Materials

Fluid Service Requirements (323.4.2)

Ü Aluminum Castings

̇ the designer is responsible for establishing design stresses and ratings if thermal cutting is used

Ü Lead, Tin & their Alloys

̇ may not be used with flammable fluids

Ü Clad Materials

̇ cladding may be considered to be part of the thickness of components under certain conditions

BECHT ENGINEERING COMPANY, INC.

Materials -

47

Deterioration in Service

Ü Selection of material to resist deterioration in service is not within the scope of the Code. (323.5) Ü Recommendations for material selection are presented in Appendix F. ̇ General considerations ̇ Specific material considerations

BECHT ENGINEERING COMPANY, INC.

Materials -

48

ASME B31.3 Process Piping Course

3. Materials

Deterioration in Service Types of Damage Mechanisms

̇ Loss of metal ̇ Stress Corrosion Cracking ̇ Metallurgical and Environmental Degradation

BECHT ENGINEERING COMPANY, INC.

Materials -

49

Materials -

50

Loss of Metal Loss of metal can be

̇ General ̇ Localized depending on the physical conditions and the specific mechanism.

A Rainbow of Rust Colors

BECHT ENGINEERING COMPANY, INC.

ASME B31.3 Process Piping Course

3. Materials

Loss of Metal Mechanisms include ̇ ̇ ̇ ̇

Galvanic corrosion Atmospheric corrosion Corrosion under insulation Crevice

BECHT ENGINEERING COMPANY, INC.

Materials -

51

Galvanic Corrosion Electrochemical process

• The anode is the site at which the metal is corroded

• The electrolyte is the corrosive medium

• The cathode forms the other electrode in the cell and is not consumed in the corrosion process

BECHT ENGINEERING COMPANY, INC.

Materials -

52

ASME B31.3 Process Piping Course

Galvanic corrosion GALVANIC SERIES IN SEA WATER

Carbon Steel Nipple Threaded into a Stainless Steel Water Tank

3. Materials

CORRODED END (Anodic) Magnesium Zinc Aluminum Cadmium Mild Steel Cast Iron Stainless Steels 18/8 (Active) Lead Tin Nickel (Active) Brass Copper Aluminum Bronze Cupro nickel Silver Solders Nickel (Passive) Stainless Steel 18/8 (Passive) Silver Titanium Graphite Gold Platinum PROTECTED END (Cathodic)

BECHT ENGINEERING COMPANY, INC.

Materials -

53

Galvanic corrosion Materials Affected

̇ All metals, with the exception of most noble metals, are affected.

Critical Factors

̇ For galvanic corrosion, three conditions must be met: • Presence of an electrolyte • Two different metals or alloys in contact with the electrolyte • An electrical connection between the anode and the cathode

̇ The relative exposed surface areas between anodic material and the cathodic material has a significant affect

BECHT ENGINEERING COMPANY, INC.

Materials -

54

ASME B31.3 Process Piping Course

3. Materials

Galvanic corrosion Prevention

̇ The best method for prevention/mitigation is through good design. ̇ The more noble material may need to be coated. If the active material were coated, a large cathode to anode area can accelerate corrosion of the anode at any breaks in the coating.

Improvements in Materials of Construction

̇ Galvanic corrosion is the principle used in galvanized steel, where the zinc corrodes preferentially to protect the underlying carbon steel. ̇ If there is a break in the galvanized coating, a large anode to small cathode area prevents accelerated corrosion of the steel. ̇ This anode-to-cathode relationship reverses at water temperatures over about 150°F (65°C).

BECHT ENGINEERING COMPANY, INC.

Materials -

55

Atmospheric Corrosion

Ü Atmospheric corrosion is a form of galvanic corrosion. Ü Different parts of the surface of the metal act as anodes and cathodes. Ü Variations in the electrolyte also contribute.

BECHT ENGINEERING COMPANY, INC.

Materials -

56

ASME B31.3 Process Piping Course

3. Materials

Atmospheric Corrosion Materials Affected

̇ Carbon and low alloy steels are most affected.

Critical Factors

̇ Marine environments can be very corrosive (20 mpy) as are industrial environments that contain acids or sulfur compounds that can form acids (5-10 mpy). ̇ Inland locations exposed to a moderate amount of precipitation or humidity are considered moderately corrosive environments (1-3 mpy). ̇ Dry rural environments usually have very low corrosion rates (