CONTENTS AND SUBJECT INDEX

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1 OVERALL PROCESS SYSTEM DESIGN ................... 1
1.1 Introduction ..................................... 1
1.2 Planning Projects and Equipment Design ............... 2
13 Equipment and Instrumentation Codes . . . . . . . . . . . . . . . . . 6
1.4 Vessel Codes and Flange Ratings .................... 10
References ..................................... 12

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2 DESIGN AND CORROSION ............................ 13
2.1 Introduction .................................... 13
2.2 Types of Corrosion ............................... 13
23 Materials Evaluation and Selection . . . . . . . . . . . . . . . . . . . 18
2.4 Design Guidelines ................................ 36
2.5 Glossary of Corrosion Terms ....................... 46
References ..................................... 50

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3 PROPERTIES AND SELECTION OF MATERIALS . . . . . . . . . . 51
3.1 General Properties and Selection Criteria . . . . . . . . . . . . . . 51
3.2 Properties of Cast Irons ........................... 53
3.2.1 Gray Cast Iron ............................ 55
3.2.2 White Cast Iron ........................... 56
3.2.3 Malleable Cast Irons ........................ 56
3.2.4 Nodular Cast Iron .......................... 57
3.2.5 Austenitic Cast Iron ........................ 57
33 Application Requirements of Cast Irons . . . . . . . . . . . . . . . 57
3.3.1 Abrasion Resistance ........................ 57
3.3.2 Corrosion Resistance ....................... 57
3.3.3 Temperature Resistance ..................... 60
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x Contents and Subject Index

3.3.4 Welding Cast Iron ......................... 60

3.4 Properties of Steels ............................... 61
3.4.1 Low Carbon Steels (Mild Steel) . . . . . . . . . . . . . . . . 62
3.4.2 Corrosion Resistance ....................... 63
3.4.3 Heat Resistance ........................... 63
3.4.4 Low Temperatures ......................... 63
3.4.5 High-Carbon Steels ........................ 63
3.4.6 Low-Carbon. Low-Alloy Steels . . . . . . . . . . . . . . . 64
3.4.7 Mechanical Properties ....................... 64
3.4.8 Corrosion Resistance ....................... 64
3.4.9 Oxidation Resistance and Creep Strength . . . . . . . . . 65
3.4.10 Low-Temperature Ductility . . . . . . . . . . . . . . . . . . 67
3.4.11 High-Carbon. Low-Alloy Steels . . . . . . . . . . . . . . . 67
3.5 Properties of High-Alloy Steels ..................... 67
3.5.1 Chromium Steels (400 Series), Low-Carbon
Ferritic (Type 405): 12-13% Chromium . . . . . . . . 68
3.5.2 Medium Carbon Martensitic: 13-17% Chromium
(Types 403. 410, 414. 416. 420. 431. 440) . . . . . . . 68
3.5.3 Medium Carbon Ferritic: 17-30% Chromium
(Types 430 and 446) ...................... 68
3.5.4 Chromium/Nickel Austenitic Steels (300 Series) . . . . 68
3.5.5 Precipitation Hardening Stainless Steels . . . . . . . . . . 71
3.5.6 Chromium/NickeliFerrite/Austenite Steels . . . . . . . . 72
3.5.7 Maraging Steels ........................... 73
3.6 Applications of High-Alloy Steels .................... 73
3.6.1 Oxidation Resistance ....................... 74
3.6.2 Mechanical Properties at Elevated Temperatures . . . . 74
3.6.3 Mechanical Properties at Low Temperatures . . . . . . . 74
3.7 Corrosion-Resistant Nickel and Nickel Alloys . . . . . . . . . . . 74
3.7.1 NickeVCopper (Alloy 400) . . . . . . . . . . . . . . . . . . . 75
3.7.2 NickeVMolybdenum ........................ 75
3.7.3 Nickel/Molybdenum/Chromium . . . . . . . . . . . . . . . . 75
3.7.4 Nickel/Chromium/Molybdenum/Iron . . . . . . . . . . . . 75
3.7.5 NickeVChromium/Molybdenum/Copper . . . . . . . . . . 76
3.7.6 NickeVSilicon ............................ 76
3.8 Heat-Resistant Nickel Alloys ....................... 76
3.8.1 NickeVChromium .......................... 76
3.8.2 Nickel/Chromium/Iron ...................... 76
3.9 Copper and Copper Alloys ......................... 77
3.9.1 Brasses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.9.2 Tin Bronzes .............................. 81
3.9.3 Aluminum and Manganese Bronzes . . . . . . . . . . . . . 81
3.9.4 Silicon Bronzes ........................... 81
3.9.5 Cupro-Nickels ............................ 83
 Contents and Subject Index xi

3.9.6 Corrosion Resistance . . . . . . . . . . . . . . . . . . . . . . . 83

3.10 Mechanical Properties of Lead and Lead Alloys . . . . . . . . . 83
3.10.1 Corrosion Resistance ....................... 86
3.11 Aluminum and Aluminum Alloys .................... 86
3.11.1 Aluminum Alloy Compositions . . . . . . . . . . . . . . . . 88
3.11.2 Aluminum of Commercial 99% Minimum
Aluminum Purity . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.11.3 Nonheat-Treatable Magnesium and
Manganese Alloys ........................ 88
3.11.4 Heat-Treatable Alloys ...................... 89
3.11.5 Casting Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.11.6 Temperature Effects ........................ 90
3.11.7 Corrosion Resistance . . . . . . . . . . . . . . . . . . . . . . . 90
3.11.8 OrganicAcids . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.12 Miscellaneous Precious Metals ...................... 93
3.12.1 Titanium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.12.2 Tantalum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.12.3 Zirconium ............................... 96
3.12.4 Precious Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.12.5 Silver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.12.6 Gold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.12.7 Platinum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.13 Metallic Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.13.1 Electrodeposition . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.13.2 Dip Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.13.3 Sprayed Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.13.4 Diffusion Coatings . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.14 Carbon, Graphite and Glass ....................... 100
3.14.1 Carbon and Graphite ....................... 100
3.14.2 Glass .................................. 101
3.15 Cements, Bricks and Tiles ........................ 102
3.15.1 Cements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.15.2 Bricks and Tiles .......................... 102
3.16 Plastic and Thermoplastic Materials . . . . . . . . . . . . . . . . . 104
3.16.1 Polyolefins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.16.2 Polyvinyl Chloride ('VC) . . . . . . . . . . . . . . . . . . . 114
3.16.3 Rigid PVC (UPVC) . . . . . . . . . . . . . . . . . . . . . . . 114
3.16.4 High-Impact PVC ........................ 114
3.16.5 Chlorinated PVC (CPVC) . . . . . . . . . . . . . . . . . . . 114
3.16.6 Plastic PVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.16.7 Acrylonitrile-Butadiene-Styrene (ABS) . . . . . . . . . 115
3.16.8 Fluorinated Plastics . . . . . . . . . . . . . . . . . . . . . . . 115
3.16.9 Polyvinyl Fluoride ('vF). . . . . . . . . . . . . . . . . . . 115
3.16.10 Acrylics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
xii Contents and Subject Index

3.16.11 Chlorinated Polyether ...................... 116

3.16.12 Nylon (Polyamide) ........................ 116
3.16.13 Miscellaneous Engineering Plastics . . . . . . . . . . . . 117
3.16.14 Acetal Resin ............................ 117
3.16.15 Polycarbonate ........................... 118
3.16.16 Polyphenylene Oxide ...................... 118
3.16.17 Polysulfone ............................. 118
3.17 Thermosetting Plastics ........................... 118
3.17.1 Phenolic Resins .......................... 119
3.17.2 Polyester Resins .......................... 119
3.17.3 Epoxy Resins ............................ 120
3.17.4 Furane Resins ........................... 120
3.17.5 Rubber Linings .......................... 121
3.18 Organic Coatings and Paints ....................... 123
3.19 Glossary of Fabrication and Plastics Terms ........... 123
Nomenclature .................................. 141
References .................................... 141

APPENDIX A: GLOSSARY OF PLASTICS AND ENGINEERING

TERMS .............................................. 145

APPENDIX B: GENERAL PROPERTIES AND DATA ON

ELAfXOMERS AND PLASTICS ........................... 161