Technical Inspection for Oil & Gas Industry Course

Lecture 5:

Material Selection For

Process Plant Piping

Dr. Farshid Malek

Tarbiat Modares University, 2021
farshidmalek@yahoo.com
 ‫به این کالس خوش آمدید‬

‫توجه‪ :‬برای صرفه جویی در زمان شما ‪ ،‬تعدادی از اسالیدها (نه همه) بر حسب نیاز دارای صوت و یا کلیپ‬
‫ویدیویی میباشند‪ .‬این عالمت یعنی * اسالید مربوطه صوت دارد‪.‬‬
‫‪.‬لطفآ در مورد مطالب با حوصله فکر نمایید‪ ،‬اما در صورت نیاز به توضیحات بیشتر (که کامآل قابل درک است) لطفآ‬
‫‪2‬‬ ‫در گروه اعالم بفرمایید‪ ،‬با کمال میل توضیح خواهم داد‪.‬‬
Contents of this lecture:

Part 1- Piping in a process plant

Part 2- Piping standards
Part 3- Material selection for piping in IPS

*
Part 1- Introduction to piping
in a process plant
 A Process plant:
Major equipment's +
Piping systems+
Structures +
Electrical +
Instruments+
Insulation+
Misc.
*
 Material costs in a process plant project
Today a 100,000 BPD refinery
costs about 1.5 billion $ to
build.
Piping material cost
represents about 25%
percent of a typical process
plant.

*
 Installation costs in a process plant project
Typically Site Labor cost
for the piping system
installation represent
about 50% of the total site
labor costs for a process
plant.

*
 Knowledge Expectation from a Piping
Engineer
Piping Engineer requires not only wide engineering knowledge but he must
also have an understanding of engineering economics and costs, of material
metallurgy, of methods of fabrication and erection. He must have some
knowledge of mechanical, chemical, civil, electrical and instrumentation
engineering so as to discuss and understand requirements and problems
with engineers in these fields. He must be aware of various standards, codes
and practices.

Reference:
https://www.theprocesspiping.com/
You will find very good information here

*
Selection of Piping Materials
• Materials selection for achievement of metallurgical
stability shall be made on the basis of design condition and
to resist possible exposures against fire, corrosion, operating
condition, service etc.
• The designer is confronted with the following concerns
regarding the material of construction as he begins the design.
These are:
a) Resistance to internal pressure at service temperature
b) Low risk of brittle fracture (leak before break)
c) Design Life (resistance corrosion, erosion, creep)
Other structural integrity concerns will be usually dealt with
after material selection in detail design (deflection, vibration,
thermal expansion, etc)

*
 ‫‪Resistance to‬‬
‫‪internal pressure‬‬
‫‪at service‬‬
‫‪temperature‬‬

‫توجه ‪ :‬در این جلسه و پروژه تمریتی ما‬

‫وارد محاسبه ضخامت بر اساس فشار و‬
‫دما و تنش مجاز ماده نخواهیم شد‪ .‬اما‬
‫اینکار را چند جلسه بعد برای ظروف تحت‬
‫فشار انجام خواهیم داد‪ ،‬چون در آن مورد‬
‫کاربرد مهمتری برای شما خواهد داشت‬

‫*‬
 ENGINEERING MATERIALS
• (1) METALLIC (2) NON-METALLIC (3)COMPOSITES
(i) FERROUS (i) ORGANIC
(ii)NON-FERROUS (ii) INORGANIC

• FERROUS NON-FERROUS ORGANIC INORGANIC

• Carbon Steel Nickel Plastics Ceramics
• Low Alloy Steels Monel Thermo-Plastics Graphite
• Stainless Steels Brasses Thermo-Setting Glass

*
 Most commonly used materials in
refineries are
• Carbon Steel
• This is the most common and cheapest material used in process plants.
Carbon steels are used in most general refinery applications. It is routinely
used for most organic chemicals and neutral or basic aqueous solutions at
moderate temperatures. Carbon steels are extensively used in temperature
range of (-) 29 deg cent to 427 deg cent... Low Carbon steel (LTCS) can be
used to a low temperature of (- 46) deg cent...
• Alloy Steels
• Low Alloy Steels contain one or more alloying elements to improve
mechanical or corrosion resisting properties of carbon steel. Nickel increases
toughness and improves low temperature properties & corrosion resistance.
Chromium and silicon improve hardness, abrasion resistance, corrosion
resistance and resistance to oxidation. Molybdenum provides strength at
elevated temperatures.

*
• Stainless Steels
• They are heat & corrosion resistant, noncontaminating and easily fabricated into
complex shapes. There are three groups of Stainless steels, viz, Martensitic,
Ferritic & Austenitic.

• Various codes, symbols in piping design are:

• ASME - American society of mechanical engg.
• API - American petroleum institute.
• ANSI - American National Standards institute.

*
ASTM NUMBER TYPE MATERIAL
A-53 Gr. A,B CARBON STEEL
A-106 Gr. A,B CARBON STEEL
A-333 Gr. 1 CARBON STEEL
A-335 P1 CARBON MOLY
A-335 P11 CARBON MOLY
A-335 P5 CARBON MOLY
A-335 P9 CARBON MOLY
A-312 304 STAINLESS
A-312 316 STAINLESS
A-312 321 STAINLESS
A-312 347 STAINLESS
A-333 Gr. 3 NICKEL
 Components of a piping system

*
Pipe types

Pipe
manufacturing
methods

*
 When to use Flanges?
• Where there is a clear need for removal of valves or equipment, for access of
maintenance, or for blinding.
• Because all flanged connections are potential leak source, their use should be
kept to the minimum needed for safe and reasonably convenient operation
and maintenance.

*
 Flange Types

Weld Neck flange Slip-on flanges

The welding neck flanges are The slips on flanges are attached by
attached by butt-welding to the welding inside as well as outside.
pipes.
 Flange Types

Socket Weld Flange Lap-Joint flange

The socket weld flanges are welded only The lap joint flanges are used with the stub
on one side and are not recommended for ends when piping is of a costly material.
severe services. These are used for small-
bore lines only.
Flange materials are different
• These are forgings having a highly refined
grain structure and generally excellent
physical properties well in excess of
recognized minimum requirements.

*
BOLTS

• Carbon steel bolts are high strength

Quenched and tempered steel.
• Choice of bolting material is governed by
service fluid and its temperature.
• The most commonly used bolts for flanges in
refinery piping are the ASTM A193 Gr.B7 Stud
bolts which fall into the high strength group.
The temperature range is from –29°C to
454°C.
GASKETS
• A gasket is a thin circular
disc, made up of soft
compressive material. The
most of valves have flanged
ends and must have a
companion or matching
flange attached. A gasket is
then inserted between
them, and the bolts are
tightened to form a flanged
joint.
What is expansion bellows?
• An expansion joint or
movement joint is an
assembly designed to
safely absorb the heat-
induced expansion and
contraction of
construction materials, to
absorb vibration, to hold
parts together, or to allow
movement due to ground
settlement or
earthquakes.
*
GATE VALVE:
It is usually manually
operated and is designed for
open or shut operation. Flow
can enter either end of the
gate body.
GLOBE VALVE:
is for throttling. Good examples of
globe valves are the faucets on
washbasin which throttle or adjust
the flow to suit a person’s needs.
Flow must enter the valve and flow
up, against the seat, and change
the direction again to the outlet.
CHECK VALVE:
“checks” flow. It lets flow go
one way and will not let it
reverse. When you have a
check valve in a line, you
have made a one-way
street. The flow can go one
way.
Valve Trim
• Valve seats need to be resistant to corrosion, erosion, and wear more
than the valve body.
• Thus , the valve trim is usually made of a different material from the
valve body. The trim materials are typically stainless steel or Stellite
alloys.
• Valve trim can be insert type or hardfaced by welding or other
surfacing processes.

*
 Valve Trims
Hardfaced valve trim Inserted valve trim

*
Part 2- Piping standards
 Some Famous Piping Design Codes:

• B31.1 Power Piping ).. ‫• لوله کشی در نیروگاههای حرارتی (بویلر‬

• B31.3 Process Piping
• B31.4 Pipeline Transportation
Systems for Liquid
Hydrocarbons
• B31.5 Refrigeration Piping
• B31.8 Gas Transportation and
Distribution Piping Systems
• B31.9 Building Services Piping
• B31.11 Slurry Transportation
Piping
‫• لوله کشی در تاسیسات فرایندی‬
‫• لوله های انتقال نفت‬
‫• لوله کشی سیستمهای خنک کننده‬
‫• لوله های انتقال گاز‬
‫• لوله کشی ساختمانها‬
‫• لوله های انتقال گل و لجنهای صنعتی‬

*
*
 Piping Material Specification (PMS)

PMS consists all material details, dimension details, type of ends,

schedules/thicknesses, branch offs, NDT requirements, various codes/standards
being followed etc. for all Piping items. Main Piping items detailed out in PMS
usually include:
• Pipes
• Fitting
• Flanges
• Bolts
• Gaskets
• Valves

*
 What does NPS mean in piping?
• It is common to identify pipes by inches using NPS (in inch)or “Nominal
Pipe Size“.
• The metric equivalent is called DN (in millimeter) or “diametre nominel“.
• NPS 2 =DN 50

*
 Pipe Schedules

• The schedule number on

pipe products relates to
the thickness of the wall
on the pipe: as the
number increases, the
thicker the wall thickness
becomes. Also, while the
schedule number can be
the same on different
sized pipes, the actual wall
thickness will be different.
*
 Example of pipe schedules from ASME B 36.10

*
 What is pipe PN rating?
• PN Is the nominal working
pressure rating. The number used
to describe PN is 10 times the value
of the maximum allowable
operating pressure (MAOP) at 20°C
(MPa x10) based on a design factor
of 1.25.
 Flange Standards

*
 What is rating (or class) in piping?
• The
pressure rating (also
known as pressure
class) is the maximum
pressure a pipe, fitting
or valve should be
capable of withstanding
at given temperature in
normal conditions.

*
 An example:
• If two flanges have the same bore size (example 6 inches), the same
material (example A105), but two different pressure ratings (one
flange is class 150, the other 300), the lower rated flange (class 150)
will be smaller, lighter, and less robust than the higher rated flange
(class 300). This is represented in the picture:

*
 FLANGE RATING CHART
CARBON STEEL ASTM A105, A350 Gr. LF2/LF6 Class 1
ANSI/ASME B16.34 ANSI PRESSURE RATING
Temperature (in F°) 150# 300# 400# 600# 900# 1500# 2500#
•Example:
< 100 285 740 985 1480 2220 3705 6170
The class 150 flange
200 260 680 905 1360 2035 3395 5655
withstands just 140 psi at
300 230 655 870 1310 1965 3270 5450
a temperature of 600
400 200 635 845 1265 1900 3170 5280
degrees F° (as per the
500 170 605 805 1205 1810 3015 5025
rating chart below)
600 140 570 755 1135 1705 2840 4730
•the class 300 flange
650 125 550 730 1100 1650 2745 4575
(bigger and stronger, but
700 110 530 710 1060 1590 2655 4425
with the same bore size)
750 95 505 675 1015 1520 2535 4230
withstands 570 psi at the
800 80 410 550 825 1235 2055 3430
same temperature of 600
850 65 320 425 640 955 1595 2655
degrees F°
900 50 230 305 460 690 1150 1915

950 35 135 185 275 410 685 1145

1000 20 85 115 170 255 430 715

Hydrostatic Test 450 1125 1500 2225 3350 5575 9275

*
Pressure (in Psig)
‫فیلم آموزشی در مورد انتخاب کالس فشار و دما برای فیتینگها‬
 Flange Materials
• Flanges made in different materials show different
pressure-temperature performance at the same
rating. The pressure rating charts for carbon,
alloy, and stainless steel flanges are different.

*
3- Material selection for
piping in IPS
IPS E-PI-221
 What is company Specification?

• Specifications are technical documents that are generated by

private companies to address additional requirements
applicable to a specific product or application.
• Piping Specs provides specific/additional requirements for the
materials, components, or services that are beyond the code
and standard requirements. For Example, if you want A106 Gr
B pipe with Maximum carbon of 0.23% against standard
requirements of 0.3% Max, you must be specified this
requirement in your purchase specification.
*
 ‫)‪Iranian Petroleum Standards(IPS‬‬
‫• استانداردهای رایج در صنعت نفت‪ ،‬گاز و پتروشیمی عبارتند از‪API, :‬‬
‫‪ASME, ASTM, ISO, DIN, … .‬در کنار اینها اما‪ ،‬از حدود سال‬
‫‪ ،۱۳۶۹‬وزارت نفت به تهیه و تدوین استانداردهای نفت ایران )‪) IPS‬‬
‫در جهت مشخص نمودن الزامات تکمیلی پروژه های خود پرداخته‬
‫است‪.‬‬
‫• این استانداردها برای کسانی که به تازگی می خواهند وارد حوزه نفت و‬
‫گاز شوند‪ ،‬نقطه شروع مناسبی هستند‪ ،‬زیرا در صفحات اولیه‬
‫استانداردهای ‪ ،IPS‬استانداردهای مرجع نام برده شده اند‪.‬‬
‫*‬
‫ساختار شماره دهی استانداردهای ‪IPS‬‬

‫• شماره استانداردهای ‪IPS‬از چهار قسمت تشکیل شده است‪:‬‬

‫• ‪IPS-x-yy-NNN‬‬
 X ‫ مرحله‬:۱ ‫جدول‬

G E D M C I

Engineering Material and Construction

General (*) Drawing Inspection
and Design Equipment and Installation

)*( ‫طراحی و مهندسی عمومی‬ ‫نقشه کشی‬ ‫اقالم و تجهیزات‬ ‫نصب و اجرا‬ ‫تست‬
 YY ‫ دیسیپلین‬:۲ ‫جدول‬

R Heating, Ventilation, Air Conditioning Cooling & Refrigeration

CE Civil
EL Electrical
GN General
IN Instrument
ME Fixed Mechanical Equipment
PI Piping & Pipelines
PM Process Machineries
PR Process & Chemical
SF Safety, Fire Fighting & Environmental Pollution Control
TP Technical Protection
 Design Standard for Piping
IPS-E-PI-240

*
 Pipe Material Thickness
IPS-E-PI-240

*
 IPS ‫دو استاندارد مهم مربوط به انتخاب مواد در‬
• For pressure vessels: IPS G-ME-150
• For Piping: IPS E-PI-221

*
 Piping Material Selection IPS E-PI-221

*
1. SCOPE
• This Standard contains piping classes primarily developed for
petroleum refineries and petrochemical plants installed onshore. It is
also intended for use in onshore exploration and production facilities
as well as booster stations as far as applicable. Facilities covered by
this Standard are all within the property limits as defined in ASME
B31.3.
 IDENTIFICATION OF PIPING CLASSES
• Each piping class is identified from two alphabetical characters which
precede a two digit figure, e.g.

XY00

*
 The first alphabetical character XY00

It is a measure of pressure/ temperature rating for diameter of the

flanges and fittings to be used with the pipe thickness:

Character A for ANSI rating PN 20 ( 150) lowest pressure /temp

Character C for ANSI rating PN 50 ( 300)
Character F for ANSI rating PN 100 ( 600)
Character G for ANSI rating PN 150 ( 900)
Character H for ANSI rating PN 250 (1500)
Character J for ANSI rating PN 420 (2500) highest pressure/temp
*
Pressure numbers (PN) compared to flange class
designations
• Piping Class Ratings based on the ASME B16.5 - Pipe Flanges and
Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch Standard - class
and the corresponding ISO 7005 PN (Pression Nominal*) ratings:

Flange Class 150 300 400 600 900 1500 2500

Flange Pressure
20 50 68 110 150 260 420
Nominal (PN)

Note! The piping rating must follow the pressure-

temperature rating of the weakest pressure containing
item in the system.
 Material group
The second alphabetical character XY00
Character N for Carbon Steel
Character P for Low and Intermediate Alloy Steel
Character S for Stainless Steel
Character T for Aluminum and Aluminum Base Alloy
Character V for Copper and Copper Alloys
Character W for Nickel and Nickel Base Alloys
Character X for Non-Metallic Material
Character Z for Carbon Steel with Lining

*
 Service condition
The two digit figure XY00
• It indicates differing service condition (e.g. process fluid being
handled and service temperature limits). The figure has not been
selected on the basis of specific purpose and as such is not
meaningful. However, piping classes which have identical figure with
same material group are for the same service condition.

*
 SELECTION OF PIPING CLASSES
• To select a piping class, the "Service Index" should be screened to see
whether the intended service is listed. If so, the appropriate ANSI
rating class shall then be identified by matching the required design
pressure and temperature with the design limits given in the piping
classes.
• For services not listed in the "Service Index", the "Piping Class Index"
can be screened to see whether a piping class is available in which the
materials are considered suitable for the intended service. Piping
class so selected, may be used provided that Company approval is
obtained.

*
 Design Codes
- Piping classes have been designed in accordance with ANSI/ASME B 31.3.
- The design limits specified in the piping classes have been derived from the
pressure/temperature ratings for flanges given in ANSI/ASME B 16.5 unless
otherwise stated in the piping class notes.
- Where specified by ANSI/ASME B 31.3 bolting calculations have been
performed to verify the ability to seat the selected gasket and to maintain a
sealed joint under the given P/T range, ASME Section VIII Division I Appendix
2 has been followed for this .
Nominal wall thicknesses and outside diameters of pipe, as specified in the
piping classes, are in accordance with ANSI/ASME B 36.10 M and ANSI/ASME
B 36.19 M.
 Design Values
• Allowable stresses for the materials specifications contained in the piping
class have been established in line with ANSI/ASME B 31.3, Paragraph
302.3.
• For API 5L Grade B, a distinction has been made between seamless pipe
and welded pipe with a weld joint factor E=0.95 (in accordance with
ANSI/ASME B 31.3, Table 302.4). For all other materials the selection of
pipe wall thickness is based on allowable internal pressure calculations for
seamless pipe only. Consequently, where welded pipe is used, a weld joint
factor of 1 shall be guaranteed.
• In accordance with ANSI/ASME B 31.3, Paragraph 302.2.2, not more than
87.5% of the nominal wall thickness has been used in calculations for butt
welding fittings.
 DESIGN CONSIDERATIONS
This Standard shall be used in conjunction with the following considerations:
7.1 General piping design requirements shall be as per IPS-E-PI-240.
7.2 Unless otherwise specified in piping material selection, corrosion considerations shall be as per
IPS-E-TP-740.
7.3 Unless otherwise noted, all pressure and temperatures referred to in this Standard are design
conditions.
7.4 Buried steel piping is not considered as new classes. These pipings shall be externally
protected in accordance with requirements of IPS-E-TP-270.
7.5 Except for parts mentioned in this Standard, valve specification shall conform to IPS-M-PI-110.
7.6 All pipe flanges and fittings shall conform to requirements of IPS-M-PI-150.
7.7 All pipes shall conform to requirements of related ASTM and API Standards.

*
*
 Service indexes and
Selection of Basic Material
(piping class)
 ‫لیست‬
‫کالسهای‬
‫موجود از‬
‫جنسهای‬
‫متفاوت‬

‫*‬
*
 Selection of specific material
(the standard) for each service index
Part II :
Piping class rating: PN 20 (150) and PN 50 (300).

*
 Example:
AN01 Line numbers
A=Pressure temperature Rating (strength) Class 150
N= Material family = Carbon steel
01= Service condition = Specific materials for pipe and…

*
*
*
*
 All carbon steel
family for class 150
* rating
 ‫تمرین و پروژه‬
‫• پس از مطالعه این ارایه و مرور استانداردهای مرتبط که برای شما تعدادی از‬
‫آنان ارسال خواهد شد‪ ،‬میتوانید سواالت خودرا درگروه مطرح کنید‪ .‬من در طول‬
‫تعطیالت هم سعی خواهم کرد پاسخ دهم‪.‬‬
‫• پروژههای شما که مرتیط با این جلسه و دو جلسه قبلی خواهد بود ‪ ،‬در سه روز‬
‫آینده در گروه اعالم میشود‪.‬‬