Presentation on Mechanical Maintenance in

Fertilizer & Petro Chemical Industries

By
Subroto Mukherjee
 Index
• Application of Material
• Standards,Codes
 Application of Material
• Knowledge of materials plays an important role in Fertilizer & Petro
Chemical Engineering Industries. Right type of material shall be
selected for a particular service to get required life of the equipment
with 100 % reliabilty. The selection and use of proper materials, cost
effectiveness, minimum failure in the designed life are the direct
responsibilities of the Mechanical Engineers in an Industry.
• An engineer must have knowledge of nature and behavior of
materials, its limitations for manufacturing, chemical compositions,
mechanical properties for fabrication and effects of its alloying
elements for the required service applications.
• Thus the selected material for a particular service must stand up to
dimensional stability and process of fabrication, service corrosion,
required hardness, strength & toughness, heat resistance, fatigue &
creep, machine ability, weld ability, heat treatments etc. All these
properties depends upon the chemical composition, macrostructure
and microstructure of the material.
 Continue..
• As per ASME, materials are divided in two major groups called
Ferrous and Non-ferrous material depending upon their alloying
elements.
• Ferrous materials are those in which main or base constituent is
Iron.
• Non-Ferrous material may or may not contain iron at all.
 Continue..

• Ferrous material can further be divided into following categories.

• Cast Iron,
• Wrought iron
• Carbon Steel(Low Carbon Steel, Medium Carbon Steel, High Carbon Steel)
• Alloy Steels and
• Stainless steel/Austenite Steel.
• (Stainless steel is a special type of Alloy Steel which renders special property of
corrosion resistance.)

• Steel :- Steel is an alloy of mainly Iron and Carbon, which contains

carbon upto 1.5%. The percentage of carbon exerts the most influence on
properties of steel. Depending on the percentage of carbon in steel, its
grades are defined as low carbon, medium carbon or carbon steels. Other
alloying elements are further added to enhance its properties in different
grades.
• Low carbon steels/mild steels (up to 0.3% carbon)
• Medium carbon steels (0.3–0.6% carbon)
• High carbon steels (more than 0.6% carbon)
• Stainless steels
• Stainless steel grades are alloyed with 10–20% chromium as
well as nickel, silicon, manganese, and carbon
• Stainless steel is the generic name for the widely popular for
corrosion-resistant metal alloys. There are several different
types of stainless steel, but they have properties in common.
When it comes to austenitic vs. martensitic, for example, the
one commonality that they all share is a 10.5% minimum
chromium content.
• Depending on the material needs, other alloying elements
such as nickel, molybdenum, or titanium can be added to
improve corrosion resistance and to provide additional
necessary properties that can enhance the performance of
the metal.
 Continue..

• Auste3nite Steel
• Ferritic Steel
• Martensite Steel
• Duplex (ferritic-austenitic) stainless steels, and
• Cast Iron :-
• The term cast iron is a large family of ferrous alloys. In Cast Iron carbon content
exceed 2.14% . Cast irons are multi component ferrous alloys. They contain major
(iron, carbon, silicon)and other alloying elements. Other alloying elements are
added for getting the improved properties for specific services.
• Cast Iron is generally weak in tensile load and cannot be used for making items like
fasteners, shaft, rotor etc. It is brittle in nature. But cast iron has good compression
strength, lubrication retaining properties and dampening properties
• Carbon in cast Iron may be found in two different forms. One is in total chemically
combined form and another is in independent form.
• When all carbon present in the matrix is in chemically combined condition with
iron forming (Fe3C) iron carbide in the form of “cementite”, it is called “ white cast
iron” .
• When all percentage of carbon is not chemically combined with Iron and also
exists as free carbon or graphite flakes, it is called “grey cast iron”.
 Continue
• Ductile or Nodular Cast Iron :- When small quantity of Magnesium or Cerinum is
added to cast iron the graphite content gets converted into nodular or spherodial
form and gets dispersed throughout the matrix. This improves the fluidity, and thus
excellent castings are made. Nodular cast iron has good strength, high toughness,
wear resistance and good impact strength.
• Forging
• For Services in which parts are exposed to tensile strength or transmission of torque
etc then forging are used. Forging may be in carbon steel, Stainless steel or Alloy
Steel.
• MARAGING STEEL :- Maraging steel is an iron based steel alloy which do not contain
Carbon. It is known for possessing superior strength without loosing malleability. Iron
with various proportions of alloying elements like Cobalt, Nickel as strengthening
agents are added with Molybdenum and Titanium. It possessMaraging steel is used in
aircraft, with applications including landing gear, helicopter undercarriages, slat tracks
and rocket motor cases – applications which require high strength-to-weight material.
• Maraging steel offers an unusual combination of high tensile strength and high
fracture toughness. Most high-strength steels have low toughness, and the higher
their strength the lower their toughness. The rare combination of high strength and
toughness found with maraging steel makes it well suited for safety-critical aircraft
structures that require high strength and damage tolerance.