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Prepared By: Date:

Walter Bordon 10 December 2009

Objective
To be able to understand the types of materials used in Oil and Gas industry, Heat Treatment application, Stress-Strain, fatigue and its application.

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Table of contents
Types of material Heat Treatment Phase Diagram Material Testing Stress-Strain Fatigue Materials in Boiler Refractory

TYPES OF MATERIALS

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Physical properties of metals, ceramics, and polymers, such as ductility, thermal expansion, heat capacity, elastic of modulus, electrical conductivity, and dielectric & magnetic properties, are direct result of the structure and bonding of the atoms and ions in the material. Most engineering materials are polycrystalline, which is composed of many grains.

Elements of Alloy Steels

Carbon, increasing carbon content in carbon steels will lead to increase in hardness and up to eutectoid composition (0.83%C) increases the tensile and yield strengths. Corresponding to these changes will be decrease in ductility, malleability and impact strength. Manganese, all commercial steels contain 0.3-0.8% manganese, to reduce oxides and to counteract the harmful influence of iron sulfide. It has a considerable strengthening effect on ferrite and increases hardenability. Nickel, are similar in behavior with manganese and both lower the eutectoid temperature. The addition of nickel to a plain carbon steel tends to stabilize the austenite phase. Nickel in moderate amount increases hardenability.

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Elements of Alloy Steels

Chromium, very small amount of chromium when added to carbon steel will cause considerable increase in hardness. Chromium is a carbide stabilizer. The main disadvantage in the use of chromium as an alloying element is its tendency to promote grain growth, with its attendant brittleness. Care must therefore be taken to avoid overheating or holding too long at the normal heat-treatment temperature.

Elements of Alloy Steels

Molybdenum, is a strong carbide stabilizer and relatively small amounts will markedly enhance the properties of plain carbon steels. Usually it is added in quantities ranging from 0.12-0.65% depending on the intended application of the steel. Its presence will raise the high temperature strength and creep resistance of high temp alloys and it is added to stainless steels in proportion up to 3.0% to improve corrosion resistance especially in chlorides and acids.

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Elements of Alloy Steels

Niobium (US Colombium), it is a strong carbide former but its effect on low carbon steels is thought to be mainly by precipitation hardening. It has a marked grain refining function sometimes reinforced by aluminum and/or vanadium additions. Such refined grain structures give high impact values. It is also a strong carbide stabilizer, is also added to some stainless steels corrosion resisting steels (type 347) of the 18/8 chromium-nickel variety to prevent weld decay sensitivity.

Elements of Alloy Steels

Vanadium, plain vanadium steels are manufactured to a very limited extent, but chromium-vanadium are widely used for small and medium sections. It has a strong carbideforming tendency. It also stabilises martensite and low temperature tempered martensite on heat treatment and increases hardenability. One of the most important effect of vanadium is it induces resistance to softening at high temperatures provided that the steel is first heat-treated to absorb some of the vanadium carbide into solution.

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Elements of Alloy Steels

Aluminium, the presence of aluminium in plain carbon and low alloy steels will tend to stabilise ferrite but as it will normally be in very low concentrations (0.05%) its direct effect on hardenability will be negligible. It can however act as a strong grain refiner (levels >0.015%) which may reduce hardenability somewhat although improving tensile and impact strengths. It is widely used as a deoxidant in low carbon mild steels where ductility is the principal quality.

Elements of Alloy Steels

Sulphur, the element of sulphur will tend to decrease hardenability somewhat, but as, with a few exceptions, considerable efforts are made to eliminate it from plain carbon and alloy steels, it is usually present only in small amounts and its effect is neglected. It is the most deleterious impurity commonly present in steel. If precautions are not taken to render it harmless it will form the brittle sulphide, FeS. The sulphur is rendered harmless by the presence of manganese with which it combines preferentially to form manganese sulphide MnS.

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Elements of Alloy Steels

Phosphorous, in the same way as sulphur, is almost always considered an undesirable element in steel and its proportion is usually kept to a minimum. Phosphorous forms the brittle phosphide Fe3P, which is soluble ferrite. In solution, it has a considerable hardening effect but it must be rigidly controlled to amounts in the region of 0.05% or less because of the brittleness also introduced.

Elements of Alloy Steels

Silicon, is widely used as a deoxidant in steel making and it is often present in quantities of 0.2-0.5%. Like nickel it encourages graphite formation and it must therefore be kept low in high carbon steels. It dissolves in ferrite where it has a substantial strengthening effect. It is included is some heat resisting steels in amounts up to 1.5% as it aids high temperature resistance to oxidation.

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Elements of Alloy Steels - Summary

Alloying element Manganese Silicon Phosphorous Nickel Chromium Copper Molybdenum Vanadium Tungsten Effect on Strengthening Ferrite Strong Strong Strong Moderate Weak Moderate Strong Weak Moderate Effect in Forming Carbides Weak None None None Moderate None Strong Strong Strong Effect on Transformation Temperatures Lowers Raises Lowers Lowers Lowers Raises Raises Raises Effect on Hardenability Strong Moderate Moderate Moderate Strong Weak Strong Mild Moderate

Raise or lowers depending on carbon content

Alloy Steel A steel which owes its distinctive properties to elements other than carbon. Steel is considered to be alloy steel when the maximum of the range given for the content of alloying elements exceeds one or more of the following limits; Manganese 1.65% Silicon 0.60% Copper 0.60% or a definite minimum quantity of the following elements; Aluminum Boron Chromium (up to 3.00%) Cobalt Columbium Molybdenum Nickel Titanium Tungsten Vanadium Zirconium Small quantities of certain elements are unavoidably present in alloy steels. When not specified or required, they should not exceed the following amounts: Copper 0.35% Chromium 0.20% Nickel 0.25% Molybdenum 0.06%

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What is Piping System

are like arteries and veins transport the medium to the points of distribution i.e. pipelines carry crude oil from oil wells to tank farm storage or to refineries for processing, convey natural gas from the source and storage tank farms to point of utilization. Piping system are utilized to carry liquids, chemicals, mixtures, gases, vapors, and solids from one location to another

What is Piping System

Piping includes pipe, flanges, fittings, bolting, gaskets, valves, and pressure containing portions of other piping components. It also includes pipe hangers and supports and other items necessary to prevent over pressurization and overstressing of the pressure-containing components. Pipe sections when joined with fittings, valves, and other mechanical equipment and properly supported by hangers and supports are called Piping.

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Pressure Vessels
Pressure vessels commonly have the form of spheres, cylinders, cones, ellipsoids, tori or composites of this. Pressure vessels can be designed as a thin-walled and thick-walled. Design rules are followed using ASME Code, Section VIII, Div.1, having a higher factor of safety to allow for the unknown stresses in the vessel.

Pressure Vessel Materials commonly used in PGB

COLUMNS A-101, CHLORIDE SCRUBBER A-201, ABSORBER A-202, THERMAL REGENERATOR A-401, DEMETHANIZER A-451, CONDENSATE STRIPPER A-601, DEETHANIZER MATERIAL A516 Gr.70 + T316L CLAD A516 Gr.70 + T304L CLAD A516 Gr.60/TP304 A240 TP304 A516 Gr.70 A537 CL1 DESIGN PRESS (KPAG) 7600 6600 350 4100 3300 3300 DESIGN TEMP (C) 60/20 145/10 60/20 -110/120 220/16 -45/130

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Pressure Vessel Materials commonly used in PGB

PRESSURE VESSEL MATERIAL DESIGN PRESS (KPAG) 7600 6200 6200 350 1150 DESIGN TEMP (C) 60/20 60/20 60/15 100/20 -45/60 M-101, INLET SEPARATOR M-102, DECANTER DRUM M-103, CONDENSATE TRANSFER DRUM M-204, ACID GAS CONDENSATE KO DRUM#2 M-701, 1ST STAGE C3 REFRIGERANT SUCTION DRUMCONDENSATE STRIPPER M-702, 2ND STAGE C3 REFRIGERANT SUCTION DRUM A516 Gr.70 + T316L CLAD A537 CL.1 A516 Gr.70 + T304L CLAD A240 TP304 A516 Gr.60

A537 CL.1

1150

-45/60

Pipe is a tube with round cross section conforming to the dimensional requirements of; - ASME B36.10M, Welded and Seamless Wrought Steel Pipe - ASME B36.19M, Stainless Steel Pipe Nominal Pipe Size (NPS) is a dimensionless designator of pipe size. e.g. NPS 2 indicates a pipe whose OD is 2.375 in., The NPS and smaller pipe has an OD greater than the size designator. NPS 14 and larger pipe is the same as the size designator.

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Pipe wall thickness Schedule is expressed in numbers (5, 5S,10, 10S, 20, 20S, 30, 40, 40S, 60, 80, 80S, 100, 120, 140, 160). The higher the schedule number, the thicker the pipe is. The schedule number followed by the letter S are as per ASMEB36.19M, and are primarily intended for stainless steel pipe

Piping Specifications (Carbon Steel)

Specification ASTM A53 ASTM 106 ASTM A369 ASTM A335 ASTM A333 ASTM A671 ASTM A672 ASTM A691 ASTM A312 API 5L Product Form Seamless/Welded Seamless Forged & Bored Seamless Seamless/Welded Elec Fusion-welded Elec Fusion-welded Elec Fusion-welded Seamless/Welded Seamless/Welded Size Range (NPS) 1/8 to 26 !/8 to 48 Custom Custom 1/8 & larger 16 & larger 16 & larger 16 & larger 1/8 & larger Application Ordinary use in gas, air, oil, water & steam High-Temp service (steam, water, gas, etc.) High-Temp Service High-Temp Service Service requiring excellent fracture toughness at low temp Low-Temp service Moderate-Temp Service High-Temp Service Low to high-Temp & corrosive service Line Pipe, Refinery & Transmission service

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Austenitic Stainless Steel

Carbon Steel contains less than 1.65% Mn, 0.60% Silicon, and 0.60% Copper Stainless Steel Austenitic Stainless Steel, contains at least 16% chromium and 6% nickel (the basic grade 304 is referred to as 18/8)

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Heat Treatment

Steel Heat Treating Practices

Annealing, Annealing several types of annealing process are used on carbon and low-alloy steel. These are full annealing, process annealing & spheroidizing annealing. Full annealing - the steel is heated to just above the upper critical temperature, held for a sufficient length of time to fully austenitize the material structure, and then allowed to cool at a slow, controlled rate in the furnace. A full anneal provides a relatively soft, ductile material, free of internal stresses. Process annealing sometime referred to as stress-relieving, is carried out at temperatures below the lower critical temp. This treatment is used to improve ductility and decrease residual stresses in work-hardened steel. Spheroidizing is to soften the steel and improve its machinability. Heating the steel that possesses a pearlite microstructure for a long time at just below the lower critical temp, followed by very slow cooling, will cause spheroidization. This is an agglomeration of the iron carbide, which eventually assumes a spheroidal shape.

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Steel Heat Treating Practices

Normalizing The carbon and low-alloy steel heat treatment is similar to the annealing process, except the steel is allowed to cool in air from temperatures above the upper critical temperature. Normalizing relieves the internal stresses caused by previous working. While it produces sufficient softness and ductility for many purposes, it leaves the steel harder and with higher tensile strength than after annealing. Normalizing is often followed by Tempering. Hardening (quenching) when steels of the higher-carbon grades are heated to produce austenite and cooled rapidly (quenched), the austenite transforms into martensite. Martensite is formed at temperatures usually below about 204C, depending on carbon content and the type and amount of alloying steel. It is the hardest form of heat-treated steel and has high strength and resistance to abrasion. Martensitic steels have poor impact strength and are difficult to machine.

Steel Heat Treating Practices

Tempering it is a secondary heat treatment performed on some normalized and almost all hardened steel structures. The object of tempering is to remove some of the brittleness by allowing certain solid-state transformation to occur. It involves heat treating to a predetermined level, always below the lower critical temperature, followed by a controlled rate of cooling. In most cases tempering reduces the hardness of steel, increases its toughness, and eliminates residual stresses.

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General Requirements for Steel Plates

Steel making processes can be either open hearth, basic oxygen, electric furnace. Specification for general requirements for steel plates for Pressure Vessels falls under SA-20 (ASTM specification A20) Under SA-20 covers the material & manufacturing, Heat Treatment, Chemical composition (i.e. heat analysis, product analysis), Metallurgy, Quality & Test Method

PHASE DIAGRAM

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Phase Diagram
Like all other metals, iron and steel are crystalline in structure, composed of atoms in a fixed lattice. Iron may exist in one of two cubic forms, body centered (BCC) or face-centered (FCC)

Phase Diagram
At room temp, pure iron is composed of body-centered cubic lattice. In this form it is known as alpha iron, also called ferrite, which is soft, ductile, and magnetic. When heated above 768C, alpha iron loses its magnetism but retains its body-centered crystalline structure. The crystal structure changes to face-centered cubic at about 910C at which alpha iron is transformed to gamma iron. Phase Diagrams are plotted in weight or atomic percent (horizontal axis) versus temperature (vertical axis).

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What is Strain
Strain is a measurable quantity. When the size or shape of a component is altered, the deformation in any dimension can be characterized by the deformation per unit length or strain (). It is proportional to stress at or below the proportional limit of the material.

Phase Diagram
Ferrite: Ferrite Alpha iron (BCC), containing a small amount of carbon (0.04-0.05%) in solid solution. This phase is soft, ductile, & relatively weak. Cementite: Cementite Iron carbide, FeC, a compound containing 6.67% carbon and 93.33% iron, which is very hard & extremely brittle. Pearlite: Pearlite A mixture of alternating plates of iron carbide (cementite) and ferrite (lamellar structure), which form on slow cooling from within gamma range. Bainite: Bainite A mixture of ferrite & cementite, which is harder and stronger than pearlite. It forms by the transformation of austenite in many steels during fairly rapid cooling, but not fast enough to cause martensite formation.

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Phase Diagram
Martensite: The hardest constituent achievable by heatMartensite treating of steels, it is formed by the rapid cooling of austenite to a temperature below the martensite temperature.

Material Test

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Material Test
Impact Test: is normally performed to ensure adequate ductility at the lower temperature the material will be in use. It is recognized that certain materials tend to become brittle at low temperatures and may be subject to failure which would not occur normally at usual temperatures or at elevated temperatures. The ASME Unfired Pressure Vessel Code arbitrarily establishes a temperature of -28.8 deg.C (-20 deg.F) as point which all vessels constructed of carbon or low-alloy steels should be impact tested with certain exemptions. No impact test are required for aluminum, austenitic stainless steel in grades 304, CF8, 304L, 316, CF8M, or 321, or copper, red brass, copper-nickel alloys, or nickel-copper alloys.

Material Test
The two most common methods used to measure metal toughness are the Charpy Impact test defined in ASTM specification E 23, and the Drop-Weight Test, defined in ASTM E 208. The Charpy test employs a small machined specimen with a machined notch that is struck by a pendulum weight. The energy loss to the pendulum as it passes through and breaks specimen, measured in kilojoules or ft-lb of force, is a measure of the toughness of the specimen.

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Material Test
The Drop-Weight test is similar in principle but employs a larger specimen with a brittle, notched weld bead used as a crack starter. A weight is dropped from a height onto the specimen, which had been cooled or heated to the desired test temperature. The test determines the nil-ductility transition temperature (NDTT), defined as the specimen temperature when, upon striking, the crack propagates across the entire specimen width.

Stress-Strain

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Stress-Strain Relationship
This gives the relation between unit stress and unit strain when plotted on a stress-strain diagram in which the ordinate represents the unit stress and the abscissa represents unit strain.

What is Stress
Stress is a defined quantity that cannot be directly observed or measured but it is the cause of most failures in manufactured products. It is defined as the force per unit area () with English units of pounds per square inch (psi) or metric units of megapascals (mpa).

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Hookes law relates stress to strain by the modulus of elasticity ().

=
where: = stress

= modulus of elasticity = strain

Stress-Strain
Modulus of Elasticity (Youngs Modulus), is the ratio of normal stress to corresponding strain for tensile or compressive stresses. This ratio is linear through a range of stress, known as Hookes law. The modulus of elasticity is measured using the tension test, the most widely used test applied to engineering materials. The test consist of applying gradually increasing load in either tension or compression, in a testing machine, to a standardized test specimen. The applied load is continuously monitored, as is test specimen elongation or contraction under load. These measured quantities are generally represented on a coordinate axis, called a stress-strain curve. stress-

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Stress-Strain
Yield Strength: when a specimen is loaded beyond the Strength point where elastic behavior can be maintained the specimen will begin to deform in a plastic manner. A gradual transition occurs as represented by a curve, or knee, in the stress-strain curve. Strength: Ultimate Tensile Strength upon further increase of applied load under constant strain rate, the specimen will continue to stretch until the loss of load-carrying cross section caused by the specimen thinning during the test cannot withstand further load increase.

Stress-Strain
Area: Elongation and Reduction of Area the ductility of the test specimen can be established by measuring its length and minimum diameter before and after testing. Stretch of the specimen is represented as a percent elongation in a given length and is calculated in the following manner: % elongation = (final length - original length) x 100 original length

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Stress-Strain
The diameter of the test specimen will decrease, or neck down, in ductile materials. Another standard measure of ductility is the reduction of area of the specimen, defined as follows:
% reduction of area = (original cross-sectional area final area) x 100 original area

Stress-Strain
Hardness: Hardness This is a measure of the materials ability to resist deformation, usually determined by a standardized test where the surface resistance to indentation is measured. The most common hardness test are defined by the indentor type and size, and the amount of load applied. The two (2) most common hardness test methods are Brinell Hardness and Rockwell Hardness, with each representing a standardized test machine with its own unique hardness scales. Approximate hardness conversion numbers for a variety of materials including steels can be found in ASTM Specification E 140.

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Material Test
Impact Test: A test to determine the behaviour of materials when subjected to high rates of loading, usually in bending, tension, or torsion. The quantity measured is the energy absorbed in breaking the specimen by a single blow, as in Charpy or Izod tests. This test is normally performed to ensure adequate ductility at the lower temperature the material will be in use. It is recognized that certain materials tend to become brittle at low temperatures and may be subject to failure which would not occur normally at usual temperatures or at elevated temperatures.

Fatigue

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What is fatigue?
Fatigue is the failure of a component due to repeated applications of load, which are referred to as cycles. An example of fatigue failure can be generated using a paper clip, bending it back and forth will cause failure in only a few cycles.

Stages of Fatigue
Fatigue failure generally consists of three stages: 1. Crack initiation 2. Stable crack growth 3. Unstable crack growth (fast fracture)

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What is a crack?
Although cracks may be created during manufacturing, they generally do not initiate until after a considerable period of usage. Cracks commonly form at metallurgical defects such as voids or inclusions, or at design features such as fillets, screw threads, or bolt holes. A crack can initiate at any highly stressed location. After a crack has initiated, it will grow for a while in a stable manner. During this stage, the crack will grow a very short distance during each load cycle.

What is a crack?
This creates pattern known as beach marks because they resemble the patterns left in sand by wave action along a beach. As cracks becomes larger, it usually grows at an increasingly rapid rate. Final failure occurs very quickly. For small components, it happens when the cross-sectional area has been reduced by the crack so much that the applied stress exceeds the ultimate strength of the material.

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What is a crack?
In larger components, fast fracture occurs when the fracture toughness of the material has been exceeded, even though the remaining crosssectional area is still large enough to keep the applied stress well below the ultimate strength.

Crack initiation analysis

The first step in calculating crack initiation life is to determine the stresses in a component. Life is related to the range of stress. These are known as S-N curves, and are plotted on log-log paper. While alternating stress is the major factor in determining life, the ratio of the minimum stress to the maximum stress also known as the R ratio, is a secondary factor. For a given alternating stress, increasing the R ratio will decrease the crack initiation life.

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Crack initiation analysis (cont.)

For example, a component with stresses varying from 50 to 100 ksi will have a lower life than a component with stresses varying from 0 to 50 ksi.

Thank You

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Atoms consist of electrons (negatively charge),

protons (positively charge) and neutrons (neutral). Atom is neutral once the number of electrons equals the number of protons. Atomic number of an element is given by the number of protons, and the atomic weight is given by the total number of protons and neutrons. e.g. Hydrogen, has one proton & one electron, therefore the atomic number is one and the atomic weight is one. Oxygen, with atomic number 8, has eight protons and eight neutrons, and therefore has an atomic weight of 16.

Grain boundaries are the regions that occur when there is no alignment between grains in a polycrystalline material. Grain boundaries are important in determining the bulk properties of a material. Impurities segregate at grain boundaries if they reduce the surface energy. Diffusion is usually faster along grain boundaries than through the bulk of the material Deformation of a material can occur by relative movement of grains.

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Most elements are metals. The structure of metals can be considered the packing of the spheres that most efficiently fills space. Three basic structures will be considered: face-centered cubic (fcc) body-centered cubic (bcc) hexagonal close-packed (hcp)

Ceramics are nonmetallic inorganic materials. The oxides of all metals such as FeO3, TiO2, Al2O3, and SiO2 and materials such as diamond, SiN, SiC, and Si are considered ceramics. Polymers are organic materials that consist of chains of C and H. The intrachain bonding is covalent, while the interchain bonding is van der Waals. The repeating structural units, monomers, qare linked together to form the polymer.

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Chemical Requirement of Carbon Steel

Carbon, maxA Manganese Phosphorus, max Sulfur, max Silicon, min Chrome, maxB Copper, maxB Molybdenum, maxB Nickel, maxB Vanadium, maxB Composition, % Grade A Grade B 0.25 0.30 0.270.93 0.291.06 0.035 0.035 0.035 0.035 0.10 0.10 0.40 0.40 0.40 0.40 0.15 0.40 0.08 0.15 0.40 0.08 Grade C 0.35 0.291.06 0.035 0.035 0.10 0.40 0.40 0.15 0.40 0.08

A For each reduction of 0.01% below the specified carbon maximum, an increase of 0.06% manganese above the specified maximum will be permitted up to a maximum of 1.35%. B These five elements combined shall not exceed 1%.

What is Creep?
Creep is plastic deformation which increases over time under sustained loading at generally elevated temperatures. Stress rupture is the continuation of creep to the point where failure takes place. At sufficiently high temp, all metals creep under stresses that vary with temp, the higher the temp the lower being the stress at which creep takes place.

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Modulus of Elasticity
= PI Ae Where: P = load, pounds, kg l = length of bar, inches, cm A = cross-sectional area acted on by the axial load P, in, cm e = total strain produced by axial load P, in, mm

Stiffness, is the ability to resist deformation under stresses. The modulus of elasticity is the criterion of the stiffness of a material. Hardness, is the ability to resist very small indentations, abrasion, and plastic deformation. There is no single measure of hardness, as it is not a single property but a combination of several properties.

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Ductility, is the ability of a material to sustain large permanent deformations in tension, such as drawing into a wire. Malleability, is the ability of a material to sustain large permanent deformations in compression, such as beating or rolling into thin sheets. Brittleness, is that property of a material that permits it to be only slightly deformed without rupture. Brittle materials have relatively short stress-strain curves.

Toughness, is the ability of the material to withstand high unit stress together with great unit strain without complete fracture. Elasticity, is that property of a material that enables it to deform or undergo strain and return to its original shape upon removal of the load. Plasticity, is that state of matter where permanent deformations or strains may occur without fracture. A material is plastic if the smallest load increment produces a permanent deformation.

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Proportional limit, is that unit stress at which unit strain begins to increase at a faster rate than unit stress. It is determined by noting on a stress-strain diagram thee unit stress at which the curve departs from a straight line. Yield Point, is the lowest stress at which strain increases without increase in stress. Yield Strength, is the unit stress at which material exhibits a specified permanent deformation or state. It is a measure of the useful limit of materials, particularly of those whose stress-strain curve in the region of yield smooth and gradually curved.

MATERIALS COMMONLY USED IN GPPA

A. PIPING MATERIAL (REFERENCE H-103) LIMITATION STAINLES STEEL CLASS DESIGNATION A1011 HC/ Flare A1031/A1041 Corr. HC, LO Demin Water, Seal Oil, Gov Oil A3012 HC, Refrigerant A3032/A3042 Corr. HC, LO FG, Seal Oil PRESSURE (KpaG) 1900 1900 1252 TEMP. (C) -46 to -199 0 204

PIPE: - 12 A312 Gr. TP 304 14-40 A358 Gr. 304 CL. 5 ELBOW/TEE/RED/CAP - 1-1/2 A182 Gr. F304 2-40 A403 Gr. WP304 FLANGE -40 A182 Gr. F304 BOLTS/NUTS A320 Gr. B8 Cl.2/A194 Gr.8

4960 4950 3251

-46 to -199 0 204

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MATERIALS COMMONLY USED IN GPPA (Cont.)

LIMITATION STAINLESS STEEL CLASS DESIGNATION A6021 HC/ Refrigerant A6043 LO Seal Oil A3012 HC, Refrigerant A3032/A3042 Corr. HC, LO FG, Seal Oil PRESSURE (KpaG) 9930 9930 6514 4960 4950 3251 TEMP. (C) -46 to -199 0 204 -46 to -199 0 204

PIPE: - 12 A312 Gr. TP 304 14-40 A358 Gr. 304 CL. 5 ELBOW/TEE/RED/CAP - 1-1/2 A182 Gr. F304 2-40 A403 Gr. WP304 FLANGE -40 A182 Gr. F304 BOLTS/NUTS A320 Gr. B8 Cl.2/A194 Gr.8

MATERIALS COMMONLY USED IN GPPA (Cont.)

LIMITATION LOW TEMPERATURE CARBON STEEL (LTCS) PIPE: - 14 A333 Gr. 6 16-32 A671 Gr. CC50 CL. 23 ELBOW/TEE/RED/CAP - 1-1/2 A350 Gr. LF2 2-42 A420 Gr. WPL6 FLANGE -42 A350 Gr. LF2 BOLTS/NUTS A320 Gr. L7/A194 Gr.84 CLASS DESIGNATION C1109 HC/ Refrigerant/ Flare C3110 HC, Refrigerant, FGl C6120 HC PRESSURE (KpaG) 1840 TEMP. (C) -10 to -46

4790

-10 to -46

9570

-46 to -199

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MATERIALS COMMONLY USED IN GPPA (Cont.)

LIMITATION CARBON STEEL CLASS DESIGNATION D1019 Instrument Air Drinking Water, Raw Water D1019A Instrument Air Drinking Water, Raw Water PRESSURE (KpaG) 1960 1875 TEMP. (C) 0 65 PIPE: - 14 A53 Gr. B ELBOW/TEE/RED/CAP - 1-1/2 A105 2-14 A234 Gr. WPS FLANGE -14 A105 BOLTS/NUTS A193 Gr. B7/A194 Gr.2H

1960 1875

-10 65

MATERIALS COMMONLY USED IN GPPA (Cont.)

LIMITATION CARBON STEEL CLASS DESIGNATION D1101 HC Inert Gas, FG, FW, SW, LLP Steam & Steam Cond, Lp Steam & Steam Cond, Flare, Process Drain,Refrigerant , Methanol, Waste Water D1101B 45% NaOH PRESSURE (KpaG) 1960 1020 TEMP. (C) -10 300 PIPE: - 24 API 5L Gr. B 26-40 A671 Gr. CC50 Cl.23 ELBOW/TEE/RED/CAP - 1-1/2 A105 2-24 A234 Gr. WPB 26-40 A420 Gr. WPL5 FLANGE -40 A105 BOLTS/NUTS A193 Gr. B7/A194 Gr.2H

1960 1890

0 60

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MATERIALS COMMONLY USED IN GPPA (Cont.)

LIMITATION CARBON STEEL CLASS DESIGNATION D1101C 98% H2SO4 D1116 Firewater PRESSURE (KpaG) TEMP. (C) 0 to 60 PIPE: - 24 API 5L Gr. B 26-40 A671 Gr. CC50 Cl.23 ELBOW/TEE/RED/CAP - 1-1/2 A105 2-24 A234 Gr. WPB 26-40 A420 Gr. WPL5 FLANGE -40 A105 BOLTS/NUTS A193 Gr. B7/A194 Gr.2H 1000

1960 1875

0 65

D1117 Cooling Water Plant Air, Raw Water D1118 Cooling Water Oil Drain, Oily water Sewer

1960 1685

0 122

1960 1875

0 65

MATERIALS COMMONLY USED IN GPPA (Cont.)

LIMITATION CARBON STEEL CLASS DESIGNATION D1306 Corrosive HC D1306A Corrosive HC Waste Water D3102 HC FG, MP Steam & Steam Cond, Water Injection D3102A HC PRESSURE (KpaG) 1960 1020 1960 1875 5110 3870 TEMP. (C) -10 300 -10 65 -10 300 PIPE: - 24 API 5L Gr. B 26-40 A671 Gr. CC50 Cl.23 ELBOW/TEE/RED/CAP - 1-1/2 A105 2-24 A234 Gr. WPB 26-40 A420 Gr. WPL56 FLANGE -40 A105 BOLTS/NUTS A193 Gr. B7/A194 Gr.2H

5110 4899

-10 65

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MATERIALS COMMONLY USED IN GPPA (Cont.)

LIMITATION CARBON STEEL CLASS DESIGNATION D3307 Corrosive HC D6103/D6308 HC/Corr. HC Methanol, Boiler Feed Water D7104/D7114 HC Process D7114A HC Process PRESSURE (KpaG) 5110 3870 10210 7750 TEMP. (C) -10 300 -10 300 PIPE: - 24 API 5L Gr. B 26-40 A671 Gr. CC50 Cl.23 ELBOW/TEE/RED/CAP - 1-1/2 A105 2-24 A234 Gr. WPB 26-40 A420 Gr. WPL56 FLANGE -40 A105 BOLTS/NUTS A193 Gr. B7/A194 Gr.2H

15320 11620 15320 14657

-10 300 -10 65

MATERIALS COMMONLY USED IN GPPA (Cont.)

LIMITATION CARBON STEEL CLASS DESIGNATION E1101 LLP Steam PRESSURE (KpaG) 1020 653 (C) 300 399 PIPE: - 24 API 5L Gr. B 26-40 A671 Gr. CC50 Cl.23 ELBOW/TEE/RED/CAP - 1-1/2 A105 2-24 A234 Gr. WPB 26-40 A420 Gr. WPL56 FLANGE -40 A105 BOLTS/NUTS A193 Gr. B7/A194 Gr.2H

TEMP.

E3102 HC process LP Steam, MP Steam E6103 HC Process E6123 HC Process HP Steam & Steam Cond.

3670 3458

300 399

7750 6913 5160 4610

300 399 300 399

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MATERIALS COMMONLY USED IN GPPA (Cont.)

LIMITATION CARBON STEEL CLASS DESIGNATION E7114 Boiler Feed water to Desuper heater PRESSURE (KpaG) 11620 10154 TEMP. (C) 300 399 PIPE: - 24 API 5L Gr. B 26-40 A671 Gr. CC50 Cl.23 ELBOW/TEE/RED/CAP - 1-1/2 A105 2-24 A234 Gr. WPB 26-40 A420 Gr. WPL56 FLANGE -40 A105 BOLTS/NUTS A193 Gr. B7/A194 Gr.2H

MATERIALS COMMONLY USED IN GPPA (Cont.)

COLUMNS A-101, CHLORIDE SCRUBBER A-201, ABSORBER A-202, THERMAL REGENERATOR A-401, DEMETHANIZER A-451, CONDENSATE STRIPPER A-601, DEETHANIZER MATERIAL A516 Gr.70 + T316L CLAD A516 Gr.70 + T304L CLAD A516 Gr.60/TP304 A240 TP304 A516 Gr.70 A537 CL1 DESIGN PRESS (KPAG) 7600 6600 350 4100 3300 3300 DESIGN TEMP (C) 60/20 145/10 60/20 -110/120 220/16 -45/130

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MATERIALS COMMONLY USED IN GPPA (Cont.)

PRESSURE VESSEL MATERIAL DESIGN PRESS (KPAG) 7600 6200 6200 350 1150 DESIGN TEMP (C) 60/20 60/20 60/15 100/20 -45/60 M-101, INLET SEPARATOR M-102, DECANTER DRUM M-103, CONDENSATE TRANSFER DRUM M-204, ACID GAS CONDENSATE KO DRUM#2 M-701, 1ST STAGE C3 REFRIGERANT SUCTION DRUMCONDENSATE STRIPPER M-702, 2ND STAGE C3 REFRIGERANT SUCTION DRUM A516 Gr.70 + T316L CLAD A537 CL.1 A516 Gr.70 + T304L CLAD A240 TP304 A516 Gr.60

A537 CL.1

1150

-45/60

MATERIALS COMMONLY USED IN GPPA (Cont.)

HEAT EXCHANGER (SHELL & TUBE) MATERIAL DP (KPAG) 1530 (FV) S 2040 (FV) T 4400 (FV) S 4640 T 3947 S 4182 4400 S 3300 T 1800 (FV) S 1800 DT (C) 230/20 300/20 395/20 320/20 300 -45/120 395 220 70/20 60/20 T-205, MEDIUM PRESSURE STEAM REBOILER SHELL/TUBESHEET/TUBE T-351, REBOILER, MEDIUM PRESSURE STEAM SHELL/TUBESHEET/TUBE T-404, DEMETHANIZER BOTTOM REBOILER SHELL/TUBESHEET/TUBE T-451, CONDENSATE STRIPPER REBOILER SHELL/TUBESHEET/TUBE T-621, DEPROPANIZER REBOILER SHELL/TUBESHEET/TUBE A516 Gr.70 + 405SS CLAD/A182 F6A CL.1/A268Gr.TP405S A515 Gr.70/A266 CL.4/A179 A516 Gr.70/A350 LF2/A334 Gr.1-S A515Gr.70/A266 Gr.4/A179 A516 Gr.70/A266 Gr.4/A214

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MATERIALS COMMONLY USED IN GPPA (Cont.)

FIRED HEATER MATERIAL DESIGN PRESS (KPAG) 1190 F-681, HOT OIL HEATER HEADER PIPE /FINNED TUBE F-101, DEETHANIZER REBOILER HEADER PIPE/ RADIANT & CONVECTION TUBES F-102, DEBUTANIZER REBOILER HEADER PIPE/ RADIANT & CONVECTION TUBES F-104, DEPROPANIZER REBOILER HEADER PIPE/ RADIANT & CONVECTION TUBES F-105, REGENERATION HEATER HEADER PIPE/ RADIANT & CONVECTION TUBES A106 Gr.B A161 Gr.LCS A106 Gr.B A161 Gr.LCS API 5LGr.B A210 Gr. A-1 API 5LGr.B A210 Gr. A-1 API 5LGr.B A210 Gr. A-1 342 3810 344

DESIGN TEMP (C)

2570

270

3510

190

4385

400

MATERIALS COMMONLY USED IN GPPA (Cont.)

AUXILIARY BOILERS MATERIAL STEAM DRUM WATER DRUM FURNACE TUBES SUPERHEATER TUBES SUPERHEATER HEADER ECONOMIZER COIL TUBE ECONOMIZER HEADER ECONOMIZER HEADER END PLATE A515 Gr.70 A515 Gr.70 A178 Gr.A A213 Gr. T11 A335 Gr. P11 A178 Gr. A A106 Gr. B 4903 264 4700 385 DESIGN PRESSURE (KPAG) DESIGN TEMP. (C)

A515 Gr.70

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MATERIALS
PIPE MATERIAL MAIN STEAM LINE Pressure: 1985 psig Temp: 1015F HOT REHEAT Pressure: 590 psig Temp: 1015F COLD REHEAT First extraction point Pressure: 615 psig Temp: 710F A335 P22 Seamless (Flanged type not allowed) A335 P22, Seamless Weld neck flange A182 F22 (B16.5) FITTINGS 2 & smaller A182 F22 Over 2 A234 WP22 2 & smaller A182 F22 Over 2 A234 WP22 RATING ANSI B16.9/B16.28 9000 Class socket welded

ANSI B16.9/B16.28 3000 class socket weld

A106 Gr. B, 2 & smaller A105 ANSI B16.9/B16.28 seamless (B16.11) 3000 class Weld neck Flange Over 2 A234 WPB socket weld A105 (B16.5) 600# RF

WP, WPB & WPC in fittings denotes the grade of the material

MATERIALS COMMONLY USED IN GPPA

ASME SECTION II PART A EDITION
SA-53 SA-105 SA-106 SA-178 SA-182 SA-193 SA-194 SA-213 SA-234 PIPE, STEEL, BLACK AND HOT-DIPPED, ZINC-COATED, WELDED AND SEAMLESS CARBON STEEL FORGINGS FOR PIPING APPLICATIONS SEAMLESS CARBON STEEL PIPE FOR HIGH-TEMPERATURE SERVICE ELECTRIC RESISTANCE WELDED CARBON STEEL AND CARBON-MANGANESE STEEL BOILER AND SUPERHEATER TUBES FORGED OR ROLLED ALLOY-STEEL PIPE FLANGES, FORGED FITTINGS, AND VALVES AND PARTS FOR HIGH-TEMPERATURE SERVICE ALLOY-STEEL AND STAINLESS STEEL BOLTING MATERIAL FOR HIGH TEMPERATURE SERVICE CARBON AND ALLOY STEEL NUTS FOR BOLTS FOR HIGH-PRESSURE AND HIGHTEMPERATURE SERVICE SEAMLESS FERRITIC AND AUSTENITIC ALLOY-STEEL BOILER, SUPERHEATER AND HEATEXCHANGER TUBES PIPE FITTINGS OF WROUGHT CARBON STEEL AND ALLOY STEEL FOR MODERATE AND HIGH TEMPERATURE SERVICE

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MATERIALS COMMONLY USED IN GPPA

ASME SECTION II PART A EDITION
SA-312 SA-320 SA-333 SA-350 SA-358 SA-403 SA-420 SA-515 SA-516 SEAMLESS AND WELDED AUSTENITIC STAINLESS STEEL PIPES ALLOY STEEL BOLTING MATERIALS FOR LOW-TEMPERATURE SERVICE SEAMLESS AND WELDED STEEL PIPE FOR LOW-TEMPERATURE SERVICE CARBON AND LOW-ALLOY STEEL FORGINGS, REQUIRING NOTCH TOUGHNESS TESTING FOR FOR PIPING COMPONENTS ELECTRIC-FUSION-WELDED AUSTENITIC CHROMIUM-NICKEL ALLOY STEEL PIPE FOR HIGH-TEMPERATURE SERVICE WROUGHT AUSTENITIC STAINLESS STEEL PIPING FITTINGS PIPING FITTINGSOF WROUGHT CARBON STEEL AND ALLOY STEEL FOR LOWTEMPERATURE SERVICE PRESSURE VESSEL PLATES, CARBON STEEL, FOR INTERMEDIATE-AND HIGHERTEMPERATURE SERVICE PRESSURE VESSEL PLATES, CARBON STEEL FOR MODERATE-AND LOWER-TEMPERATURE SERVICE

MATERIALS COMMONLY USED IN GPPA

ASME SECTION II PART A EDITION
SA-240 SA-537 SA-671 SA-214 SA-266 SA-335 SA-161 SA-210 API 5L HEAT-RESISTING CHROMIUM AND CHROMIUM-NICKEL STAINLESS STEEL PLATE, SHEET, AND STRIP FOR PRESSURE VESSELS PRESSURE VESSEL PLATES, HEAT-TREATED, CARBON-MANGANESE-SILICON STEEL ELECTRIC-FUSION WELDED STEEL PIPE FOR ATMOSPHERIC AND LOWER TEMPERATURES ELECTRIC-RESISTANCE-WELDED-CARBON STEEL HEAT-EXCHANGER AND CONDENSER TUBES CARBON STEEL FORGINGS FOR PRESSURE VESSEL COMPONENTS SEAMLESS FERRITIC ALLOY-STEEL PIPE FOR HIGH-TEMPERATURE SERVICE NOT MENTIONED IN ASME SEC. II PART A SEAMLESS MEDIUM-CARBON STEEL BOILER AND SUPERHEATER TUBES SPECIFICATION FOR LINE PIPE

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MATERIALS COMMONLY USED IN GPPA

IDENTIFICATION A AUSTENITIC STAINLESS STEEL TYPE 304 C LOW TEMPERATURE CARBON STEEL D CARBON STEEL FOR SERVICE TEMPERATURE UP TO 300C H AUSTENITIC STAINLESS STEEL TYPE 316 Z POLYETHYLENE LINED CARBON STEEL B CHLORINATED POLYVINYL CHLORIDE (CPVC) CORROSION ALLOWANCE: CLASS 0: NONE CLASS 1: 1.3mm CLASS 3: 6.3 mm

MATERIALS
CORROSION RESISTANT Corrosion Resistance of steel is substantially improved by the addition of Aluminium, Silicon and Chromium. These metals form thin but dense and adherent oxide films which protect the surface of steel from further attack. Out of the elements mentioned Chromium is the most useful when mechanical properties have to be considered. STRENGTH Hardness is increased by stabilizing the carbides; strength is increased when alloying elements dissolve in the ferrite; toughness is improved by the refinement of the grain size.
Carbide is a compound of carbon with a more electropositive element or group. Ferrite is the pure iron constituent of ferrous metals, as distinguished from the iron carbides

Source: Introduction to Metallurgy

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MATERIALS
ALLOYING ELEMENT EFFECT ON STRENGTHENIN G FERRITE Strong Strong Strong Moderate Weak Moderate Strong Weak Moderate EFFECTS IN FORMING CARBIDE Weak None None None Moderate None Strong Strong Strong EFFECT ON EFFECTS ON TRANSFORMATIO HARDENABILITY N TEMPERATURE Lowers Raises Lowers Lowers Strong Moderate Moderate Moderate Strong Weak Strong Mild Moderate

Manganese Silicon Phosphorous Nickel Chromium Copper Molybdenum Vanadium Tungsten

*
Lowers Raises Raises Raises

* Raises or lowers depending on Carbon content Ferrite is the pure iron constituent of ferrous metals, as distinguished from the iron carbides
Source: Introduction to Metallurgy

MATERIALS
Recommended liquid flow through piping is 2 to 5 meters per second. Impact test shall be required for materials to be used at temperature lower than -20F (-29C). UG-84 Charpy Impact Test, ASME Sec. VIII Div.1 Insulation For Hot Service - Calcium Silicate, for equipment and piping 650C and below. Calcium silicate shall not be applied for Austenitic Stainless Steel to avoid stress corrosion cracking. - Rock Wool, for expansion joints of towers & vessels and for insulation at irregular surface of equipment 600C and below. For Cold Service - Cellular Glass, for equipment & pipings -180C to 120C - Rock Wool, for contraction joints of towers, vessels & pipings and for irregular surface -180C to 600C

47