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Piping Material Selection: A Comprehensive Guide

Introduction


Material selection for piping systems is a critical optimization process that balances capital cost, operational costs, and overall life cycle costs while ensuring safety and reliability. Effective material selection involves evaluating several key factors to ensure that the chosen materials meet the required performance and durability standards.


Key Factors in Material Selection


1.     Availability: Ensure the material is readily available.

2.     Design Life: Material should be suitable for the design life, including considerations for corrosion allowance.

3.     Process Compatibility: The material must be compatible with the process fluid.

4.     Design Conditions: Suitability for design temperature, pressure, and cyclic loading is crucial.

5.     Environmental Conditions: Consider the impact of environmental conditions (e.g., saline environments) on material effectiveness.

6.     Ultraviolet Degradation: Assess potential UV degradation of materials.

7.     Support Arrangements: Feasibility of providing economical supporting arrangements.

8.     Past Experience: Leverage past experience with materials used in similar applications.

9.     Corrosion Protection: Include additional requirements for corrosion protection, such as cathodic protection, chemical injection, and monitoring.

10.                        Weight Reduction: Aim for weight reduction where feasible.

11.                        Costs: Consider fabrication, inspection, and installation costs.

12.                        Failure Evaluation: Evaluate failure probabilities, failure modes, and consequences.


Approach to Material Selection


The material selection process typically follows these progressive steps, particularly in the oil and gas industry:


1.     Bare Carbon Steel: Use without internal coating, with a corrosion allowance.

2.     Corrosion Inhibition: Apply corrosion inhibition to bare carbon steel.

3.     Internal Coating or Lining: Use carbon steel pipes with internal coating or lining.

4.     Cathodic Protection: Implement cathodic protection for carbon steel.

5.     Corrosion Resistant Alloy (CRA): Opt for more advanced materials like CRA when necessary.


Types of Piping Materials


Piping materials are generally classified into metallic and non-metallic categories:


Metallic Materials


Ferrous Piping

  • Carbon Steel

  • Stainless Steel

  • Duplex Steel

  • Cast Iron

  • Ductile Iron


Non-Ferrous Piping

  • Copper

  • Copper Nickel

  • Inconel 625

  • Titanium

  • Aluminium


Material Characteristics


  • Carbon Steel: Suitable for many applications with corrosion allowances. Performs well between -29°C and 427°C. For higher durability, consider a corrosion allowance of 3 mm, with 6 mm as an upper limit.

  • Low-Temperature Carbon Steel: Used for subzero temperatures.

  • Low-Alloy Carbon Steel: Suitable for high-temperature applications.

  • Stainless Steel: Used for many corrosive service applications.

  • Duplex Steels and Corrosion Resistant Alloys: Consider for more aggressive environments.


Role of Metallurgists and Corrosion Engineers


Metallurgists or Corrosion Engineers are typically responsible for developing material selection philosophies, preparing material selection reports, and creating material selection diagrams. These reports and diagrams are crucial for developing appropriate piping material classes.


ASTM Grades and Standards


ASME B31.3 provides a list of commonly used metallic piping materials. The following table includes ASTM codes for both ferrous and non-ferrous materials used in plant facilities:


List of ASTM Codes for Piping Materials - Ferrous Materials

ASTM Grade

Material Description

A48

Standard Specification for Gray Iron Castings

A53

Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc Coated, Welded and Seamless

A105

Standard Specification for Forgings, Carbon Steel, For Piping Components

A106

Standard Specification for Seamless Carbon Steel Pipe For High-Temperature Service

A126

Standard Specification for Gray Cast Iron Castings For Valves, Flanges, and Pipe Fittings

A134

Standard Specification for Pipe, Steel, Electric-Fusion (Arc)-Welded (Sizes Nps 16 and Over)

A135

Standard Specification for Electric-Resistance-Welded Steel Pipe

A139

Standard Specification for Electric-Fusion (Arc)-Welded Steel Pipe (Nps 4 and Over)

A167

Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet and Strip

A179

Standard Specification for Seamless Cold-Drawn Low-Carbon Steel Heat- Exchanger and Condenser Tubes

A181

Standard Specification for Forgings, Carbon Steel For General Purpose Piping

A182

Standard Specification for Forged Or Rolled Alloy-Steel Pipe Flanges, Forged Fittings, and Valves and Parts For High-Temperature Service

A197

Standard Specification for Cupola Malleable Iron

A200

 

Standard Specification for Seamless Intermediate Alloy-Steel Still Tubes for Refinery Service

A202

Standard Specification for Pressure Vessel Plates, Alloy Steel, Chromiummanganese-Silicon

A203

Standard Specification for Pressure Vessel Plates, Alloy Steel, Nickel

A204

Standard Specification for Pressure Vessel Plates, Alloy Steel, Molybdenum

A213

Standard Specification for Seamless Ferritic and Austenitic Alloy-Steel Boiler, Superheater, and Heat- Exchanger Tubes

A214

Standard Specification for Electric-Resistance-Welded Carbon Steel Heat-Exchanger and Condenser Tubes

A216

Standard Specification for Steel Castings, Carbon, Suitable For Fusion Welding For High-Temperature Service

A217

Standard Specification for Steel Castings, Martensitic Stainless and Alloy, For Pressure-Containing Parts Suitable For High-Temperature Service

A234

Standard Specification for Piping Fittings Of Wrought Carbon Steel and Alloy Steel For Moderate and Elevated Temperatures

A240

Standard Specification for Heat-Resisting Chromium and Chromium-Nickel Stainless Steel Plate, Sheet and Strip For Pressure Vessels

A249

Standard Specification for Welded Austenitic Steel Boiler, Superheater, Heat-Exchanger, and Condenser Tubes

A268

Standard Specification for Seamless and Welded Ferritic Stainless Steel Tubing For General Service

A269

Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing For General Service

A270

Standard Specification for Seamless and Welded Austenitic Stainless Steel Sanitary Tubing

A271

Standard Specification for Seamless austenitic Chromium-Nickel Steel Still Tubes for Refinery Service

A278

Standard Specification for Gray Iron Castings For Pressure-Containing Parts For Temperatures Up To 650°F

A283

Standard Specification for Low and Intermediate Tensile Strength Carbon Steel Plates, Shapes and Bars

A285

Standard Specification for Pressure Vessel Plates, Carbon Steel, Low- and Intermediate-Tensile Strength

A299

Standard Specification for Pressure Vessel Plates, Carbon Steel, Manganese-Silicon

A302

Standard Specification for Pressure Vessel Plates, Alloy Steel, Manganese Molybdenum and Manganese-Molybdenum-Nickel

A312

Standard Specification for Seamless and Welded Austenitic Stainless Steel Pipe

A333

Standard Specification for Seamless and Welded Steel Pipe For Low-Temperature Service

A334

Standard Specification for Seamless and Welded Carbon and Alloy-Steel Tubes For Low-Temperature Service

A335

Standard Specification for Seamless Ferritic Alloy Steel Pipe For High-Temperature Service

A350

Standard Specification for Forgings, Carbon and Low-Alloy Steel Requiring Notch Toughness Testing For Piping Components

A351

Standard Specification for Steel Castings, Austenitic, Austenitic-Ferritic (Duplex) For Pressure-Containing Parts

A352

Standard Specification for Steel Castings, Ferritic and Martensitic, For Pressure Containing Parts Suitable For Low-Temperature Service

A353

Standard Specification for Pressure Vessel Plates, Alloy Steel, 9% Nickel, Double Normalized and Tempered

A358

Standard Specification for Electric-Fusion-Welded Austenitic Chromium-Nickel Alloy Steel Pipe For High-Temperature Service

A369

Standard Specification for Carbon Steel and Ferritic Alloy Steel Forged and Bored Pipe For High-Temperature Service

A376

Standard Specification for Seamless Austenitic Steel Pipe For High-Temperature Central-Station Service

A381

Standard Specification for Metal-Arc-Welded Steel Pipe For Use With High-Pressure Transmission Systems

A387

Standard Specification for Pressure Vessel Plates, Alloy Steel, Chromium molybdenum

A395

Standard Specification for Ferritic Ductile Iron Pressure-Retaining Castings For Use At Elevated Temperatures

A403

Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings

A409

Standard Specification for Welded Large Diameter Austenitic Steel Pipe For Corrosive Or High-Temperature Service

A420

Standard Specification for Piping Fittings Of Wrought Carbon Steel and Alloy Steel For Low-Temperature Service

A426

Standard Specification for Centrifugally Cast Ferritic Alloy Steel Pipe For High Temperature Service

A451

Standard Specification for Centrifugally Cast Austenitic Steel Pipe For High Temperature Service

A479

Standard Specification for Stainless and Heat-Resisting Steel Bars and Shapes For Use In Boilers and Other Pressure Vessels

A487

Standard Specification for Steel Castings Suitable For High-Pressure Service

A494

Standard Specification for Castings, Nickel and Nickel Alloy

A498

Standard Specification for Seamless and Welded Carbon, Ferritic, and Austenitic Alloy Steel Heat-Exchanger Tubes with Integral Fins

A511

Standard Specification for Seamless Stainless Steel Mechanical Tubing

A515

Standard Specification for Pressure Vessel Plates, Carbon Steel, For Intermediate and Higher-Temperature Service

A516

Standard Specification for Pressure Vessel Plates, Carbon Steel, For Moderate- and Lower-Temperature Service

A524

Standard Specification for Seamless Carbon Steel Pipe For Atmospheric and Lower Temperatures

A537

Standard Specification for Pressure Vessel Plates, Heat-Treated, Carbon Manganese-Silicon Steel

A553

Standard Specification for Pressure Vessel Plates, Alloy Steel, Quenched and Tempered 8 and 9% Nickel

A554

Standard Specification for Welded Stainless Steel Mechanical Tubing

A570

Standard Specification for Hot-Rolled Carbon Steel Sheet and Strip, Structural Quality

A571

Standard Specification for Austenitic Ductile Iron Castings For Pressure-Containing Parts Suitable For Low-Temperature Service

A587

Standard Specification for Electric-Welded Low-Carbon Steel Pipe For The Chemical Industry

A632

Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing (Small-Diameter) for General Service

A645

Standard Specification for Pressure Vessel Plates, 5% Nickel Alloy Steel, Specially Heat Treated

A671

Standard Specification for Electric-Fusion-Welded Steel Pipe For Atmospheric and Lower Temperatures

A672

Standard Specification for Electric-Fusion-Welded Steel Pipe For High-Pressure Service At Moderate Temperatures

A688

Standard Specification for Welded Austenitic Stainless Steel Feedwater Heater Tubes

A691

Standard Specification for Carbon and Alloy Steel Pipe, Electric Fusion-Welded For High-Pressure Service At High Temperatures

A778

Standard Specification for Welded, Unannealed Austenitic Stainless Steel Tubular Products

A789

Standard Specification for Seamless and Welded Ferritic Austenitic Stainless Steel Tubing For General Service

A790

Standard Specification for Seamless and Welded Ferritic Austenitic Stainless Steel Pipe

A803

Standard Specification for Welded Ferritic Stainless Steel Feedwater Heater Tubes

A813

Standard Specification for Single- or Double-Welded Austenitic Stainless Steel Pipe

A814

Standard Specification for Cold-Worked Welded Austenitic Stainless Steel Pipe

A815

Standard Specification for Wrought Ferritic, Ferritic Austenitic and Martensitic Stainless Steel Fittings

A851

Standard Specification for High-Frequency Induction Welded, Unannealed, Austenitic Steel Condenser Tubes

A928

Standard Specification for Ferritic/Austenitic (Duplex) Stainless Steel Pipe Electric Fusion Welded with Addition of Filler Metal

 

List of ASTM Codes for Piping Materials - Non-Ferrous Materials

B21

 

Standard Specification for Naval Brass Rod, Bar, and Shapes

B26

Standard Specification for Aluminum-Alloy Sand Castings

B42

Standard Specification for Seamless Copper Pipe, Standard Sizes

B43

Standard Specification for Seamless Red Brass Pipe, Standard Sizes

B61

Standard Specification for Steam or Valve Bronze Castings

B62

 

Standard Specification for Composition Bronze or Ounce Metal Castings

B68

Standard Specification for Seamless Copper Tube, Bright Annealed

B75

Standard Specification for Seamless Copper Tube

B88

Standard Specification for Seamless Copper Water Tube

B96

Standard Specification for Copper-Silicon Alloy Plate, Sheet, Strip, and Rolled Bar For General Purposes and Pressure Vessels

B98

Standard Specification for Copper-Silicon Alloy Rod, Bar, and Shapes

B127

Standard Specification for Nickel-Copper Alloy (UNS N04400) Plate, Sheet, and Strip

B133

Standard Specification for Copper Rod, Bar, and Shapes

B148

Standard Specification for Aluminum-Bronze Castings

B150

Standard Specification for Aluminum-Bronze Rod, Bar, and Shapes

B152

Standard Specification for Copper Sheet, Strip, Plate, and Rolled Bar

B160

Standard Specification for Nickel Rod and Bar

B161

Standard Specification for Nickel Seamless Pipe and Tube

B162

Standard Specification for Nickel Plate, Sheet, and Strip

B164

Standard Specification for Nickel-Copper Alloy Rod, Bar, and Wire

B165

 

Standard Specification for Nickel-Copper Alloy (UNS N04400) Seamless Pipe and Tube

B166

Standard Specification for Nickel-Chromium-Iron Alloy (UNS N06600) Rod, Bar, and Wire

B167

Standard Specification for Nickel-Chromium-Iron Alloy (UNS N06600-N06690) Seamless Pipe and Tube

B168

Standard Specification for Nickel-Chromium-Iron Alloy (UNS N06600-N06690) Plate, Sheet, and Strip

B169

Standard Specification for Aluminum Bronze Plate, Sheet, Strip, and Rolled Bar

B171

Standard Specification for Copper-Alloy Condenser Tube Plates

B187

Standard Specification for Copper Bar, Bus Bar, Rod, and Shapes

B209

 

Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate

B210

Standard Specification for Aluminum-Alloy Drawn Seamless Tubes

B211

Standard Specification for Aluminum-Alloy Bars, Rods, and Wire

B221

Standard Specification for Aluminum-Alloy Extruded Bars, Rods, Wire, Shapes, and Tubes

B241

Standard Specification for Aluminum-Alloy Seamless Pipe and Seamless Extruded Tube

B247

Standard Specification for Aluminum-Alloy Die, Hand, and Rolled Ring Forgings

B280

Standard Specification for Seamless Copper Tube For Air Conditioning and Refrigeration Fluid Service

B283

Standard Specification for Copper and Copper-Alloy Die Forgings (Hot-Pressed)

B265

Standard Specification for Titanium and Titanium Alloy Strip, Sheet, and Plate

B333

Standard Specification for Nickel-Molybdenum Alloy Plate, Sheet, and Strip

B335

Standard Specification for Nickel-Molybdenum Alloy Rod

B337

Standard Specification for Seamless and Welded Titanium and Titanium Alloy Pipe

B345

 

Standard Specification for Aluminum-Alloy Seamless Extruded Tube and Seamless Pipe For Gas and Oil Transmission and Distribution Piping Systems

B361

Standard Specification for Factory-Made Wrought Aluminum and Aluminum Alloy Welding Fittings

B366

Standard Specification for Factory-Made Wrought Nickel and Nickel-Alloy Welding Fittings

B381

Standard Specification for Titanium and Titanium Alloy Forgings

B407

Standard Specification for Nickel-Iron-Chromium Alloy Seamless Pipe and Tube

B409

Standard Specification for Nickel-Iron-Chromium Alloy Plate, Sheet, and Strip

B423

 

Standard Specification for Nickel-Iron-Chromium-Molybdenum-Copper Alloy (UNS No8825 and N08221) Seamless Pipe and Tube

B424

Standard Specification for Nickel-Iron-Chromium-Molybdenum-Copper Alloy (UNS No8825 and N08221) Plate, Sheet, and Strip

B425

Standard Specification for Nickel-Iron-Chromium-Molybdenum-Copper Alloy (UNS No8825 and N08221) Rod and Bar

B435

Standard Specification for UNS N06002, UNS N06230, UNS N12160, and UNS R30556 Plate, Sheet, and Strip

B443

Standard Specification for Nickel-Chromium-Molybdenum-Columbium Alloy (UNS N06625) Plate, Sheet, and Strip

B444

Standard Specification for Nickel-Chromium-Molybdenum-Columbium Alloy (UNS N06625) Seamless Pipe and Tube

B446

Standard Specification for Nickel-Chromium-Molybdenum-Columbium Alloy (UNS N06625) Rod and Bar

B462

Standard Specification for Forged or Rolled UNS N06030, UNS N06022, UNS N06035, UNS N06200, UNS N06059, UNS N10362, UNS N06686, UNS N08020, UNS N08367, UNS N10276, UNS N10665, UNS N10675, UNS N10629, UNS N08031, UNS N06045, UNS N06025, UNS R20033 Alloy Pipe Flanges, Forged Fittings, and Valves and Parts for Corrosive High-Temperature Service

B463

Standard Specification for UNS N08020 Alloy Plate, Sheet, and Strip

B464

Standard Specification for Welded Chromium-Nickel-Iron-Molybdenum-Copper columbium Stabilized Alloy (UNS N08020) Pipe

B466

Standard Specification for Seamless Copper-Nickel Pipe and Tube

B467

Standard Specification for Welded Copper-Nickel Pipe

B491

Standard Specification for Aluminum and Aluminum Alloy Extruded Round Tubes For General-Purpose Applications

B493

Standard Specification for Zirconium and Zirconium Alloy Forgings

B514

 

Standard Specification for Welded Nickel-Iron-Chromium Alloy Pipe

B517

Standard Specification for Welded Nickel-Chromium-Iron-Alloy (UNS N06600, UNS N06603, UNS N06025, and UNS N06045) Pipe

B523

Standard Specification for Seamless and Welded Zirconium and Zirconium Alloy Tubes

B547

Standard Specification for Aluminum and Aluminum-Alloy Formed and Arc-Welded Round Tube

B550

Standard Specification for Zirconium and Zirconium Alloy Bar and Wire

B551

Standard Specification for Zirconium and Zirconium Alloy Strip, Sheet, and Plate

B564

Standard Specification for Nickel Alloy Forgings

B575

Standard Specification for Low-Carbon Nickel-Molybdenum-Chromium Alloy Plate, Sheet, and Strip

B581

Standard Specification for Nickel-Chromium-Iron-Molybdenum-Copper Alloy Rod

B582

Standard Specification for Nickel-Chromium-Iron-Molybdenum-Copper Alloy Plate, Sheet, and Strip

B584

Standard Specification for Copper Alloy Sand Castings For General Applications

B619

Standard Specification for Welded Nickel and Nickel-Cobalt Alloy Pipe

B620

Standard Specification for Nickel-Iron-Chromium-Molybdenum Alloy (UNS N08320) Plate, Sheet, and Strip

B621

Standard Specification for Nickel-Iron-Chromium-Molybdenum Alloy (UNS N08320) Rod

B622

Standard Specification for Seamless Nickel and Nickel-Cobalt Alloy Pipe and Tube

B625

Standard Specification for Nickel Alloy Plate and Sheet

B649

Standard Specification for Ni-Fe-Cr-Mo-Cu-N Low-Carbon Alloys (UNS N08925, UNS N08031, UNS N08034, UNS N08354, and UNS N08926), and Cr-Ni-Fe-N Low-Carbon Alloy (UNS R20033) Bar and Wire, and Ni-Cr-Fe-Mo-N Alloy (UNS N08936) Wire

B658

Standard Specification for Zirconium and Zirconium Alloy Seamless and Welded Pipe

B675

Standard Specification for UNS No8366 and UNS No8367 Welded Pipe

B688

Standard Specification for Chromium-Nickel-Molybdenum-Iron (UNS No8366 and UNS N08367) Plate, Sheet, and Strip

B690

Standard Specification for Iron-Nickel-Chromium-Molybdenum Alloys (UNS No8366 and UNS N08367) Seamless Pipe and Tube

B705

Standard Specification for Nickel-Alloy (UNS No6625 and N08825) Welded Pipe

B725

Standard Specification for Welded Nickel (UNS N02200Kjns N02201) and Nickel Copper Alloy (UNS N04400) Pipe

B729

Standard Specification for Seamless UNS N08020, UNS N08026, and UNS N08024 Nickel-Alloy Pipe and Tube

B804

Standard Specification for UNS No8367 Welded Pipe

 

“The content of this article is taken from web open source. The blogs are intended only to give technical knowledge to young engineers. Any engineering calculators, technical equations and write ups are only for reference and educational purpose.

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