MATERIAL SELECTION

&
SPECIFICATION
Umesh Mondal
December 2021
 Topic content
1. Safety Topic
2. Introduction of Material Selection
3. Process Factors to Consider for selecting Pipe Material
4. Mechanical Factors Affecting Selection of Pipe Material
5. Reference Code/Standard of Piping Material Selection
6. ASTM – American Society for Testing and Materials
7. Classification of Piping Materials
8. Commonly Used Piping Materials for Process Piping
9. Qualification of Materials
10. Piping Material Specification

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 DIET and Exercise Tips
• While Winter Season might increase risk for weather related injury, the biggest risk for our overall health is lack of attention to diet and exercise Routines
• During the Holidays , we find ourselves busy finalizing Travel Plans, Finishing Up with Tasks at work , Buying Wrapping gifts . We Often forget to prioritize our healthy habits

• LET’S HAVE A LOOK AT WHAT DO WE NEED TO DO INORDER TO MAINTAIN A HEALTHY DIET

• Calm Your Carb Cravings
Cold season tends to ignite our cravings for more carbs and comfort foods , Why?
After consumption of these foods your serotonin level rises making your brain think you are happy
to counter this, add protein packed breakfast to keep your energy levels up for the day.
By the time, the afternoon rolls around you’re still craving sweets or carbs.
Be sure to have low fat and healthy snacks to minimize sweet or carbs cravings

• Add Omega 3 Fatty Acids

They include fish , nuts and Plant Seeds
Great for reducing joint pain and stiffness as they are a natural anti-inflammatory foods
which help reduce levels of depression which people commonly feel during shorter days of winter

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• Eat More Fibers
Soluble Fiber found in apples , oats and nuts is an
important way to decrease inflammation and boost immune system Function
Helps reduce Cholesterol Levels in body and aids in weight loss
Protection against diabetes
• COOK with Spices
It goes without saying Indian food already has many spices in them.
They make food taste great, but they are also known to improve immune function
• Eat Greener and Orange Vegetables
Important in ensuring you are getting healthy nutrients

Last but not the least plan a week’s exercise in advance

(consisting of different workouts)so that they don’t get
monotonous and help keep you fit during the winter
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 Introduction to Material Selection

Appropriate material selection is the cornerstone of

pressure equipment and piping design. The primary
objective in materials selection is the achievement of
metallurgical stability to prevent failure resulting from
the environment, normal operation time exposure and
upset conditions. The secondary objective is the
economy for achievement of the design life by the use
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of appropriate construction materials.

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 Introduction to Material Selection

Flow Chart of Pipe material selection

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PROCESS FACTOR TO CONSIDER FOR SELECTING PIPE MATERIAL

• Fluid Being Transported

• Temperature & Pressure of Fluid Passing
Through
• Design Life
• The Cost of the Material & Availability
• Environmental conditions
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• Ease of Maintenance

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MECHANICAL FACTORS AFFECTING SELECTION OF PIPING MATERIALS

• Ultimate Tensile Strength

• Yield Strength
• Elasticity
• % Elongation
• Hardness
• Toughness 8

• Creep resistance
• Fatigue Resistance

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REFERENCE CODE/STANDARD OF PIPING MATERIALS SELECTION

• ASME- American Society for Mechanical Engineers

• ASTM-American Society for Testing & Materials
• API- American Petroleum Institute
• NACE- National Association of Corrosion Engineers
• MSS - Manufacturers Standardization Society
• ASM- American Society for Metals
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• AWS-American Welding Society

• TEMA- Tubular Exchanger Manufactures Association

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 ASTM – AMERICAN SOCIETY FOR TESTING AND MATERIALS

Most widely used standard specification for steel products in the

United States
• Specifications starting with “A” are for steel.
• Specifications starting with “B” are for non-ferrous alloys (bronze, brass,
copper nickel alloys, aluminum alloys and so on).
• Specifications starting with “D” are for plastic material, as PVC.
Grade A, B and C
• Grade A, being a softer steel, which is easier to bend.
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• Grade B has higher tensile and yield strength than Grade A. It has higher
stress values and is better suited for machining operations.
• Grade C has higher tensile and yield strength than Grades A and B.

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 ASTM – AMERICAN SOCIETY FOR TESTING AND MATERIALS

The Requirements of an ASTM specification cover the following:

• Chemical requirements (the significant chemicals used in the production

and the volumes).
• Mechanical requirements (yield, tensile strength, elongation, hardness).
• Method of manufacture.
• Heat treatment.
• Weld repairs.
• Tolerances. 11

• Certification.
• Markings.
• Supplementary notes.

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 ASTM – AMERICAN SOCIETY FOR TESTING AND MATERIALS

Commonly Used ASTM Specifications

• A53/A53M-02. Standard specification for pipe—steel, black and hot-dipped, zinc-coated,
welded, and seamless.
• A105/A105M-02. Standard specification for carbon steel forgings for piping applications.
• A106-02 Standard specification for seamless carbon steel pipe for high-temperature service.
• A181/A181M-01. Standard specification for carbon steel forgings, for general-purpose piping.
• A312/A312M-03. Standard specification for seamless and welded austenitic stainless-steel
pipes.
• A333/A333M-99. Standard specification for seamless and welded steel pipe for low-
temperature service. 12

• A358/A358M-01. Standard specification for electric-fusion-welded austenitic chromium-nickel

alloy steel pipe for high-temperature service.
• A671-96(2001). Standard specification for electric-fusion-welded steel pipe for atmospheric
and lower temperatures.

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CLASSIFICATION OF PIPING MATERIALS

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COMMONLY USED PIPING MATERIALS for PROCESS PIPING

• Ferrous Metal - Carbon Steel, Alloy Steel, Stainless Steel

• Non-Ferrous Metal - Copper/Copper Alloys, Nickel/Nickel Alloys,

Aluminum/Aluminum Alloys, Titanium/Titanium Alloys

• Non-Metal - PVC/CPVC, HDPE, GRE/GRP, Cement pipes

• Lined Pipe - lined material: PTFE, Rubber, Glass, FRP (Fiber reinforced
plastic) 14

• Clad Pipe – Clad material: Duplex, Nickel Alloy etc.

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 FERROUS MATERIAL – CARBON STEEL

Classification of Carbon Steel

Based on carbon %, steel can further classify as
• Low carbon steel : Carbon content less than 0.3%
• Medium Carbon Steel : Carbon content in the range of 0.3 – 0.6%
• High Carbon Steel: Carbon content 0.6 – 1.4%

Characteristics
• Tensile strength reduces at higher temperatures.
• At low temperature (< -18°F/-28°C), the material becomes brittle.
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• Low Carbon steel (LTCS) is suited for a low temperature of -46°C.

• Above 800°F/425°C, the strength decreases and creep decreases.
• Alloy steels are recommended for temperatures > 800°F/425°C.
• Poor against most acids, alkalis and salts.

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 FERROUS MATERIAL – CARBON STEEL

• Killed Carbon Steel Pipes

General chemical composition of Carbon Steel is C - 0.07- 1.56 %, Mn – 1.6 %,

Si – 0.6 %, S – 0.1%, P – 0.1%.

Applications
• Non-corrosive piping system (fresh water, plant air, nitrogen, fuel gas, etc)
• Temperature ranges from -18°F/-28°C to around 800°F/425°C.
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Commonly use CS material grades in Process piping.

• For Pipes: ASTM A53 Gr A/B, A106 Gr. A/B/C, API 5L Gr B
• For Forged Product: ASTM A105, A350 Gr LF1/LF2, A181

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 FERROUS MATERIAL – ALLOY STEEL

Alloy Steel
• To add various metallic and non-metallic elements in a specific
amount to carbon steel, it will change the properties of carbon
steel.
• We can manipulate these percentages of alloying elements in steel
to achieve better property than plain carbon steel.

Alloy steel can further classify as

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Low alloy steels: in which the sum of total Alloying elements is < 5%
High alloy steels: in which sum of total Alloying elements is > 5%

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 FERROUS MATERIAL – ALLOY STEEL

Alloying Elements Effect on the Properties

Chromium Increases Resistance to corrosion and oxidation. Increases hardenability and wear
resistance. Increases high temperature strength.
Nickel Increases hardenability. Improves toughness. Increases impact strength at low
temperatures.
Molybdenum Increases hardenability, high temperature hardness, and wear resistance.
Enhances the effects of other alloying elements. Eliminate temper brittleness in
steels. Increases high temperature strength.
Manganese Increases hardenability. Combines with sulfur to reduce its adverse effects.
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Vanadium Increases hardenability, high temperature hardness, and wear resistance.
Improves fatigue resistance.
Titanium Strongest carbide former. Added to stainless steel to prevent precipitation of
chromium carbide.
Silicon Removes oxygen in steel making. Improves toughness. Increases hardness ability

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 FERROUS MATERIAL – ALLOY STEEL

Alloying Elements Effect on the Properties

Boron Increases hardenability. Produces fine grain size.
Aluminum Forms nitride in nitriding steels. Produces fine grain size in casting. Removes
oxygen in steel melting.
Cobalt Increases heat and wear resistance.
Tungsten Increases hardness at elevated temperatures. Refines grain size.

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 FERROUS MATERIAL – ALLOY STEEL

Role of alloying elements

Depending on the quantities of alloying elements following properties of
material get affected such as
• Corrosion resistance
• Hardenability
• Machinability
• High or low-temperature Stability
• Ductility
• Toughness 20

• Better Wear resistance

• Improved Weldability

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 FERROUS MATERIAL – ALLOY STEEL

Use of Alloy Steel

Alloy steel can be used in a process area where carbon steel has limitation
such as
• High-temperature services such as Heater tubes
• Low-temperature services such as Cryogenic application
• Very High presser service such as Steam Header

Here you can see the common alloy steel grade that you will come across.
For Pipes: ASTM A335 Gr P1, P5, P11, P9
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For Forged Fittings: ASTM A182 F5, F9, F11 etc.

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 FERROUS MATERIAL – STAINLESS STEEL

• After carbon steel, Stainless Steel is the second most widely used material
in Process industries because of its excellent corrosion resistance property.
• Stainless steel must contain at least 10.5% chromium and maximum carbon
content of less than 1.20%.
• Posses greater percentage of chromium which forms a chromium oxide film
exposed to air that prevents chemical attack of moist air on the material
surface
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Types of Stainless Steel

Based on microstructure SS can be classified as
Austenitic Stainless Steel, Ferritic Stainless Steel, Martensitic Stainless Steel,
Precipitation Hardened Stainless Steel, Duplex/ Super Duplex Stainless Steel

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 FERROUS MATERIAL – STAINLESS STEEL

Austenitic stainless steel (200-300 series)

• Austenitic stainless steel is non-magnetic in nature and has very high
corrosion resistance.
• High Corrosion resistance at temp up to 1500°F.
• Hardenable by cold working.
• Very easy to weld
• Crystallographic form –FCC (fine grain structure).
• Possess high impact strength at low temp.
• These types of SS are widely used in the process industry and a variety of
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industrial applications, cookwares are also manufactured from Austenitic

stainless steel.
• Type 304, 304L, 316, 316L are some of the examples of Austenitic stainless
steel.

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 FERROUS MATERIAL – STAINLESS STEEL

Ferritic stainless steel (400 series)

• Ferritic stainless steel is magnetic and contains high carbon, therefore it is
brittle and relatively poor corrosion resistance than austenitic SS.
• Non-hardenable by heat treatment.
• Body-centered cubic -BCC (coarse grain structure).
• Ferritic stainless steel has a high resistance to chloride stress corrosion
cracking, so it is used in marine, petrochemical, heat exchangers,
furnace application, where high chloride content is there.
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• Type 409, 430, 439 are examples of Ferritic stainless steel.

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 FERROUS MATERIAL – STAINLESS STEEL

Duplex / Super Duplex stainless steel

• Duplex and Super Duplex stainless steel contain both Austenite and Ferrite
in the microstructure
• Offers benefits of both Austenite & Ferrite stainless steel
• Good resistance to pitting and crevice corrosion.
• High strength and high resistance to stress corrosion cracking.
• Very easy to weld
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• Used in the seawater system, heat exchanger, and structural application
• ASTM A790 (UNS S31803), ASTM A815 UNS S31803, ASTM A182 Gr.F51 are
examples of Duplex and Super Duplex stainless steel

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 FERROUS MATERIAL – STAINLESS STEEL

Martensitic stainless steel (400 series)

• First stainless steels developed because of the inability to obtain low
carbon steel
• Martensitic stainless steel has high hardness and poor corrosion resistance
than austenitic SS.
• Heat treatable to high hardness level.
• Crystallographic form-distorted structure.
• Hard to impossible to weld 26

• Martensitic stainless steel is usually used for non-welded components such

as forged parts in compressors or as seamless threaded pipe for downhole
production/injection tubing.
• Type 410,420 are examples of Martensitic stainless steel.
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 NON-FERROUS MATERIAL

Non-Ferrous Material
• Non-ferrous materials are a small part of the total piping materials, and
they are used in a very aggressive environment. Non-ferrous material
contains no iron or in a very insignificant amount.
• These materials are more expensive than ferrous metals. Some of the non-
ferrous material used in Process Industries are listed below. The non-
ferrous materials are also known as exotic material.
i. Nickel and Nickel Alloys
ii. Copper and Copper Alloys 27

iii. Aluminum and Aluminum Alloys

iv. Titanium and Titanium Alloys
v. Zirconium and Zirconium Alloys

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 NON-FERROUS MATERIAL (Continue…)

Nickel and Nickel Alloys

• Good resistance to oxidation and corrosion
• Monel 400, Inconel and Hastelloy are a well-known example of nickel
alloys
• These alloys are used in piping systems, pressure vessel, turbine blades,
valves, and power plant accessories that handle steam at very high
pressure and temperature
• Nickel alloys are frequently used as a cladding material with carbon steel
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 NON-FERROUS MATERIAL (Continue…)

Copper and Copper Alloys

• Good thermal conductivity and good corrosion resistance
• Brasses, Bronzes (Cu-Sn) and Cupronickels (Cu-Ni) are some of the
examples of the copper alloy
• Cupronickels have the highest corrosion resistance among Cu alloys
• Cupronickels are used for heat exchanger tubing and seawater application
• It can be used as a cladding material with carbon steel in heat exchanger
tube sheets. 29

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 NON-FERROUS MATERIAL (Continue…)

Aluminum and Aluminum Alloys

• Good thermal conductivity
• It is most workable metal
• Highly resistant to atmospheric conditions
• But When coupled with more noble materials it is subject to galvanic attack
• And Loses strength rapidly above 175°C
• Aluminum and Aluminum Alloys rarely used in process piping
• However, it is used as an external cladding material to protect the
insulation from water ingress. 30

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 NON-FERROUS MATERIAL (Continue…)

Titanium and Titanium Alloys

• High strength to weight ratio
• Similar to SS, Titanium Oxide is formed on the surface which prevents
corrosion
• Titanium and Titanium Alloys has resistant to nitric acid, which is very
corrosive in nature. Hence, it is used in this kind of process environments.
• Weld Titanium and Titanium Alloys, the inert atmosphere is required.
• It starts losing its strength above 400°C
• Titanium is also used as a clade material with carbon steel to reduce the
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cost of equipment

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 NON-METALLIC

• Non-metallic materials are used in non-critical services such as water

and drainage, where operating pressure and temperature are not
significant. In this lecture, I will give you an overview of these materials.
• Commonly used non-metallic piping materials are
i. PVC / CPVC
ii. HDPE
iii. GRE/GRP
iv. Cement pipes
• These non-metallic materials offer some great advantages over metallic
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piping but also have some limitations. They are resistant to chemical
attack but poor in strength.

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 NON-METALLIC (Continue…)

PVC / CPVC Pipes

• PVC and CPVC are tough and exceptionally resistant to chemical attack
• PVC and CPVC required protection from ultraviolet exposure if installed
outdoor and start softening when subjected to high temperature.
• PVC has many applications in industries and it’s also used in home water
piping.
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 NON-METALLIC (Continue…)

PE/HDPE Pipes
• High-Density Polyethylene has many desirable qualities over LDPE and
PVC
• It has improved tensile strength & low-temperature brittleness
• Higher softening point & chemical resistance
• It is widely used in water distribution and low-pressure natural gas
services 34

• It also used as lined material with carbon steel pipe

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 NON-METALLIC (Continue…)

GRE/GRP Pipes
• GRE/GRP pipes are getting popularity in seawater and sewage transport
applications.
• These pipes offer excellent corrosion resistance property over all other
types of pipes.
• GRP is used in Water supply application, Wastewater / Sewerage
collection and seawater transport application
• GRE pipes are used in the offshore platform and water treatment plant
to handle salty water. 35

• Due to excellent chemical and corrosion resistance, it also used as a

lining material in sewage effluent tanks

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 NON-METALLIC (Continue…)

Cement Pipes
• Cement Pipes are not used for any process application. However, it is
used in a processing facility for various other purposes
• Cement pipes are manufactured from reinforced or non-reinforced
concrete
• They mainly used in stormwater, Industrial waste and gravity services
• They also used in culverts and irrigation application

• Some non-reinforced concrete pipe material specifications are ASTM

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C14, AASHO M86, ASTM C412, etc.

• Non-reinforced pipe sizes vary from 12” to 24”
• Some reinforced concrete pipe material specifications are ASTM C76,
AASHO M170, SS-P-375, etc.

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 CLAD PIPING

• The lined pipe has a Mechanical bonding between pipe and line
material.

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 LINED PIPING (Continue…)

Advantages of Lined Pipe

• A lined pipe can withstand in tough chemical environments
• Also offer an abrasion-resistant property with hard-lined material
• It is a cost-effective solution for non-critical services

Disadvantages of Lined pipe

• Lined Pipe has a limitation of non-metal such as it cannot be used in
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high temperature and pressure services

• The lined pipe is manufactured in small length pipe spools hence, large
no of flange joints in line, which increased maintenance costs and
chances of leakages.

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 CLAD PIPING

• A clad pipe has a Metallurgical bond between pipe and cladding

material

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 CLAD PIPING (Continue…)

Base Material of Pipes:

ASTM A53 B, A106 Gr. B, API 5L, ASTM A333

Lining Material: UNS S31703, S31803, S30400, S30403, S31600, S31603,

S32100, N08904, N08825, N06600, N04400
Nonferrous metal such as Titanium, Copper, Aluminum, etc

Line pipe WT: 0.5~6mm

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 CLAD PIPING (Continue…)

Advantages of Clad Pipe

• Clad carbon steel can withstand tough chemical environments.
• A clad pipe can be used in high temperature and pressure services
• It is cost effective for critical services as carbon steel can be used with a
cladding of exotic materials.

Disadvantages of Clad pipe

• Fabrication of clad material is difficult, a special skill required for
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welding
• Clad pipes are costly compared to lined pipe

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 QUALIFICATION OF MATERIALS

Qualified materials shall fulfil the following requirements:

• The material is listed by the relevant design code for use within the stated
design requirements.
• The material is standardized by recognized national and international
standardization bodies.
• The material is readily available in the market and stocked by relevant
dealers.
• The material is readily weldable, if welding is relevant, and known by
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potential fabricators.
• The material has a past experience record for the applicable use, e.g. same
type of component and dimensional range.

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PIPING MATERIAL SPECIFICATION

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 What is a Piping Material Specification (PMS)?

• Piping Material Specification (Pipe Spec, in abbr.) is the most

important piping documents for a project that is prepared during
the design phase of any project. They provide all the basic
guidelines that need to be followed while proceeding in the
design of the project.
• PMS provides the appropriate selection, Specification and
Material Grade of Pipe and Piping components for a given
service. 44

• For all subsequent maintenance and repair on a section of pipe,

the piping specification remains as the key to correct material
selection.

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 Basis of Piping Material Specification

The piping material engineer will need the following information:

• List of all commodities like the feed, all products, all waste streams, all
utilities, and all additives that are part of the project.
• Complete chemistry of each commodity which includes Toxic
classifications and reactions to changes in temperature.
• Maximum sustained operating pressure and temperature of every
commodity. Also, Any short term or upset condition that may cause an
increase or decrease in pressure or temperature.
• Corrosion rate for different pipe materials when in touch with the above
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commodities.
• Expected maximum and minimum pipe size (Nominal Bore) for the
project.
• Jobsite Location with environmental conditions.
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 Design Criteria of Piping Material Specification

• Design Pressure
• Design Temperature
• Minimum Wall Thickness
• Fittings
• Flange Types & Flange Facing
• Gasket & Bolting 46

• Branch Connection Chart

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 What is a Material Specification?

Why did Specification require?

• It allows a purchaser to include special requirements as per
design and service conditions.
• It also allows customization of the product.
• Please note requirement in the specification is Must meet
requirements.
• Normally, oil & gas facilities generate their own specification
during the FEED stage that is front-end engineering and design
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or sometimes uses readily available specifications from well-

established companies such as Shell, Bechtel, EIL, and chevron.

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 FEATURES OF A MATERIAL SPECIFICATION

• Material of construction, end construction, end

connections and wall thicknesses for various ranges
• Individual line class of the piping materials
• Codes and standards relevant to the pipes and
fittings of the specified material class
• Line class coding system
• Pressure-Temperature ratings for various fittings and
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limiting sizes of fittings

• Other general notes and design criteria as applicable
to the material class
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Q & A……

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