Linepipe Materials

Dr. ir. Hermawan Judawisastra

hermawan.judawisastra@material.itb.ac.id

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Material Selection in Design

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Materials Science & Engineering

Chemical
Composition

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 Specification and Requirement
 Material Properties :
 Mechanical Properties (Strength, toughness,
ductility)
 Easy to fabrication (Weldability, adhesivity)

 Environmental Resistance (Corrosion, humidity,

UV etc)

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Specification and Requirement (cont’d)
 Steel pipe are manufactured to particular
specifications :
 Chemical composition
 Strength, hardness, impact, etc..

 Corrosion resistance*

 Weldability

 Tolerance

 The well-known spec. for pipeline = API 5L

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 Philosophy of Materials Selection
 The fundamental criteria for the selection of
material :
 Environmental resistance
 Mechanical properties
 Ease to fabrication and construction
 Maintainability/repairability
 Cost
 Availability

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 The basic information to evaluate
pipeline material selection
1) Maximum operating pressure
2) Preliminary determination diam. & wall thickness
3) Material strength requirements to contain pressure
4) Max & min design temperature
5) Method of production in special condition
6) Composition of gasses and fluids
7) Erosion problems (i.e. the presence of sand)
8) Corrosive media (i.e. H2S, CO2, O2, etc)
9) Other environmental condition (humidity, UV etc)
10) Design life of pipeline

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 Steel Selection for Corrosion
Resistance
1) Low Alloy
Steels
2) High Alloy
Steels

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 Steel Selection for Corrosion Resistance
(cont’d)
Low Alloy Steel
 Low alloy steel are used as materials of construction for pipelines
because of low cost, availability and ease of fabrication
 The most aggressive condition commonly encountered in pipeline
systems occur in presence of water and dissolved H2S and CO2.

 The characteristic of CO2 and H2S corrosion are different :

 CO2
 General weight loss with additional localized corrosion where water
collected.
 H 2S
 Doesn’t normally involve general weight loss, but rather, localized
corrosion in the form of stress corrosion cracking or hydrogen
induced cracks.
 General weight loss at T > 60 °C & partial pressure > 0.1 atm.

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 Steel Selection for Corrosion Resistance
(cont’d)
Low Alloy Steel
 Low alloy steel are used as materials of construction for pipelines
because of low cost, availability and ease of fabrication
 The most aggressive condition commonly encountered in pipeline
systems occur in presence of water and dissolved H2S and CO2.

 The characteristic of CO2 and H2S corrosion are different :

 CO2
 General weight loss with additional localized corrosion where water
collected.
 H 2S
 Doesn’t normally involve general weight loss, but rather, localized
corrosion in the form of stress corrosion cracking or hydrogen
induced cracks.
 General weight loss at T > 60 °C & partial pressure > 0.1 atm.

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 Steel Selection for Corrosion Resistance
(cont’d)
Low Alloy Steel
 Basis for low alloy steels
• Maximum hardness limitation
• Maximum nickel content of 1%
• Heat treatment condition
 Hydrogen induced cracking (HIC) is a further form of hydrogen
sulphide corrosion which may occur, especially in low alloy
material.
 Today, considered only to be a problem at partial pressure of
H2S over 0.05 psi when precaution against Stress Sulfide
Cracking (SSC) must be adopted.
 Precaution to minimize the risk of corrosion:
• Material composition control
• Specialized corrosion testing
• Compliance with NACE MR -01-75
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 Steel Selection for Corrosion
Resistance (cont’d)
High Alloy Steel
 A chloride containing environment, the final choice of
Corrosion Resistant Alloys (CRA) should be on the basis
of its resistance to pitting and crevice corrosion.
 This can be establish using the Pitting Resistance
Equivalent (PRE)

PRE  %C R  3.3%  M O  16  % N

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 Steel Selection for Corrosion
Resistance (cont’d)

Application of High Alloy Material

1) Duplex Stainless Steel
• Austenite : Ferrite = 50 : 50
• There are 2 types : one based on 22% chromium, and the other
based on 25% chromium (called super duplex stainless steel)
• 22 % chromium duplex stainless steel has a PRE = 34, resistant to
pitting up to 30 °C, but susceptible to crevice corrosion at lower
temperatures
• 25 % chromium super duplex stainless steel has a PRE > 34,
resistant to pitting & crevice corrosion up to T = 60 °C.

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 Steel Selection for Corrosion Resistance
(cont’d)
2) Austenitic Stainless Steel (typically 316 L)
• Excellent corrosion resistance to CO2 dan H2S
• PRE = 27
• At T > 60 °C, austenitic stainless steel are liable to
stress corrosion cracking by chloride.

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 Metallic Selection for Corrosion
Resistance (cont’d)
3) High Nickel Alloys
• Containing up to 25-65 % Ni
• No limitation are given for CO2 corrosion, whereas
H2S corrosion resistance is determine by nickel
content
• For nickel content of 25 – 52 %, temperature
limitation are 160 °C – 275 °C
• Incoloy alloy 825 & inconel alloy 625 are probably
most widely used in pipeline

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 Metallic Selection for Corrosion
Resistance (cont’d)
4) CRA Clad Carbon Steel
• Where high nickel alloys are selected, consideration
should be given to the use of clad materials due to
high cost of solid alloy pipes
• The use of duplex stainless steel clad pipes is
limited due to the difficulty in maintaining the
required duplex structure of the cladding during
heat treatment of carbon steel pipe following pipe
manufacture.

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Steel Selection for Yield Strength
Requirement

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 Steel Selection for Yield Strength
Requirement (cont’d)

Low Alloy Steels

• Yield Strength of 70 ksi are now feasible provide that
installation & operation condition are satisfied.
• Controlled rolled steels and normalized steel used additions
of Titanium, Vanadium, and/or Niobium to give enhanced
yield strength capability through precipitation hardening &
grain refinement
• Pipe grades up to X65, using controlled rolled steel &
normalized steels,

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 Steel Selection for Yield Strength
Requirement (cont’d)
Low Alloy Steels (con’t)
 For higher strength steel (i.e. X70 & X80) development have
been centered around the use of thermomechanical treatment
coupled with accelerated cooling
 These process have enabled the production of higher strength
steels with reduced quantities of alloying elements, in particular
with low carbon contents (less than 0.01%)
 For optimum strength/toughness combination, accelerated
cooling should be started around Ac3 transformation
temperature.

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 Steel Selection for Yield Strength
Requirement (cont’d)
High Alloy Steels
 Only duplex (austenitic/ferritic) stainless steel can
be used for high strength requirement
 Duplex stainless steel is normally supplied in the
following form solution annealed (typically at 1050
°C).
 High nickel stainless steels & austenitic stainless
steel have to be used in the clad form, as they have
limited yield strength used as internal cladding on
conventional high strength low alloy steel.

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 Steel Selection for Fracture
Control Design Requirement
• In large diameter pipe, fracture control must
consider not only base material but also weld seam
and Heat Affected Zone (HAZ)
• The principal demands placed on pipe materials for
gas transmission lines is that toughness properties
remain unimpaired by operating pressure and
circumferential stress
• Fracture mechanics has been constantly improved
and updated as research and testing have highlighted
the controlling parameters.

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Steel Selection for Fracture Control
Design Requirement (cont’d)
• This is true as long as welds and base material are
virtuals free from defects, the weld treating cycle has
not affected the transition temperature, and large stress
concentration factor don’t exist.
• For high strength ductile material, these condition
don’t exist, and more relevant fracture control criteria
have been developed.
• Full scale experiment have led to the development of
semi-empirical formulae for determining the critical
flaw size in pipelines

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Steel Selection for Fracture Control
Design Requirement (cont’d)
For fracture initiation, if the pipe material is ductile
with an establish minimum toughness level and the
crack go through wall. Formula is given by :

σ  π  R  AC
2
CV  H

E
Where :
CV = Charpy energy at 100% shear (ft/lbs)
σH = nominal hoop stress (ksi)
R = Pipe radius (inch)
AC = Cross sectional area of Charpy impact specimen (inch2)
E = Young’s modulus (103 ksi)

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 Steel Selection for Fracture Control
Design Requirement (cont’d)
• It has been long known that for very tough materials crack can
propagate over large distance in gas transmission pipelines.
• From semi-empirical formulae developed by the Batelle
Memorial Institute, correlation has made between Charpy
energy & the arrest of fracture propagation.
• Formula :
Where :
1
CV = Charpy energy required (ft/lbs)
C V  0.0873  σ  (R t )  A C
2
H
3
σH = nominal hoop stress (ksi)
R = Pipe radius (inch)
t = Wall thickness (inch)
AC = Cross sectional area of Charpy
impact specimen (inch2)

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Steel Selection Based on Weldability
 A pre-requisite of competent pipeline construction &
installation, which can often be undertaken in adverse
weather condition, is that the pipeline steels show good
weldability
 The following welding processes available for field welding in
the fixed position are of particular interest :
 Shield manual metal arc welding, using cellulosic electrodes
 Shield manual metal arc welding, using basing, low hydrogen
electrodes.
 Fully mechanised gas shielding arc welding

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Steel Selection Based on Weldability
(cont’d)
 Low Alloy Steels
 Field weldability of high strength low alloy steels is
greatly enhanced by the use of low carbon content :

 Mn   Cr  Mo  V   Cu  Ni 
CE  C     
 6   5   15 

 The higher value of Carbon equivalent (CE), the less

weldable the steel
 This formula was originally developed for higher carbon
steel (i.e. above 0.12 %) which achieved strength mainly
by carbon & manganese and by heat treatment

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Steel Selection Based on Weldability
(cont’d)
 Low Alloy Steels
 The quantitative statements given using this formula
to calculate weld hardenability can’t really be
considered accurate for modern large diameter pipe
steel with low carbon, vanadium, and nickel
addition.
 Equation (critical metal parameter ) should be
considered for determining if preheating is
necessary:
 Si   Cr  Cu  Cr   Mo   Ni   V 
Pcm  C               5B
 30   20   15   60   10 
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Steel Selection Based on Weldability
(cont’d)
 High Alloy Steels
 High alloy steels are weldable using:
a) Gas tungsten Arc Welding (GTAW)
b) Shielding Metal Arc Welding (SMAW)
c) Gas Metal Arc Welding (GMAW)
 Thermal conductivity of high alloy steels (e.g. duplex
stainless steel) = 1.5 carbon steel
 Problem of carbide precipitation & sigma phase
formation caused by heat retention, can lead to
enhanced susceptibility to corrosion & embrittlement

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Steel Selection Based on Weldability
(cont’d)
 High Alloy Steels
 A number of problems have emerged with the use of these
steel :
a) High construction cost associated with low productivity and
the GTAW process often used.
b) Very high girth weld repair rates when using the SMAW
process
c) Obtaining girth weld with mechanical & corrosion
properties ( particularly in the root & HAZ) which approach
those of base pipe.

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Steel Selection Based on Weldability
(cont’d)
 High Alloy Steels
 Duplex stainless steel has been used in a number of
offshore pipeline application
 Difficulty : Controlling the austenite & Ferrite
volume fractions in the weld metal & HAZ
 Solution : Careful selection of welding consumable is
required.
 Defect tolerance is also a problem with regard to
specifying existing codes.

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Steel Selection Based on Weldability
(cont’d)
 High Alloy Steels
 Microalloying with V and Nb to achieve a more fine
grained structure is used for strength classes up to
X60.
 Thermomechanically treated low-carbon steel is used
for strength classes X60 – X70 and above
 For strength above X70, quenched & tempered, or
in certain cases, TMCP steel may be used to obtain
necessary toughness while maintaining weldability

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 Non Metallic Pipe
 Thermoplastic (PE, PVC)
 Low friction
 Corrosion resistance
 Limited pressure and temperature
 Composite (Fiber Reinforced Plastic)
 Low friction
 Corrosion resistance
 Higher pressure resistance (up to 5000 psig)
 Limited temperature
 Low maintenance cost
 Ease of installation

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 Non Metallic Pipe
 Limitation of Thermoplastic Pipe
 Limited P and T
 PVC : T < 65 0C, Stress < 4 ksi
 PE : T < 40 0C, Stress < 625 psi

 Shall
be buried (to protect from sunlight, fire,
mechanical damage)
 Low resistance to vibration

 Low fire properties

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 Non Metallic Pipe
 Limitation of Fiberglass Reinforeced Plastic (FRP) Pipe
 Limited temperature, up to 70 C or rarely up to 150 C
 Not recommended for depressurized systems
 Sensitivity to environmental degradation shall be considered
(temp, humidity, UV, chemicals etc)
 Low fire properties
 Low resistance to vibration
 fitting?, NDT?

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 Linepipe Material Alternatives
 Carbon Steel
 Stainless Steel
 Duplex Stainless Steel
 Stainless Steel 304
 Stainless Steel – 316
 Nonferrous Alloy
 Cu - Ni Alloy
 Ni Alloy
 Aluminum - Magnesium Alloy
 Non-metallic Pipe
 Glass Fiber Reinforced Plastics
(GFRP)
 Carbon / Epoxy Composite
 High Density Polyethylene (HDPE)
 Internally Clad Pipe, Carbon Steel Outer
Material
 304L SS - Carbon Steel Clad Pipe
 316L SS - Carbon Steel Clad Pipe
 Duplex SS - Carbon Steel Clad Pipe
 CuNi Alloy - Carbon Steel Clad Pipe
 Internally Coated Carbon Steel
 Fusion Bonded Epoxy (FBE) Coating
 Coal Tar Epoxy Coating
 Ceramic Epoxy Coating
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 Carbon Steel

Material Type Carbon Steel

Serviceable under a wide variety of conditions and

especially adaptable to low-cost techniques of mass
production.
Ease of fabrication
adequate strength
Advantages
excellent finishing characteristics to provide
attractive appearance after fabrication
compatibility with other materials and with various
coatings and processes.
Not expensive
Susceptible to Chemical reaction
Disadvantages
Low corrosion resistance

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 Stainless Steel
Stainless steel type:
 Duplex Stainless Steel
 Stainless Steel 304
 Stainless Steel – 316

Material Type Duplex Stainless Steel
Excelent Corrosion Resistance
High Strength
Advantages Weldable by all standard methods
Better stress-corrosion cracking
resistance
Disadvantages Expensive
Stainless Steel 304 Stainless Steel 316
Excellent in a wide range of Excellent in a range of
atmospheric environments atmospheric environments and
and many corrosive media. many corrosive media -
generally more resistant than
Excellent forming 304.
Susceptible to stress cracking Susceptible to stress cracking
Susceptible to sensitisation
Has lower stiffness compared (grain boundary carbide
to Polypropylene precipitation) when heated
until 425-860 0C
High mould shrinkage and Cannot be hardened by
poor UV resistance thermal treatment.

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 Nonferrous Alloy
Cu – Ni alloy type: Ni alloy type:
 90Cu - 10Ni – 70Ni – 30Cu
 80Cu - 20Ni – Inconel
– Aluminum - Magnesium Alloy
 70Cu - 30Ni
Aluminum -
Material
90Cu - 10Ni 80Cu - 20Ni 70Cu - 30Ni 70Ni - 30Cu Inconel Magnesium
Type
Alloy
excellent corrosion excellent
excellent electrical and thermal conductivities,
resistance in mechanical typically
outstanding resistance to corrosion, ease of
reducing chemical properties and displays
fabrication, and good strength and fatigue
environments and in presents the excellent
resistance . Can be readily soldered and
Advantag sea water desirable electrical and
brazed. Can be welded by various gas, arc,
es excellent ductility and combination of high thermal
and resistance methods. Can be plated,
can be readily strength and good conductivity,
coated with organic substances, or chemically
fabricated and workability.
colored to further extend the variety of
formed into a variety Good resistance to
available finishes. Low density
of shapes. corrosion and heat
Expensive
Lower strength
Disadvan sometimes have limited usefulness in certain environments because
Very expensive than
tages of hydrogen embrittlement or stress-corrosion cracking (SCC).
ferousbased
Metal 40
 Non-Metallic Pipe
Non-Metallic type:
 Glass Fiber Reinforced Plastics (GFRP)
 Carbon / Epoxy Composite
 High Density Polyethylene (HDPE)

GFRP
Material Aliphatic Anhydiride Aromatic Carbon / Epoxy
HDPE
Type Amine Cured Cured Amine Cured Composite
Epoxy Epoxy Epoxy
Corrosion Control - Resists corrosion Good mechanical Good low temperature impact
caused by CO2, H2S and salt water properties resistance
Advantag Reduced cost of the piping and reduced Good chemical
Excellent chemical resistance
es maintenance costs resistance
Lowest shrinkage Exceptional resistance to rapid-
Reduced weight on the platform deck
(highest stability). crack propagation
May react with oxygen and strong
Disadvan
Low performance in high temperature Expensive oxidizing agents, such as chlorates,
tages
nitrates, peroxides, etc.

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Internally Clad Pipe, Carbon Steel Outer Material

Internally Clad type:

 304L SS - Carbon Steel Clad Pipe
 316L SS - Carbon Steel Clad Pipe
 Duplex SS - Carbon Steel Clad Pipe
 CuNi Alloy - Carbon Steel Clad
Pipe
304L SS - 316L SS - Duplex SS - CuNi Alloy -
Material Type
Carbon Steel Carbon Steel Carbon Steel Carbon Steel
Advantages Combining the features of metallurgical & mechanical
Expensive
Disadvantages
Need High Level on joining

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 Internally Coated Carbon Steel
 Fusion Bonded Epoxy (FBE) Coating
 Coal Tar Epoxy Coating
 Ceramic Epoxy Coating

Material
FBE Coating Coal Tar Epoxy Coating Ceramic Epoxy Coating
Type
Holiday (pinhole) testing per applicable
Suitable for intermittent exposure to ASTM, NACE, And SSPC Industry
ease of application,
300°F standards
Can be applied to the bell and spigot of
less waste of
Excellent chemical resistance ductile iron pipe for total "Wet Area"
material,
protection
Advantages
Field repairs are completed with the same
rapid application, Excellent adhesion product as is applied at the factory, not
coal tar epoxy or "Pipe Joint Compound
cure schedules, which Can be stored outside indefinitely without
Convenient 2A to 3B mix ratio by
means faster disbondment from the substrate (some
volume
production rates. chalking will occur)

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Internally Coated Carbon Steel (cont’d)
 Fusion Bonded Epoxy (FBE) Coating
 Coal Tar Epoxy Coating
 Ceramic Epoxy Coating

Material Type FBE Coating Coal Tar Epoxy Coating Ceramic Epoxy Coating
Excellent abrasion resistance (Alpha
Finished coated High build to 40 mils per coat Phase alumina ceramics - Hardness just
pieces can be below s diamond)
moved to the
Advantages storage area 100% solids, 0.0 lbs. VOC
Superior bonding to the substrate (three
within minutes Sprayable, Tough and flexible times that of any other ceramic epoxy or
after the polyethylene product)
application Moisture insensitive and Low
temperature curing
Do not use below 40°F
Store material under dry conditions
Disadvantages
For best results, applied condition
material to 70°F or higher.

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Terimakasih

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