CONSTRUCTION

MATERIALS FOR
PRESSURE VESSELS

By
N Velliyangiri (LEMF)
Agenda

General Considerations
Material Classification Based on Service
Non Corrosive Service
Corrosive Service
Stainless Steels
Hydrogen Attack
Overview of Common Materials
General Considerations

Corrosion resistance
Strength requirements
Cost
Fabricability
Quality of future maintenance
Availability
 Material Classification
Non Corrosive service
C ryo ge n ic Te m p era tu re
(-2 5 0 - -1 0 0 °C )
In te rm e d ia te T e m p e ra tu re
(0 - 4 25 °C )
C o ns truc tion M a teria ls
( D e pe n d in g o n S erv ic e)
Corrosive Service
L o w T e m p e ra tu re
(-1 0 0 - 0 °C ) C o rro sio n R e s is ta nt P ro te c tive L in ing
M a te rial
E le va te d T e m p e ra tu re
(4 2 5 °C a n d a bo ve ) In te gra lly a p p lid ed S trip o r sh e et
C la dd ing C la dd in g
W e ld O v e rla y
C la d ing
Cryogenic Temperatures (-250 to -100 °C)

CS and LAS are brittle, Posses sharp Transition temp

Austenitic stainless steels or nonferrous metals like
aluminum alloys can be employed here as they
exhibit no loss in the impact strength

FCC Materials

BCC Materials
Absorbed
Energy

Temperature
Low Temperatures (-100°C to 0 °C)

Here Low Alloy Steels and fine grain Carbon

Steels (ASTM above 5) are employed

Intermediate Temperatures (0 °C to 425 °C)

Here Low Carbon Steels are employed due to

their elastic behavior below 425 °C
Elevated Temperatures (Above 425 °C)

The steels begin to exhibit a drop in UTS & YS

and cease its elastic nature and starts
becoming plastic in nature
Under Constant load continues increase in
permanent deformation - Creep
So coarse grained structure is preferred for
superior creep – rupture strength.
Non-Corrosive Service – Summary
 Carbon Steels (-30 – 425 °C )
• Below 350 °C , strength of CS varies as carbon content varies.
 But all have similar properties in creep range
 CS are easy to fabricate and are economical compared to alloy
steels, as the alloying elements increases the cost of material and
the difficulties in fabrication increases
• With an internal refractory lining, thick enough to keep the wall
temp below 425 °C , CS can be used at elevated temp. applications
Non-Corrosive Service – Summary….

Carbon Steels….
Material Grade Grain Size UTS YS Temp. Range
(Ksi) (Ksi)

SA515 60 Coarse 60 to 80 32 0
65 Coarse 65 to 85 35 to
70 Coarse 70 to 90 38 420°C

55 Fine 55 to 75 30 -30
SA516 60 Fine 60 to 80 32 to
65 Fine 65 to 85 35 420°C
70 Fine 70 to 90 38
Non-Corrosive Service – Summary….
 Low and intermediate Cr-Mo alloy steels
•-150 – 600 °C
•Resistance to graphitization and hydrogen attack
•High creep-rupture strength at high temperatures
•Over 345°C it is economical
 Stainless Steel (-250 – 815 °C )
 Special high temperature resisting alloys
•Above 815 °C
•SA240 TP310 and Incoloy
 Material for Non - Corrosive Service

Application Temp. Range Suitable Materials Remarks

Cryogenic -250 - -195 SA 240 TP 304, 304 L, 347 SS

Temp -199 - -100 SA 240 TP 304, 304 L, 316, 316 L SS
SA 353 9 Ni

Low -100 - 60 SA 203 Gr C, D 3.5 Ni

Temp -60 - -45 SA 203 Gr A, B 2.5 Ni
-45 - 0 SA 516 CS

Intermediate 0 - 16 SA 285 Gr C CS
Temp SA 515 CS
16 - 410 SA 285 Gr C CS
SA 515, SA 516 CS

Elevated 410 - 470 SA 204 Gr B, C C - 0.5 Mo

Temp 470 - 540 SA 387 Gr 11, 12, Cl 1 Cr - 0.5 Mo
540 - 600 SA 387 Gr 22, Cl 1 2.25Cr - 1Mo
600 - 815 SA 240 TP 304, 316, 321, 347 SS
Above 815 TP 310 SS
Incoloy Ni
Corrosive Service
Here corrosion resistant material has to be
employed else protective lining has to be done
on the base material
For up to 10mm thick vessel shells SS plate is
economical to use and above that CS or LAS
shells with applied corrosion resistant layer (of
SS) are used i.e. Cladding
3 methods are employed for attaching the
protective layer:
1. Integrally Applied Cladding

Fabricated in steel mills by hot rolling of

assemblies of CS or LAS plates (backing) &
corrosion resistant sheet (liner)
At high temp. the pressure creates a solid-
phase weld between the backing and cladding
metals
2. Strip or Sheet Lining
In strip lining, strips of 3-5 ft. long and 3-6 in.
width are attached to the shell by continuous
weld around edges
In sheet type lining, sheets of several ft in
width and length is tightly attached to the
shell wall by resistance spot or seam welds on
a standard square spacing
3. Weld Overlay Cladding
Welding process in which a material with
desired properties is deposited on the surface
of base material i.e. continuous bonded layer
of corrosion resistance
From SMAW to ESSC can be employed
Stainless Steel
Stainless Steel

Alloy of Cr and Fe (Cr: 11-30%)

Advantages

• Corrosion Resistance – Increase the life and safety

• Strength at elevated Temp.

• Oxidation Resistance at elevated Temp.

• High Impact strength at Cryogenic Temp.

Properties
Retains Strength at elevated Temperature (Above 600°C)
Higher Stress relieving Temp and Long Holding time

Barrier Layer
Formation of un reactive Cr Oxide film with 10 – 100 atom thick

Pickling & Passivation

 Removing surface contamination by Acids
 Artificial Oxide film by strong Oxidizing agent like HNO3
Sensitization
At high temp Carbon molecules diffuse to the
grain boundaries

Precipitates as Cr4C – depletion of Cr

Corrosion at grain boundaries –

Intergranular Corrosion

Poor Cr envelope is anodic with respect to rest

of grain – Galvanic Corrosion
 Classification
Stainless Steel
Depending on Alloying E lem ents

Straight Cr Group Cr - Ni Group Cr-Ni-Mn Group

Cr upto 30% Cr-18,Ni-8 P ortion of Ni is replaced by Mn
400 Series Cr,N i>23% 200 Series
300 Series

Stain less Steel

D e p en d ing o n M icro structu re

A u stinitic StainlessSteel Ferritic Stain less Steel M artensitic Stainless Steel D up lex Stain less steel Pricipitation H ard en ing SS
N o n h ard e na b le , No n Ma gn e tic N o n h ard e na b le , M a g ne tic H a rde n ab le , M a gn e tic N o n H a rde n ab le , M a gn e tic H a rde n ab le , M a gn e tic
3 0 0 S e ries, 20 0 Se ries 4 0 0 S eries 4 0 0 Se ries M a rte n site w ith m icro p ricip ita tes
% C - 1 7 % C r > 12 % C - 1 7 % C r < 12
Austenitic Stainless Steel
Formation:
• Solution Annealing above 1000°C

• Austenite is a powerful Solvent

• Cr, Ni, C dissolved in Austenite matrix

• To retain microstructure Cooled rapidly to 425°C

• Corrosion Resistance, Ductility, Strength are Max

425 – 870˚C - Sensitization

• 3-6 mm Band away from and parallel to weld
Austenitic Stainless Steel- Classification

Au stin itic S tain less S teel

D e p en d ing o n th e P o ss ib ility of S e ns itiza tion

Gr I G r II G r III
C a n be A ffe cted Im m u na ted R o o t is E lim in a ted
C a n b e cu re d 3 21 ,3 47 3 04 L, 3 1 6L
3 04 , 3 1 6 , 3 0 9 ,3 10
Austenitic Stainless Steel- Group I

Sensitization may be encountered by

Welding/Flame cutting

Cure (Desensitization) – Full Solution Annealing

• Heating above 870° C to dissolve carbide
• Rapid cooling- Introduce Residual Stresses
• Stress Relieving at 425°C

Operating Temperature stay below 425 °C

Austenitic Stainless Steel- Group II
Alloying elements like Ti, Cb have higher affinity to
carbon than Cr

They form carbides in preference to Cr

These carbides dispersed through metal

Can be sensitized by heating above 1220 °C and cooling

rapidly - Knife line attack

Operating temperature above 425°C

347(Cb) is superior than 321(Ti)

Austenitic Stainless Steel- Group III
Extra low carbon grades (<=0.03%) like 304L, 316L

Low carbon – Low strength

Re sensitized if temp remains 425 - 815°C for

prolonged period of time

Limited up to 425°C

Expensive because of difficulty and cost of removing

of carbon
Ferritic Stainless Steel
No general transformation from austenitic to
martensite – Non hardenable

Brittle in heat affected zone because of Rapid

grain growth

Sensitized by heating above 930°C and cooling

in air. Desensitized by heating to 790°C
(Allows Cr to diffuse)
Ferritic Stainless Steel
The composition of electrode is so chosen to
produce austenitic or air- non hardanable high
alloy weld metal

475°F Embrittlement - Toughness is reduced

when heated to 400 – 480°F due to the
precipitation of Cr rich ferrite

Exhibits lower ductility at lower temperature

Ferritic Stainless Steel

Seldom used for construction of Pr. Vessel

except as a cladding (405)
They are Magnetic
Martensitic Stainless Steel

Straight Cr steels

Hardenable by heat treatment

Magnetic

Rarely used for construction of Pr. Vessel

Least corrosion resistance among SS

Hydrogen Attack

Mono atomic hydrogen diffuses in to the

metal.

At voids and slag inclusions they combine

each other and form molecular hydrogen

As the time grows pressure also grows

Hydrogen Attack

Effects
• Near surface – Crack
• At depth – Blistering

• At high temp (>315°C) Fe3C decompose and

hydrogen combine with C and forms CH 4. Pressure

builds up and leads to Intergranular crack
Hydrogen Attack – Suitable Materials

Cs and LAS at low temp and high Pr or high

temp and low Pr.
Austenitic Stainless Steel
Under hydrogen service both clad and base
material should be a hydrogen attack
resistance
Special materials like SA 516 HIC
 Overview of common Materials
SA 203 Ni SA302 Mn-Mo SA515 SA612
SA204 C-Mo SA353 Ni SA516 SA724/737
SA240 SA387 Cr-Mo SA517 SA738
SA263 Cr-Clad SA533 SA812
SA264 Cr-Ni Clad SA537
SA265 Ni- Clad SA542
SA283 SA553 Ni
SA285
SA299

CS AS SS

In °C