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INTRODUCTION :-
Materials plays very important role in any industry.
wrong selection of material may lead to catastrophic failures and outrage of plants and
even loss of human lives.
Right selection of material leads to long life of plant.
there is a wide vareity of materials use to construct process equipment . The types of
material selected depends on its compability with process conditions and cost.
METALS
Metal that are not mixed with any other materials are known
as pure metals. Metals listed in the Periodic Table are pure
metals
E.g. Iron (Fe), Copper (Cu) and Zinc (Zn)
METALS NON-METALS
TEFLON
RUBBER
FERROUS METALS :- ferrous metals are metals that consist mostly of iron(greater
than 50%) and small amount of other metals ferrous metals are prone to rusting if
exposed to moisture. It can also be picked by a magnet. The rusting and magnetic
properties in ferrous metals are both down due to the iron.
1.) CAST IRON :- it is a very strong metal when it is in compression and is also
very brittle . It consist of 93% iron and carbon contents between 2 and 5%.
Silica inclusion between 1 and 3%.
Mechanical properties:- melting point below carbon steel
Excellent fluidity (required for casting purpose)
Poor weldability and ductility
2.) CARBON STEEL:-carbon steel has less than 2.0 % carbon. No alIoying
elements is added excep carbon is easy to fabricate , has better strength and
easier to weld than cast iron. The main disadvantages in using carbon steel is
its susceptibility to corrosion.
Uses:- steam condensate line, cooling water line, inst. Air line and load bearing
structure and sheets
Grades -API 5L GR.B.
melting point – 1600 C
Uses :- hand tools such as screw drivers, chisels, punches, hammers, saws, garden
tools and rail road wheels etc
melting point – 1800 C
d.). KILLED CARBON STEEL :- deoxidizer are added in sufficient
quantity, carbon steel with inclusion of Al orSi. A steel deoxdized to such a
level that essentially no reaction occurred between carbon and oxygen during
solidification. The purpose of deoxidizing is to avoid gas bubble in the material
in order to fulfil the quality requirement given in material standards.
ALLOY STEEL:- So, there was a need to create better types of steels, which are
alloy steels, ie., additions of alloys (low amounts of Mn, Ni, Cr, Ti, Si, etc) to improve
its properties.
low alloy steel alloying element upto 8.0%
chemical composition:- cr upto 2.25%, mo upto 1.25%
alloying effects Cr increases corrosion resistance, Mo adds elevated temp.
strength
Mech Properties:- high strength at high temp. upto 650C.
Uses:- piping , valves, and vessels for very high pressure steam
Alloying increases the cost of the steel, but the enhanced properties are essential in
many applications.Alloying improves corrosion resistance (particularly with the
addition of Chromium), producing the stainless steels.
Alloys are mixtures of two or more metals formed together
with other elements/materials to create new metals with improved Mechanical
Properties and other properties of the base metal.
Over 150 grades of SS available, usually categorized into 4 series containing alloys
w/ similar properties.
AISI classes for SS:
200 series = chromium, nickel,manganese (austenitic)
300 series = chromium, nickel (austenitic)
400 series = chromium only (ferritic)
500 series = low chromium <12% (martensitic)
The standard ferritic grades are alloyed with chromium (11.2–19 %), but with no, or
very small addition of nickel.
AISI %C % MN %P % SI % CR
430 .12 .04 .03 1.0 14 TO 18
it is a more complex material because the addition of nickel (3.5 to 22%) allows it to
retain its austenitic microstructure at all temperature.
It has a high tensile strength and best impact strength, ductility and corosion
resistance of all the stainless steel over a wide range of temperatures.
However, austanitic steel with high molybdenum content (1 to 3 %) have improve
resistance to pitting.
Austenitic steels in high temperature service.
These alloys are basically chromium nickel steels.
series. Grades 301, 302, 303, 304, 316, and other 300 series.
High strength, hardness, resistance to abrasion; used in turbine parts, bearings, pump
shafts, impeller for corrosion service knives, cutlery and generally Magnetic. Grades 17-4, 410, 416,
420, 440 and other 400 series.
AISI %C % MN %P % SI % CR
410 .15 1.0 .04 1.0 11.5 to TO
13.5
420 .15 1.0 .04 1.0 12 to 14
d.) DUPLEX STAINLESS STEEL
Duplex grades
HVD 1
SAFUREX(STAMI CARBON)
DP28W(TOYO PLANT )
Light weight
High temperatureproperties
Non Ferrous
Oxidation resistance
Corrosion resistance
High Cost
Thermal / electrical conductivity
Biocompatibility
PROFESSIONAL ORGANIZATION AND THEIR SCOPE OF CONCERN
STEAM MORE ALLOY STEEL ASTM A335 GR.P11 C- .15%, Mn- .60%, P- .
THAN 400 C & P22 025% ,S- .025%, Si- .
50%,
Cr- 1.9-2.6%, Mo - .87-
1.13%
AUSTENETIC STAINLESS STEEL
AISI USES
304 DM WATER, LUBE OIL, WASTE WATER, CO2
304L VACUUM SECTION
309 ITS FILLER WIRE & ELECTRODES ARE USED TO WELD CARBON
STEEL WITH AUSTENITIC STAINLESS STEEL
316L M.P. SECTION, L.P. SECTIONS AND HYDROLYZER SECTION
ALLOY C P S SI MN Cr Ni MO N
304 .08 .045 .030 1.0 2.0 18-20 8-10.5 - -
304L .03 .045 .030 1.0 2.0 18-20 8-12 - -
316 .08 .045 .030 1.0 2.0 16-18 10-14 2-3 -
316L .03 .045 .030 1.0 2.0 16-18 10-14 2-3 -
316LM .02 .015 .010 .40 1.70 17.5 14 2.6 .18
2RE-69 .02 .015 .010 .40 1.70 25 22 2.1 .12
(snam.)
HVD-1 .05 CU-1.5 .02 .038 1.25 25 8.5 2.5 -
SAFUREX .03 .03 .03 .50 .8-1.25 28-30 5.8-7.5 1.5-2.6 .3-.4
(STAMI
CARBON) CU<.8
DP28W .03 W- 2.1- 27-28 7-8.2 .8-1.2 .3-.4
(TOYO) 2.5
S.NO. MOC ADVANTAGES DISADVANTAGES
1. TITANIUM Good passivation properties 1. Susceptible to
with less air Erosion
2. Difficult to Weld
3. Costly
2. STAINLESS STEEL 1. Immune to Erosion 1. Large amount of
2. Good Weldability passivation air
3. 316LM 1. Excellent Weldability 1. Large amount of
2. Fair corrosion Passivation air
3. Relatively less cost
4. 2RE69(SAIPEM) 1. Excellent weldability Susceptible to SCC
2. Better Corrosion resistance by chloride
than 316LUG 2. Costly
5. SAFUREX(STAMICARBON) 1. Good Weldability 1. Costly
2. Excellent Corrosion
Resistance
3. Passivation air is not
required
6. DP28W(TOYO) Excellent corrosion resistance 1.) costly
very high mechanical strength
good weldability and
formability
corrosion rate lower than
titanium
Chromium (Cr)
This is the most important alloying element and it gives stainless steels their basic
corrosion resistance. All stainless steels have a Cr-content of at least 12.0 % and the
corrosion resistance increases with increasing chromium content. Chromium also
increases the resistance to oxidation at high temperatures .
It is essential for formation of passive film to resist corrosion.
It improves hardness and wear to resistance .
Nickel (Ni)
The main reason for the nickel addition is to promote an austenitic microstructure.
Nickel generally increases ductility and toughness and ease to welding. It also
reduces the corrosion rate in the active state and is thus advantageous in acid
environments. it improves resistance to fatigue failure
Molybdenum (Mo)
Molybdenum significantly increases the resistance to both crevice and pitting
corrosion.
Copper (Cu)
Copper enhances the corrosion resistance in certain acids and promotes an
austenitic microstructure. It can also be added to decrease work hardening in grades
for improved machinability. It may also be added to improve formability. Used in
concentration of about 0.5 % or less. Produces a tenacious self sealinG oxide film on
a metal surface .
Manganese (Mn)
it prevents to form iron sulphide which is harmful to steels.
Manganese is generally used in stainless steels in order to improve hot ductility.
Silicon (Si)
Silicon increases the resistance to oxidation, both at high temperatures and in
strongly oxidising solutions at lower temperatures.
Carbon (C)
Carbon is a strong austenite former that also significantly increases the mechanical
strength.
Nitrogen (N)
Nitrogen is a very strong austenite former that also significantly increases the
mechanical strength. Nitrogen increases the resistance to localised corrosion,
especially in combination with molybdenum.
It enhances pitting resistance.
Sulphur (S)
Sulphur is added to certain stainless steels, the free-machining grades, in order to
increase the machinability.
TITANIUM
ZIRCONIUM
2RE69
AISI316LM
DUPLEX STEEL
2RE69 is a fully austenitic stainless steel with extra low carbon and impurity
contents. The grade is characterized by:
Excellent resistance to corrosion in ammonium carbamate and nitric acid.
High resistance to pitting and crevice corrosion.
Good weldability.
Alloy 316/316L is a chromium-nickel molybdenum austenitic stainless steel
developed to provide improved corrosion resistance to Alloy 304/304L in moderately
corrosive environments.
It also provides higher creep, stress-to-rupture and tensile strength at elevated
temperatures.
Alloy 316/316L has excellent strength and toughness at cryogenic
temperatures.
Uses:- it is used for lining and tube material of ammonia stripper in snamprogetti's
urea plants.
Used for lining of urea reactors of toyo plants at panipat and bhatinda
REACTOR (R-1)
Cladding:- the process of bonding one metal to another usually to protect the inner
metal from corrosion .
Liner:- carbon steel -1000 mm/year(if carbamate is high).
A protective layer is needed to protect the carbon steel. The thickness of the liner
varies between 4 & 10 mm and depend on licenser.
STRIPPER (E-1)
A.) TOP & BOTTOM DOMES - 2RE-69
B.) TUBES – BIMETALLIC (OUTER SIDE -2RE-
69{2.0MM})
(INNER SIDE – Zr{0.7MM})
C.)FERRULES –---------------------------------- 2RE-69
D.) SHELL –---------------------------------- CS
E.) INTERNALS –-------------------------------- 2RE-69
PROPERTIES OF MATERIAL
HARDNESS:- hardness is resistant offered by material to identation , resistance to
bending , scratching, abrasion or cutting.
ELASTICITY :-the property of material due to which it comes to its original shape
after the removal of load is called elasticity.