pemilihan material pipa

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BAB IIPemilihan Material Pipa

Bab I IntroductionBab I Introduction

Pipe Stress Analysis & DesignPipe Stress Analysis & DesignPipe Stress Analysis & Design

Pipe

line

Des

ign

PIPELINE DESIGN

Material Selection

On Bottom-Stability

Route Selection

Buckling

Wall Thickness

Spanning

Cathodic Protection

Fatigue

Thermal Expansion

Parameter Design Enviromental DataRoute Survey

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Linepipe Material SelectionLinepipe Material Selection

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1. Spec. and Req. of Linepipe1. Spec. and Req. of Linepipe

The following properties :StrengthToughnessDuctilityWeldabilityCorrosion Resistance

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1. Spec. and Req. of Linepipe (1. Spec. and Req. of Linepipe (concon’’tt))

Steel pipe are manufactured to particular specifications :– Chemical composition– Strength data– Tolerance

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

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2. Linepipe Metallurgy and Pipe 2. Linepipe Metallurgy and Pipe GradesGrades

HISTORYMid 1950

• API 5LA, B and 5L X42, X52, and X56. • Wall thickness less than 0.50”• The yield strength of the X52/X56 steel were

obtained by use of relatively rich alloy content, and cold working.

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2. Linepipe Metallurgy and Pipe Grades 2. Linepipe Metallurgy and Pipe Grades ((concon’’tt))

Late 1950 • The importance of good weldability become recognized

because of frequent of hydrogen cracking in the HAZ in girth weld.

• Increased strength from microalloying addition of Niobium (0.04%) and/or Vanadium (0.08%).

• The strength of first fine grained High Strength Low Alloy (HLSA) API 5L X60 pipes was achieved by combination of grain size control and normalizing after hot rolling.

• The normalized steel plates contained :Level of Nb & V with C = 0.2Carbon Equivalent = 0.45

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1960 :• The steel plate process route develop from normalizing to

controlled rolling (CR).• This practice consisted of low temperature finishing of the

plates during hot rolling on the plate mill and thus producing a finer ferrite pearlite microstructure

• The implementation of CR can reduce cost, because :• CR was being practiced from 1968 to produce pipe having

SMYS up to X65 (1968)Avoiding normalizingReduction in C level, from 0.20 % to 0.12%

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Mid 1960’s :• The early higher steel pipes, as the strength increased,

failure resulted in fractures over long distance.• Research showed that the distance a fracture would

propagate was a function of temperature and toughness• The requirement designed The fracture was

ductile at operating temperature or operating temperature was higher than brittle-ductile toughness transition temperature of the steel

• Research showed that a reduction of pearlite fraction and additional grain refinement was needed to meet the transition temperature requirement

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1970 • Laboratory and industrial investigation showed that with a

proper choice of chemical composition & CR schedules, finer-grained acicular ferrite (AF) steel, could be produced with guaranteed superior weldability & yield strength levels up to X70

• In the development of the accelerated cooling (AC) technology, due to the higher cooling rates in TMCP rolling, leaner compositions can be used to obtain fine structure

• Low sulphur (S) contents (<0.005%) and sulphide shape control provided a solution to hydrogen induced cracking

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1980• This finding together with the need of lower C

level (Weldability and SCC) influenced the steel making and rolling practice

• This led to steelmaking practices with very strict control of residual elements (S, P, H, N, and O) and a gradual switch from Controlling Rolling (CR) to Thermo-Mechanically Controlled Rolling (TMCP)

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2. Linepipe Metallurgy and Pipe 2. Linepipe Metallurgy and Pipe Grades (Grades (concon’’tt))

For thick wall thickness (t>30 mm), homogeneous through thickness properties can’t met by TMCP, met by quenching and tempering process (Q &T).Q & T pipe steel have both high yield strength and good toughness without necessity for high level of alloying.Currently, For strength up to X52, rolled normalized carbon-manganese steel is commonly used.

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3. Philosophy of Materials Selection3. Philosophy of Materials Selection

The fundamental criteria for the selection of material :Mechanical propertiesCorrosion resistanceEase to fabrication (Weldability)CostAvailability

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3. Philosophy of Materials Selection 3. Philosophy of Materials Selection ((concon’’tt))

The basic information to evaluate pipeline material selection :

1) Maximum operating pressure2) Preliminary determination diam. & wall

thickness3) Material strength requirements to contain

pressure4) Max & min design temperature5) Method of production in special condition

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6) Composition of gasses and fluids7) Erosion problems (i.e. the presence of

sand)8) Corrosive media (i.e. H2S, CO2, O2, etc)9) Design life of pipeline

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3.1. Material Selection Based on Corrosion Resistance :

1) Low Alloy Steels2) High Alloy Steels

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3. Philosophy of Materials Selection (3. Philosophy of Materials Selection (concon’’tt))

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.

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Low Alloy SteelThe characteristic of CO2 and H2S corrosion are different :

– CO2 = General weight loss with additional localized corrosion where water collected.

– H2S = 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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Low Alloy SteelBasis for low alloy steels:• Maximum hardness limitation• Maximum nickel content of 1%• Heat treatment condition

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Low Alloy Steel– 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 SSC must be adopted.

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Low Alloy SteelPrecaution to minimize the risk of corrosion:1) Material compositional control2) Specialized corrosion testing3) Compliance with NACE MR-01-75

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High Alloy SteelA 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)

NMCPRE OR %16%3.3% ⋅+⋅+=

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Application of High Alloy Material1) 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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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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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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4) 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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5) 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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3.2. Selection Based on Mechanical Requirement :1) Yield Strength2) Fracture Control Design Requirement3) Weldability requirement

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3.2.1. Yield Strength :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

• Satisfactory properties have been obtained for pipe grades up toX65, using controlled rolled steel & normalized steels,

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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 coolingThese 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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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 o conventional high strength low alloy steel.

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3.2.2. 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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3.2.2. Fracture Control Design Requirement (con’t)• 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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3.2.2. Fracture Control Design Requirement (con’t)For fracture initiation, if the pipe material is ductile with anestablish minimum toughness level and the crack go through wall. Formula is given by :

i

EARπσC C

2H

V⋅⋅⋅

=

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

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3.2.2. Fracture Control Design Requirement (con’t)• 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.

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Where :CV = Charpy energy required

(ft/lbs)σH = nominal hoop stress (ksi)

R = Pipe radius (inch)t = Wall thickness (inch)AC = Cross sectional area of

Charpy impact specimen (inch2)


Formula :

C31

t2HV A)(Rσ0.0873C ⋅⋅⋅=

NOTE : These formula weren’t developed using The high strength pipeline materials (i.e. X65)

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3.2.3. Weldability Requirement :1) Low Alloys Steels2) High Alloy Steels

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3.2.3. Weldability Requirement :– 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 electrodesShield manual metal arc welding, using basing, low hydrogen

electrodes.Fully mechanised gas shielding arc welding

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Low Alloy Steels– Field weldability of high strength low alloy steels is greatly

enhanced by the use of low carbon content :

– 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

⎟⎠⎞

⎜⎝⎛ +

+⎟⎠⎞

⎜⎝⎛ ++

+⎟⎠⎞

⎜⎝⎛+=

1556NiCuVMoCrMnCCE

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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 should be considered for determining if preheating is necessary:

BVNiMoCrCuCrSiCPcm 51060152030

+⎟⎠⎞

⎜⎝⎛+⎟

⎠⎞

⎜⎝⎛+⎟

⎠⎞

⎜⎝⎛+⎟

⎠⎞

⎜⎝⎛ ++

+⎟⎠⎞

⎜⎝⎛+=

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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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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

processc) Obtaining girth weld with mechanical & corrosion

properties ( particularly in the root & HAZ) which approach those of base pipe.

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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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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 PipeNon Metallic Pipe

Non Metallic PipeNon Metallic Pipe

Thermoplastic (PVC) :Thermoplastic (PVC) :–– Corrosion resistanceCorrosion resistance–– Limited pressure and temperatureLimited pressure and temperature–– Shall be buried or supportedShall be buried or supported–– Resistance to UVResistance to UV

Composite (Fiber Reinforced Plastic) Composite (Fiber Reinforced Plastic) ::–– Higher pressure resistance than PVCHigher pressure resistance than PVC–– Resistance to vibrationResistance to vibration–– Resistance to ultravioletResistance to ultraviolet–– Fitting methods ?Fitting methods ?–– NDT methods ?NDT methods ?

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LIMITATION OF THERMOPLASTIC PIPELIMITATION OF THERMOPLASTIC PIPE

Limited P and TLimited P and T

–– PVC : T < 65 C, Stress < 4 PVC : T < 65 C, Stress < 4 ksiksi–– PE : T < 40 C, Stress < 625 PE : T < 40 C, Stress < 625 psipsi

Shall be buried (to protect from sunlight, fire, mechanical Shall be buried (to protect from sunlight, fire, mechanical damage)damage)

Low resistance to vibrationLow resistance to vibration

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Fiberglass Reinforced Plastic (FRP) PipeFiberglass Reinforced Plastic (FRP) Pipe

Excellent corrosion resistance propertiesExcellent corrosion resistance propertiesEase of installationEase of installationLow maintenance costLow maintenance costApplications : Freshwater, potable water, chilled water, Applications : Freshwater, potable water, chilled water, seawater, chlorinated seawaterseawater, chlorinated seawaterHigher tensile strength than HDPE pipeHigher tensile strength than HDPE pipeT < 95 T < 95 ooCC. P < 20 bar. P < 20 barNot recommended for depressurized systemsNot recommended for depressurized systemsShall be buried (to protect from sunlight, fire, mechanical Shall be buried (to protect from sunlight, fire, mechanical damage)damage)Low resistance to vibrationLow resistance to vibration

1. Unidirectional composite structure

2. Two-part adhesive systems

3. Load transferring component

Carbon Steel Pipe repair

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Linepipe Material Selection Case Study

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Bab I IntroductionBab I Introduction

Pipe Stress Analysis & DesignPipe Stress Analysis & DesignPipe Stress Analysis & Design

Pipe

line

Des

ign

PIPELINE DESIGN

Material Selection

Burial & Crossing

Route Selection

Buckling

Wall Thickness

Spanning

Protection

Fatigue

Thermal Expansion

Parameter Design Enviromental DataRoute Survey

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Philosophy of Materials SelectionPhilosophy of Materials Selection

The fundamental criteria for the selection of material :Mechanical propertiesCorrosion resistanceEase to fabrication & ConstructionMaintainability/repairabilityCostAvailability

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Mechanical PropertiesMechanical Properties of Linepipeof Linepipe

StrengthToughnessDuctilityConstructability

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MethodologyPreliminary study & Data Collection

Establish Material Criteria

Choose Material Alternatives

Generate material type-properties-operational

criteria matrix

Material Accepted?

Material Recommendation

NO

YES

UnrecommendedMaterial

Back

Fluid Composition

Fluid system flow inside the line pipe consist of :– Hydrocarbon– Water – Gas – Impurities – Wax..– etc

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Linepipe Material Alternatives

• Stainless Steel– Duplex Stainless Steel– Stainless Steel 304– Stainless Steel – 316

• Nonferrous Alloy– Cu - Ni Alloy– Ni Alloy– Aluminum - Magnesium Alloy

• Composite 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

• Carbon Steel

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

Material Type Duplex Stainless Steel Stainless Steel 304 Stainless Steel 316Excelent Corrosion Resistance High Strength Weldable by all standard methodsBetter stress-corrosion cracking resistance

Excellent forming

Susceptible to stress cracking Susceptible to stress cracking

Has lower stiffness compared to Polypropylene

Susceptible to sensitisation (grain boundary carbide precipitation) when heated until 425-860 0C

High mould shrinkage and poor UV resistance

Cannot be hardened by thermal treatment.

Advantages

Excellent in a range of atmospheric environments and many corrosive media - generally more resistant than 304.

Excellent in a wide range of atmospheric environments and many corrosive media.

ExpensiveDisadvantages

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Nonferrous AlloyCu – Ni alloy type:– 90Cu - 10Ni– 80Cu - 20Ni– 70Cu - 30Ni

Material Type

90Cu - 10Ni 80Cu - 20Ni 70Cu - 30Ni 70Ni - 30Cu InconelAluminum - Magnesium

Alloyexcellent corrosion resistance in reducing chemical environments and in sea water

Good resistance to corrosion and heat Low density

ExpensiveLower strength than ferousbased Metal

excellent mechanical properties and presents the desirable combination of high strength and good workability.

typically displays excellent electrical and thermal conductivity,

excellent ductility and can be readily fabricated and formed into a variety of shapes.

Very expensivesometimes have limited usefulness in certain environments because of hydrogen embrittlement or stress-corrosion cracking (SCC).

Advantages

excellent electrical and thermal conductivities, outstanding resistance to corrosion, ease of fabrication, and good strength and fatigue resistance . Can be readily soldered and brazed. Can be welded by various gas, arc, and resistance methods. Can be plated, coated with organic substances, or chemically colored to further extend the variety of available finishes.

Disadvantages

Ni alloy type:– 70Ni – 30Cu– InconelAluminum - Magnesium

Alloy

Composite PipeComposite type:– Glass Fiber Reinforced Plastics (GFRP)– Carbon / Epoxy Composite– High Density Polyethylene (HDPE)

Aliphatic Amine Cured

Epoxy

Anhydiride Cured Epoxy

Aromatic Amine Cured

EpoxyGood mechanical properties

Good low temperature impact resistance

Good chemical resistance

Excellent chemical resistance

Lowest shrinkage (highest stability).

Exceptional resistance to rapid-crack propagation

Disadvantages Expensive

May react with oxygen and strong oxidizing agents, such as chlorates, nitrates, peroxides, etc.

GFRPMaterial

TypeCarbon / Epoxy

CompositeHDPE

Low performance in high temperature

Advantages

Corrosion Control - Resists corrosion caused by CO2, H2S and salt waterReduced cost of the piping and reduced maintenance costs

Reduced weight on the platform deck

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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

Material Type304L SS -

Carbon Steel316L SS -

Carbon SteelDuplex SS - Carbon Steel

CuNi Alloy - Carbon Steel

Advantages Combining the features of metallurgical & mechanical

Disadvantages ExpensiveNeed High Level on joining

Internally Coated Carbon Steel

– Fusion Bonded Epoxy (FBE) Coating– Coal Tar Epoxy Coating– Ceramic Epoxy Coating

Holiday (pinhole) testing per applicable ASTM, NACE, And SSPC Industry standards

Suitable for intermittent exposure to 300°Fease of application,

Advantages

For best results, applied condition material to 70°F or higher.

Store material under dry conditions

Do not use below 40°F

Disadvantages

Moisture insensitive and Low temperature curing

Sprayable, Tough and flexibleSuperior bonding to the substrate (three times that of any otherceramic epoxy or polyethylene product)

100% solids, 0.0 lbs. VOC

Excellent abrasion resistance (Alpha Phase alumina ceramics -Hardness just below s diamond)

High build to 40 mils per coatFinished coated pieces can be moved to the storage area within minutes after the application

Can be stored outside indefinitely without disbondment from the substrate (some chalking will occur)

Convenient 2A to 3B mix ratio by volume

cure schedules, which means faster production rates.

Field repairs are completed with the same product as is applied at the factory, not coal tar epoxy or "Pipe Joint Compound

Excellent adhesionrapid application,

Can be applied to the bell and spigot of ductile iron pipe for total "Wet Area" protectionExcellent chemical resistanceless waste of

material,

Ceramic Epoxy CoatingCoal Tar Epoxy CoatingFBE CoatingMaterial Type

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Carbon Steel

Not expensive

excellent finishing characteristics to provide attractive appearance after fabrication

compatibility with other materials and with various coatings andprocesses.

adequate strength

Ease of fabrication

Low corrosion resistance

Susceptible to Chemical reactionDisadvantages

Serviceable under a wide variety of conditions and especially adaptable to low-cost techniques of mass production.

Advantages

Carbon SteelMaterial Type

Back

General Matrix

No MaterialResistance to injection

Fluid

External Corrosion/

Degradation Resistance

Strength

Pressure Containment

Toughness

Construction / Joinability

Expansion / Flexibility

Damage Due To

Accidental Load

Maintainability

Life time

Availability Cost

Final Score

20% 5% 10% 5% 5% 10% 5% 3% 7% 5% 10% 15% 100%1 X1 B A A A A C C A A A D E 722 X2 C A A A A B A A A A B C 823 X3 B A A A A B A A A A B D 834 X4 A A C C C C A C C B D B 745 X5 A A C C C C A C C B D B 746 X6 A A C C C B A C C B D B 767 X7 A A B B B C C B C B D B 76.68 X8 A A A A A E A A A A E E 729 X9 E C C C C C B C C C C C 5310 X10 B C E E E B A E A D B A 68.6

Note: A: Very good; B: Good; C: Fair; D: Bad; E: Very bad

SelectedMaterial

Chemical/corrosion Resistance

Degradation Resistance

Mechanical Strength

Construction/Joinability Maintainability

Availability

Cost

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