Part 4
Metallic & Non-Metallic Pipes
Dr Asaad Kareem 1
Piping Materials
Depending mainly on the type of the fluid to be transported, especially
its corrosivity, flow regime, temperature and pressure, the selection of
pipeline material type can become a fundamental issue which should be
decided at the conceptual design stage of a pipeline project.
The selection of pipeline material should be made after careful
consideration of all internal and external corrosion conditions to ensure
that the pipeline can remain fit-for-purpose throughout its life time.
Internal corrosion and erosion of the pipe wall are governed by process
conditions such as corrosivity, temperature, pressure and velocity of the
fluid as well as deposition of solids.
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Ferrous Metal Piping
1. Carbon Steel
• Carbon steel pipe is the most commonly used material for process piping.
Why Carbon Steel?
• It has the advantage of wide availability, high strength, and a large array of
connection possibilities, for example, screwed, socket-welded, and buttwelded.
Applications
• Carbon steel pipe is used for liquid, gas, and steam services both above- and
belowground services. It is not recommended for use in corrosive services but
may be used in caustic services.
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Steel Pipe Vs. Other Alloys
Relative cost comparison of steel pipe versus other alloys
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Manufacturing Process of Carbon Steel
• Carbon steel and malleable iron piping are classified according to the
manufacturing methods as follows:
Seamless Pipes And Tubes (SMLS)
Electric resistance weld (ERW)
Submerged arc weld (SAW)
Double submerged arc weld (DSAW)
Furnace weld, butt-welded or continuous weld
Spiral-welded pipe
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Ferrous Metal Piping
2. Stainless Steel
• Stainless steel pipe is used when corrosion resistance is required.
• Austenitic stainless steels (300 series), contain a maximum of
0.15% carbon and a minimum of 16% chromium, along with
nickel and/or manganese.
• The addition of chromium gives stainless steel its corrosion
resistance properties.
Applications
• Stainless steel piping is used whenever iron dissolution cannot be tolerated.
• Stainless steel is used whenever corrosion needs to be avoided, as in heat exchangers and
boilers
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Manufacturing Process of Stainless Steel
• Stainless steel manufacturing processes are similar to those of carbon steel.
• The material cost of stainless steel is three times more than that of carbon
steel.
• Therefore, manufacturers have developed lighter wall thicknesses to make
stainless steels more attractive.
• Usually, any corrosion allowances of the stainless steels can be eliminated in
the thickness calculation because stainless resists corrosion under most
applications.
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Ferrous Metal Piping
3. Cast iron
• Cast iron contains between 2% and 6.67% carbon.
• These metals are strong but brittle.
• They exhibit very low ductility and malleability and cannot
be drawn, rolled, or worked at room temperature.
• A sharp blow with a hammer can crack a cast iron pipe.
Cast irons melt readily and can be cast into complicated
shapes and machined.
Applications
• Since cast iron is so brittle, it is not often used for pressure piping applications,
• Cast iron pipe is used primarily for drain, waste, and vent applications.
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Ferrous Metal Piping
4. Ductile Iron
• Due to its metallographic structure, ductile iron is stronger
and tougher than cast iron.
• Ductile iron replaced cast iron pipe in pressure applications.
• Ductile iron pipe is available in five pressure classes, defined
as the rated working pressure of the pipe.
• Ductile iron pipe is manufactured in the same way as cast
iron pipe.
Applications
• Ductile iron, like cast iron, is used for sewage service.
• It is also used for potable water service.
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Ferrous Metal Piping
5. Corrugated Steel
• Corrugated steel pipes are thin-wall, large-diameter pipes
made of galvanized steel sheets having either helical or
annular corrugations.
• Corrugated pipes come in a great range of sizes, and have a
large variety of fittings.
• Some corrugated pipes are fabricated to have a pecan-
shaped (arched) instead of circular cross section.
Applications
• Due to its low cost, the corrugated steel pipe is used extensively in sewer and drainage
systems where both the internal pressure (water pressure) and the external pressure (soil
pressure) are low, and where leakage will not cause serious problems.
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Nonferrous Metal Piping
1. Aluminium
• It has good corrosion resistance, low density, and good
electrical conductivity.
• The corrosion resistance of aluminium is due to the presence
of a thin oxide layer which is only a few atoms in thickness.
• High-purity aluminium is too weak to be used for many
purposes.
• The material commonly termed pure aluminium is an
aluminium iron alloy, by adding up to 0.5% of iron.
• This small iron addition gives a considerable increase in
strength, although there is some reduction in ductility and
corrosion resistance.
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Nonferrous Metal Piping
2. Copper
• Copper may be alloyed with a number of elements to provide a range of useful
alloys. The important alloy systems are:
– copper-zinc (brasses),
– copper-tin (zinc) (bronzes and gun metals),
– copper-aluminium (aluminium bronzes),
– copper-nickel (capronickels).
• Copper-nickel alloys (mainly Cu-Ni 90-10) in particular are used in the oil and gas
and petrochemical industries. They are used in seawater networks particularly for
sizes less than or equal to 1 1/2 in. In recent years, they are being replaced by
fiberglass pipe except in the ½-1½-in. range as fiberglass pipe is not available in
these sizes.
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Non-Metallic Pipes
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Plastic Pipes
Use
• As all-plastic pipe
• As “filed” plastic materials (glass-fiber-reinforced, carbon-filled, etc.)
• As lining or coating materials.
Advantages
• They resist corrosion;
• They alleviate the problem of paraffin and scale buildup;
• They are less resistant to flow that allows the use of smaller diameter pipe or less
hydraulic horsepower.
Disadvantages
• They may rupture or fail if subjected to heat or flame impingement.
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Types of Plastic Pipes
1. Polyvinyl Chloride (PVC)
• It is widely available and relatively inexpensive;
• It is used for cold-water pressure piping and potable water service;
• It is used to handle acids, bases, salts, and other corrosives;
• It may be damaged by ketones, aromatics, and certain chlorinated hydrocarbons;
• It is not suitable for hot water, since it has a maximum temperature limit of only 60 °C;
• It cannot be used for compressed gases, nor is it to be
tested with gases under pressure;
• It should be painted with latex paint if it is to be exposed
to sunlight;
• If it is stored outdoors, it should be covered with a tarp
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Types of Plastic Pipes
2. Chlorinated Polyvinyl Chloride (CPVC)
• It is widely available and relatively inexpensive;
• It is used for cold-water pressure piping and potable water service;
• It is used to handle acids, bases, salts, and other corrosives;
• It may be damaged by ketones, aromatics, and certain chlorinated hydrocarbons;
• It is not suitable for hot water, since it has a maximum temperature limit of only 60 °C;
• It cannot be used for compressed gases, nor is it to be tested with gases under pressure;
• It should be painted with latex paint if it is to be exposed to sunlight;
• If it is stored outdoors, it should be covered with a tarp.
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Types of Plastic Pipes
3. Polyethylene (PE)
• It is used to transport water or low-pressure gas;
• It can tolerate abuse and may be deformed without
losing its strength;
• It does not corrode and offers very good flow
characteristics as the surfaces are smooth;
• Its resistance to corrosion makes it a more economical choice for underground piping than
coated and wrapped carbon steel;
• The design stress is 630 psi at 73.4 °F (23 °C) and the maximum service temperature is
180 °F (82 °C).
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Types of Plastic Pipes
4. Polypropylene (PP)
• It can tolerate abuse and may be deformed without
losing its strength;
• It is used where resistance to sulfur-bearing
compounds is useful, such as saltwater disposal lines,
low-pressure gas gathering systems, and crude oil
flow piping;
• The design stress is 630 psi at 73.4 °F (23 °C) and the
maximum service temperature is 210 °F.
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Types of Plastic Pipes
5. Reinforced Thermosetting Resin Pipe (RTRP)
• It has a fixed shape. Once it is cured, and the shape
cannot be changed;
• The resins are thermosetting epoxy or polyester and
the glass fibers are embedded within these resins to
impart mechanical strength;
• It is used in upstream oil and gas facilities to transport
chemicals in liquid and vapor phases;
• The maximum design stress levels range from 4000 to 6300 psi, depending on the grade;
• The maximum temperature rating is 200-300 °F, depending on the type of resin binder.
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Activity
Review Questions
1) Name three types of plastic pipes?
2) Name three types of Ferrous and nonferrous pipes?
3) What are the advantages and disadvantages of plastic pipes?
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