Process Piping Fundamentals, Codes and Standards – Module 1

1.8. DIFFERENCE BETWEEN PIPE AND TUBE

Tubing is supplied in sizes up to four inches in diameter but has a wall thickness less
than that of either large bore or small bore piping. The essential difference between
pipe and tube is that pipe is specified by nominal bore and schedule. Tube is
specified by the outside diameter (OD) and a wall thickness.

For example: The actual outside diameter of 1¼" pipe is 1.625" – while 1¼" tube has
a true 1.25" outside diameter

1.9. FREQUENTLY USED PIPE MATERIALS

1.9.1. Carbon Steel

The vast majority of piping is made of Carbon Steel.

Carbon steel contains only a tiny amount of carbon; sometimes much less than 1%
and is classified as:

• Mild Steels - up to 0.3% Carbon

• Medium Carbon Steels (or simply Carbon Steels) - 0.3 to 0.6 % carbon

• High Carbon Steels - over 0.6% Carbon

The carbon %age influences the mechanical characteristics of the material.

• Material containing carbon more than 0.35 becomes brittle.

• Material containing carbon more than 0.43 are NOT weldable

Low carbon steel is the most common industrial piping material. The material
specifications are governed by ASTM A53 and ASTM A106 standards which defines
three Grades A, B and C. The grades refer to the tensile strength of the steel, with
Grade C having the highest strength. Grade B permits higher carbon and manganese
contents than Grade A. A106 is preferable for more stringent high temperature and
high pressure services.

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1.9.2. Alloy Steel

• Nickel Steels - These steels contain from 3.5% nickel to 5% nickel. The nickel
increases the toughness and improves low temperature properties (up to -
150°F/-100°C). Nickel steel containing more than 5% nickel has an increased
resistance to corrosion and scale.

• Molybdenum - Molybdenum provides strength at elevated temperatures. It is

often used in combination with chromium and nickel. The molybdenum adds
toughness to the steel and can be used in place of tungsten to make the
cheaper grades of high-speed steel for use in high-pressure tubing. An
addition of about 0.5% Molybdenum greatly improves the strength of steel up
to 900°F/480°C. Moly is often alloyed to resist corrosion of chlorides (like sea
water).

• Chromium Steels - Chromium and silicon improve hardness, abrasion

resistance and corrosion resistance. An addition of up to 9% Chromium
combats the tendency to oxidize at high temperatures and resists corrosion
from sulfur compounds. Stainless Steels contain at least 10.5% Chromium.

• Chrome Vanadium Steel - This steel has the maximum amount of strength
with the least amount of weight. Steels of this type contain from 0.15% to
0.25% vanadium, 0.6% to 1.5% chromium, and 0.1% to 0.6% carbon.

• Tungsten Steel - This is a special alloy that has a characteristic property of

red hardness. It has the ability to continue to cut after it becomes red-hot. A
good grade of this steel contains from 13% to 19% tungsten, 1% to 2%
vanadium, 3% to 5% chromium, and 0.6% to 0.8% carbon.

• Manganese Steels - Small amounts of manganese produce strong, free-

machining steels. Larger amounts (between 2% and 10%) produce somewhat
brittle steel, while still larger amounts (11% to 14%) produce steel that is
tough and very resistant to wear after proper heat treatment.

1.9.3. Stainless Steel

Stainless steel pipe and tubing are used for a variety of reasons: to resist corrosion
and oxidation, to resist high temperatures, for cleanliness and low maintenance
costs, and to maintain the purity of materials which come in contact with stainless.

The ability of stainless steel to resist corrosion is achieved by the addition of a

minimum of 12% chromium to the iron alloy. Nickel, molybdenum, titanium and other

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elements are often alloyed along in varying quantities to produce a wide range of
Stainless Steel grades, each with its unique properties.

Stainless steel is classified by the American Iron and Steel Institute (AISI) into two
general series named the 200-300 series and 400 series.

1.9.4. Austenitic Steel

The 200-300 series of stainless steel is known as Austenitic. There are eighteen
different grades of Austenitic steel, of which type SS 304 is the most widely used.

Grade SS304 contains 18% chromium and 8% nickel. It has a maximum carbon
content of .08%.

It is not recommended for use in the temperature range between 400°C and 900°C
due to carbide precipitation at the grain boundaries which can result in inter-granular
corrosion and early failure under certain conditions.

Type 304L. Is the same as 304 except that a 0.03% maximum carbon content is
maintained which precludes carbon precipitation and permits the use of this analysis
in welded assemblies under more severe corrosive conditions.

Grade SS316 contains 16% chromium, 10% nickel and 2% molybdenum. It has high
resistance to chemical and salt water corrosion.

Stainless steel pipe is manufactured in accordance with ASTM A312 when 8” or

smaller sizes are needed.

Large sizes (8” and up) of stainless steel pipe are covered by ASTM A358.

Extra light wall thickness (schedule 5S) and light wall thickness (schedule 10S)
stainless steel pipes are covered by ASTM A409.

400 Series Stainless Steel

The 400 series of steel is subdivided into two main groups: Ferritic and Martensitic.

1.9.5. Ferritic Steel

These are plain chromium stainless steels with chromium content between 12 and
18% but with low carbon content in ranges of 0.08% to 0.20%. They offer moderate
corrosion resistance, not hardenable by heat treatment.

• They are magnetic.

• Weldability and formability are poor.

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• They are frequently used for a decorative trim with the equipment being
subjected to high pressures and temperatures.

• The typical grade is 430.

1.9.6. Martensitic Steel

Martensitic SS exhibit relatively high carbon content (0.1-1.2%) with 12 to 18%

chromium. They were the original commercial SS.

• They are magnetic.

• They offer moderate corrosion resistance and can be heat treated.

• They have high strength but weldability is bad.

• The typical grade is 410.

1.9.7. Duplex Stainless Steel

Duplex Stainless Steel has high chromium content (between 18 and 28%) and a
reasonable amount of nickel (between 4.5 and 8%). These steels exhibit a
combination of ferritic and austenitic structure and hence called duplex. Some duplex
steels contain molybdenum from 2.5-4%.

• They offer excellent resistance to stress corrosion cracking.

• These have better resistance to chlorides.

• They are better than austenitic and ferritic steels in tensile and yield strength
while offering good weldability and formability.

• The typical grade is 2205.

1.9.8. Cast Iron /Ductile Iron

Cast iron is any iron containing greater than 2% carbon. The high carbon content
makes it extremely hard and brittle. Cast iron has a high compressive strength and
good wear resistance; however, it lacks ductility, malleability, and impact strength.

Two types of cast iron are used, grey cast iron and ductile iron. Both Grey Iron and
Ductile Iron are prepared by adding carbon in the hot beds where they are liquefied
but ductile iron develops high strength and ductility with the addition of small amounts
of magnesium to gray iron.

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1.9.9. Galvanized Pipe

Galvanized iron pipe (GI) is a regular iron pipe that is coated with a thin layer of zinc.
The zinc greatly increases the life of the pipe by protecting it from rust and corrosion.
GI usually comes in 6-meter (21-foot) lengths, and is joined together by threaded
connections.

1.9.10. Titanium

Titanium has superb corrosion resistance especially for seawater duties in heat
exchanger tubes/piping. This material is relatively expensive compared to most other
materials; however, if lifetime costing is considered, it would likely be competitive.

1.9.11. Copper, Brass, Copper Nickel Alloys

Copper tubing is used where ease of fabrication is important.

70%/30% - Cu/Zn brass is a good general purpose material used for a variety of
applications, e.g. heat exchanger tubes and closed circuit systems.

Brass with 76%/2%/0.04%- Cu/Al/As and Remainder Zn has good resistance to

seawater attack and is used for diverse process plants for transferring seawater
under turbulent conditions to resist corrosion and impingement attack.

Admiralty brass 70% /1%/29% - Cu/Sn/Zn has slightly improved resistance to

polluted water compared to 70/30 brass.

Cupro Nickel Containing 31%/2% - Ni/Fe and “Kunifer" containing 10.5%/1.7% -

Ni/Fe are also used for transferring seawater and high good strength at elevated
temperatures.

1.9.12. Plastic Piping Systems

The two most common types of plastic pipe are Polyethylene (PE) and Polyvinyl
chloride (PVC).

• Polyethylene pipe (PE) and HDPE are lightweight, flexible pipes that come in
large coils 30 meters or more in length. The pipe varies in density and is
generally joined by heat fusion. The joint is typically leak free.

• Plastic polyvinyl chloride pipe (PVC) is a rigid pipe, usually white or gray in
color. It comes in 3 or 6 meter lengths and is joined primarily by solvent
cement. The pipe varies in density and, when buried is extremely resistant to
corrosion.

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