PIPELINE ENGINEERING I APSC 498P

COURSE NOTES

2014-2015 Winter

Module 1 - Pipe Materials, Specifications,

Manufacturing, and Pipe Components

Instructor: Dr. Hung M. Ha Department of Materials Engineering

University of British Columbia Vancouver, B.C.

Canada

Learning Objectives

Understand modern pipeline materials and their applications

Knowledge of important material properties

Understand corrosion and degradation issues of materials

Understand the basics of pipe manufacturing processes

Understand the basic pipe components

Pipes in Ancient Times

Babylonia is often referred to as the birth place of pipe.

The Romans developed some of the most advanced technologies in ancient plumbing systems

Source: Cast Iron Pipe, Standard Specifications Dimensions and Weights (Burlington, New Jersey: United States Cast Iron Pipe & Foundry Co.,1914), p. 13.

Baked clay knees and T-joints made about 2000 B.C in Babylonia

Source: Grantwiggins, grantwiggins.wordpress.com Roman aqueducts (about 100 B.C)

Modern Pipelines Plastic pipe

Concrete pipe

Steel pipe

Sub-sea stainless steel pipe

Pipe/Tubing Materials

Metallic pipes

Steel pipe

Cast-iron pipe

Ductile-iron pipe

Stainless steel pipe

Copper pipe

Polymeric pipes

Plastic pipe (PVC, PE, PP)

Rubber pipe

Elastomer pipe

Composite pipes

Fiberglass pipe

Concrete pipe

Steel Pipe

Seamless steel pipe

Corrugated steel pipe

Alloy of Fe and C (~0.02-2% by weight)

Strong and durable

Susceptible to corrosion

Widely used in the oil and gas industry

Stainless Steel Pipe

Containing > 12% Cr makes the steels stainless

Expensive

Used for critical pipes in chemical plants and nuclear power plants

Used widely in pharmaceutical and food industries

Cast-Iron and Ductile-Iron Pipe

Alloy of Fe and C (2.1 4% by weight)

Lower strength than steel pipes and more brittle

More corrosion resistant than steel pipes (many existing pipes are more than 100 year old)

Used in gas, water and sewage transmission systems

Copper and Copper Alloy Pipe

Lower strength than iron and steels

Ductile and easy to form and bend

Good corrosion resistance Antimicrobial ability Good thermal conductivity Expensive Used mostly in heat

exchangers and household plumbing

Plastic Pipe

Not as strong and durable as metallic pipes

Excellent chemical and corrosion resistance

Light weight

Used for

Water

Waste water

Fiberglass Pipe

Stronger than plastic pipes

Excellent chemical and corrosion resistance

Light weight

Used for Water

Waste water

Natural gas

Concrete Pipe

Strong and corrosion resistant

Rigid and inflexible

Bulky and heavy

Used for

Waste water

Drainage

Stress-Strain Curve ST

RES

S

STRAIN

Stone

Steel

Rubber

Yield strength

Toughness vs. Strength

M. F. Ashby, H. Shercliff, D. Cebon, 2007 Materials: engineering, science, processing and design

STEELS

CAST-IRON DUCTILE-IRON

CONCRETE

PVC, PP, PE

Strength vs. Density

PVC, PP, PE

STEELS

CONCRETE

Strength vs. Cost

PVC, PP, PE ( ~ 0.9 1.4 g/cm3)

STEELS ( ~ 7.7 8 g/cm3) CONCRETE

( ~ 2.2 2.4 g/cm3)

Corrosion - Principle

Metal Oxide (Corrosion) Corrosion is a thermodynamically favorable

process

G < 0

Stainless metals/alloys are not truly non-corrodible. The kinetics of corrosion is just slow.

Corrosion of Metals

H2SO4

Zn

H2SO4

Cu

CORROSION POTENTIAL (V vs. Saturated Calomel Electrode) In sea water

Rust on Iron and Steels

Type of iron oxides: FeO (Wustite) Fe3O4 (Magnetite) -Fe2O3 (Hematite) -Fe2O3 (Maghemite) -FeOOH (Goethite) -FeOOH (Lepidocrocite) -FeOOH (Feroxyhyte)

Patina on Copper

Copper oxide: Cu2O (cuprite), CuO (cupric oxide) Copper chloride: Cu2Cl(OH)3 (atacamite) Copper sulfate: Cu4SO4(OH)6 (brochantite),

Pin Hole Leak on Stainless Steel Pipe

A hole through the pipe due to localized corrosion

Passive Layer

Dense oxide layer

Good bonding to the base material

Act as a barrier to separate the base material with the environment

Metals promoting passivity include: Cr, Al, Ni, (Fe), etc

several nm

Stainless Steels

%Cr 12%

Degradation of Polymeric Materials

Upon exposure to environments, polymer chains can be degraded to lower molecular weight molecules or monomers

Several degradation routes include: photolysis reaction (UV, X-ray, gamma rays, )

thermal degradation

chemicals degradation (oxidation, hydrolysis, )

Polymeric materials loss their strength, shape, color and may also release harmful compounds when degrade

Environmental Factors

Chemicals degradation (oxidation, hydrolysis, )

Thermal degradation Polymer + O2 CO2 + CO + H2O

Photolysis reaction (UV, X-ray, gamma rays, ) R-H R* (radical) + H* (radical)

T

UV

Environmental Effects on Polymeric Materials

Ozone attack on rubber pipe Chlorine-induced cracking on Acetal pipe

Discoloring of paint