Piping Material Selection & Rating Classification

Introduction

Compared with other forms of transport, pipelines allow a more continuous, stable, and high-capacity supply of hydrocarbons to reach end-users. Pipeline transportation has the advantages of being well-established, efficient, cost-effective, and readily expandable. The products carried in liquid pipelines include a wide range of materials. Process fluid systems gather production from onshore and offshore fields, while transmission lines transport them to terminals, interconnection points, and refineries. Materials selection plays an important role in piping systems. It is crucial to select a piping material that can cope with a variety of applications and damage mechanisms including corrosion, high/low temperatures, constant and cyclic loads, etc. Pipe inspection also plays an important role, in making sure that optimal materials requirements are adhered to. This training course will combine the various disciplines of pipeline engineering, including design, structural integrity, hydraulic considerations, materials types and selection, inspection and maintenance as well as the applications of relevant codes such as ASME B31.3 and API 570.

This course will highlight:

• Main aspects of pipeline design and manufacturing considerations
• Knowledge of the governing principles, related to materials testing
• Relevant structural integrity, pipe failure and corrosion principles
• Main Types of pipeline materials and selection
• Relevant pipe inspection and maintenance techniques

Objectives

At the end of this course, the participants will,

• Develop a deep understanding &  familiarity with basic principles of pipeline design for various industrial applications.
• Be familiar with the practical aspects of structural integrity, related to pipeline operation
• Know the various types of structural and corrosion failure in process pipes
• Have the necessary knowledge about pipeline materials and selection
• Understand aspects of pipe inspection and maintenance practices

Training Methodology

The course will be conducted along workshop principles with formal lectures and interactive work examples included in several workshops. The emphasis in the course will be on the explanation of all technical phenomena and providing answers to problems that are encountered in everyday industrial practice related to the design and materials selection of pipeline systems. Each learning point will be reinforced with practical examples. Computer simulations and videos will be used to illustrate the main aspects of the course. Delegates will receive electronic versions of the course material together with relevant computer simulations and videos. There will be ample opportunities for active discussion and sharing of professional experiences and exchanges that will help solidify the gained knowledge.

Who Should Attend?

• Process engineers
• Chemical engineers
• Mechanical and structural engineers
• Operation personnel
• Engineers and consultants dealing with planning of new production lines and retrofitting plants

Course Outline

1 : Overview of Pipelines and Materials Testing

• Overview of main elements of oil and gas pipelines and systems
• Types of Metallic pipes and main manufacturing techniques, seamless, continuous welded, etc.
• Flanges and Gaskets
• Mechanical Test Requirements
• Tensile testing
• Charpy Impact test
• Hardness testing

Day 2 : Pipeline Materials and Requirements

• Ferrous alloys - Classification of carbon steels, Low-Carbon Steels, Medium-Carbon Steels, High- Carbon and tool Steels, Alloy Steels
• Microstructure of carbon steel
• Alloying selection
• Heat treatment of steel, hardening of carbon steel (by quenching), annealing, hot working, service temperature
• Stainless Steel, Ferritic, Austenitic, Martensitic, Duplex Stainless Steel, full stainless steel technical data
• Cast Irons – types and selection.
• Nickel-based alloys, selection for corrosion and elevated service temperature
• Titanium alloys - types of titanium alloys (α, β and αβ) and selection of titanium alloys for corrosion resistance

Day 3 : Mechanical Design Considerations

• Temperature variations expansion loops and expansion joints
• Stress analysis examples, thermal expansion
• Maximum allowable pressure and wall thickness calculations and corrosion allowance
• Welding types and requirements
• Heat Affected Zone (HAZ)
• Alternative materials, Glass Fibre Reinforced (GRP), Polyethylene pipes, etc.
• ASME B31 and materials-related considerations

Day 4 : Failure Mechanisms, Corrosion Damage and Corrosion Mitigation

• Cyclic loading (Fatigue) damage of piping materials
• High temperature (Creep) failure of piping materials
• Corrosion principles and Electrochemical cell
• Types of corrosion, uniform, bimetallic, hydrogen-induced, erosion-corrosion, etc.
• Materials selection examples
• Cathodic Protection
• Coatings

Day 5 : Pipeline Maintenance and Inspection

• Pigging methods for cleaning
• Pigging Inspection
• Hydro-testing
• Inspection (NDT) techniques, x-ray, ultrasonic, holiday detection, etc.
• Pipe repairs
• Overview of API 570 Pipe Inspection Code