Duplex Stainless Steels to

mitigate Corrosion Under

Insulation (CUI) in process
plant piping systems

Martin Holmquist
Sandvik Materials Technology

Sandvik Materials Technology

IOM Conference - Sheffield, UK - 2004-01-14
l Problem background
l Pressure calculations
l Duplex stainless steels
ü Grades
ü Mechanical properties
ü Corrosion properties
l Conclusions

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l Corrosion Under Insulation (CUI) is a significant and
widespread problem
l Significant maintenance expenses are spent on external
piping inspection, insulation removal and re-installation,
painting and pipe replacements
l ExxonMobil Chemical:
ü “Cost for CUI is about 10 percent of the total maintenance
budget”
ü “60-80% of piping maintenance cost is associated with CUI”
l Typically more than 80% of experienced CUI leaks are
associated with piping, and small diameter pipe (equal or
less than 3”) is especially prone to this form of corrosion

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 “Paint & Inspect” “Maintenance &
Inspection free”

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l Painted/Coated Carbon Steel (CS) pipe
l Thermal spray aluminum coated CS pipe
l Stainless Steel (SS) pipe or wrapped/painted SS pipe
ü Austenitic stainless steels
ü Duplex stainless steels

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l While CUI for carbon steel is a relatively slow process,
stress corrosion cracking of standard stainless steel can be
much more rapid and uncontrollable
l Austenitic steels => Susceptibility to Stress Corrosion
Cracking (SCC)
ü This may occur at temperatures above about 60°C (140°F) if
the steel is subjected to tensile stresses and at the same time
comes into contact with certain solutions, particularly those
containing chlorides
l In applications demanding high SCC resistance it is
normally recommended to use duplex stainless steels:
ü E.g. SAF 2304 (low alloy), SAF 2205 (medium alloy) or SAF
2507 (high alloy)

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 American standard ASME B31.3
process piping pressure calculations
l The internal pressures are calculated by using the following
formula:
ü P = (2×tmin×S) / (OD-(2×Y×tmin))
l Where:
üP Internal pressure (ksi)
ü tmin Min wall thickness (mm)
üS Allowable stress (ksi)
ü OD Nominal outside diameter (mm)
üY 0.4 for tmin < OD/6
üY (OD-(2×tmin)) / 2×(OD-tmin) for tmin = OD/6

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l Piping according to ASTM A312 / A790
l Maximum allowed pressure at 90°C (200°F) according to
ASME B31.3:

1” 2” 3”
TP304L Sch40S 219 (3.18) 137 (1.98) 130 (1.88) bar (ksi)
TP304 Sch40S 263 (3.81) 163 (2.37) 155 (2.25)
SAF 2304 Sch10S 296 (4.29) 159 (2.31) 118 (1.71)
SAF 2205 Sch10S 319 (4.62) 171 (2.49) 127 (1.84)
SAF 2507 Sch10S 372 (5.39) 200 (2.90) 148 (2.15)

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l If Sch40S tp304 piping is considered, there is a good
chance that Sch10S duplex pipe will suffice
ü Calculations based on actual design parameters are needed

l Example: Pipe up to 8” and max 260°C (500°F), ASME B31.3

ü Design pressure = 30 bar
ü Allowed pressure for SAF2304 8” Sch10S = 52 bar

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l Pipe thickness reduction will not only save on direct
material cost, but also lead to:
ü Less welding, i.e. lower labor, less supervision and welding
material costs
ü Less total weight, i.e. lower cost for scaffolding, handling etc.

Sch40S => Sch10S

Pipe OD size 3" 8"
Wall thickness reduction 5,49 mm => 3,05 mm 8,18mm => 3,76 mm
Weight reduction/m > 40% > 50%

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 Light phase = Austenite
Dark phase = Ferrite
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l Benefits of Duplex Stainless Steel to mitigate CUI include:
ü Two to three times the strength level of AISI 304
ü Thermal elongation similar to carbon steel
ü Superior or vastly superior resistance to pitting and crevice
corrosion compared to AISI 304
ü Vastly superior stress corrosion cracking resistance
compared to AISI 304
ü Relatively low alloying costs

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 Sandvik Cr Ni Mo N C Si Mn P S
max max max max max

SAF 2507 25 7 4 0.3 0.02 0.8 1.2 0.030 0.015

SAF 2205 22 5.5 3.2 0.18 0.03 1.0 2.0 0.030 0. 015

SAF 2304 23 4.5 - 0.1 0.03 0.5 1.2 0.035 0. 015

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 Rp0,2
MPa N SAF
600 2507
SAF
500 SAF 2205
2304
400

300

304
200

100

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l Hall-Petch effect due to small l Interstitial strengthening with
grain size Nitrogen
1
Hall-Petch: σ 0.2 = σ 0 + k—
d
d = grain size a /2
a/ 2

σ 0.2

Nitrogen atom

1 Fe,Cr,Ni...
—
Decreasing grain size d
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 Duplex stainless steel

Carbon steel

AISI 304

0 5 10 15 (x10 –6)
per °C (20–100°C)

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Main environmental factors that influence pitting:

l The chloride content

l The pH value (the acidity)
l The temperature
l The presence of oxidising agents – oxygen or certain metal
ions.

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 PRE = wt-% Cr + 3.3 x wt-% Mo + 16 x wt-% N

Grade % Cr % Mo %N PRE
SAF 2507 25 4 0.3 41
SAF 2205 22 3.2 0.18 35
SAF 2304 23 - 0.1 24
316/316L 17 2.2 - 24
304/304L 18 - - 18

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l SAF 2507 > SAF 2205 > SAF 2304 > TP 304
CPT, °C (°F), 300 mV SCE
100 CPT,°C (°F), 600 mV SCE
(210) 100
Pitting (210)

80 90
(175) (195)
SAF 2304 SAF 2205
SAF 2507
80
60 (175)
(140)
AISI 316L
70
(160)
40
(105) 25 Cr – Duplex
60
AISI 304L (140)

20
(68) 50 SAF 2205
(120)
No pitting
40 Cl–,%
(105)
0 3 6 9 12 15
(32) 0.01 0.02 0.05 0.10 0.20 0.50 1.0 2.0
5 10 15 20 25
Cl–, weight-%
NaCl, weight-%

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SCC results from the combined action of:
l Tensile stress
l A corrosive medium (e.g. chloride-bearing)
l Elevated temperature (for standard austenitic stainless
steels temp > 60 °C)

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 Temperature,°C (°F)
300
(570)
SAF 2507
904L No cracking
SCC
250
(480)
N08028/Sanicro 28
200
(390)
SAF 2205
SAF 2304
150
(300)

100
(210)

50 AISI 304/304L
(120) AISI 316/316L
No SCC
0
(32) 0.0001 0.001 0.01 0.1 1 10
Cl–, weight-%
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 l For the purpose of comparisons, the following estimates
have been made as to relative price differences per meter
for different piping alternatives:
ü Seamless pipe, ASTM A312/A790
1” 2” 3”
ü Sandvik 5R10 (TP304) Sch40S 100 220 480
ü Sandvik SAF 2304 Sch10S 83 170 330
ü Sandvik SAF 2205 Sch10S 92 200 390
ü Sandvik SAF 2507 Sch10S 140 260 500

l Total costs must encompass the Total Erected Cost (TEC)

and the Life Cycle Costs (LCC)

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 Relative cost (1" - 3" seamless pipe)

600
500
5R10 (TP304) Sch40S
400
Index

SAF 2304 Sch10S

300
SAF 2205 Sch10S
200
100 SAF 2507 Sch10S

0
1” 2” 3”
Pipe size

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l Life Cycle Cost include:
ü Lifetime Cost of Acquisition
• Total Erected Cost (TEC), i.e. the sum of all the direct and indirect
costs to install one linear foot of pipe, including the cost to buy,
fabricate, and install the pipe at the plant
• Total Erected Costs of any piping that needs to replaced
ü Lifetime Support Cost
• The total cost of resources and yearly costs for operation and
maintenance
ü Lifetime Unavailability Cost
• The sum of yearly costs due to unavailability of system and loss of
earnings
l Life cycle savings are inherent in the use of Duplex SS pipe
and should be very significant
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l Duplex Stainless Steel may be considered an interesting
option for a long term strategy to mitigate Corrosion Under
Insulation
l In comparison to TP304 austenitic stainless steel, duplex
stainless steels offer important benefits, including
ü significantly higher resistance to pitting corrosion and stress
corrosion cracking
ü higher strength, giving possibility to use Sch10S piping
instead of Sch40S
l Duplex stainless steels are particularly interesting for pipe
sizes equal or less than 3”, where most CUI problems are
seen to occur
l Total Erected Cost and Life Cycle Cost considerations are
important in the evaluation
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