MATERIALS & CONSTRUCTION PART A Flashcards
The overriding
considerations when selecting engineering materials for chemical process plant?
High temperature strength
Ability to resist corrosion
Who is responsible for recommending materials
that will be suitable for the process conditions?
Process Designer
Who must also consider the requirements of the
mechanical design engineer
Process engineer
The material selected by the process engineer must have?
- Sufficient strength
- Easily worked
What material should be selected?
Most economical that satisfies both process and mechanical requirements
The material selected will be a material that gives ?
lowest cost over the working life of the plant allowing for maintenance and replacement
What are other factors to be considered when selecting a material?
Product contamination
Process safety
The most important characteristics to be considered when selecting a material of construction are? (7)
Mechanical Properties
Effect of temperature on mechanical properties
Corrosion Resistance
Any special properties required
Ese of Fabrication
Availability in standard sizes
Cost
Under mechanical properties
Strength
Stiffness
Toughness
Hardness
Fatigue
Creep resistance
Measured through tensile strength
strength
Measured through elastic modulus (Young’s Modulus)
Stiffness
Measured through fracture resistance
Toughness
measured through wear resistance
Hardness
Under effect of temperature on mechanical properties particularly the effects of:
high temp
low temp
thermal cycling
Under ease of fabrication
Forming
Welding
Casting
Under Special properties required
Thermal conductivity
Electrical resistance
Magnetic properties
Under Availability in Standard sizes
Plates
Section
Tubes
What materials are satisfactory in all fabrication operations?
Nickel and Monel
Material with the highest annealing temp
Nickel
A measure of the basic strength of a material
Tensile Strength/Stress
the maximum stress that the material will withstand, measured by a standard
tensile test
Tensile Strength/Stress
Older name of Tensile strength/stress
Ultimate Tensile Strength (UTS)
the stress to cause a specified permanent extension
Proof stress
Metals/Alloy that has the highest tensile strength
Monel
Percentage of proof stress
0.1%
What codes are calculated from Tensile strength/stress
ASME Boiler and Pressure Vessel (BPV)
European EN 13445 Pressure vessel code
Hardest metal/alloy
Monel
Ability to resist bending and buckling
Stiffness
Function of elastic modulus of the material and the shape of the cross-sectional area of the member (the second moment area)
Stiffness
Slope=
Stiffness
The stress beyond which a material becomes plastic
Yield point
An indication the tendency for an element to return to its original form after being subjected to a force
Stiffness
Measures how much stress can be applied to an element before it deforms permanently or fractures
Strength
Measures a material’s resistance to surface deformation
Hardness
Associated with tensile strength
Toughness
Measure of the material’s resistance to crack propagation
Toughness
What ductile materials stop the propagation of crack by local yielding at the crack tip. They have crystal structure
Steel
Aluminium
Copper
The crystal structure of the ductile materials stop the propagation of crack by?
Local yielding at the crack tip
In this materials, the local yielding does not occur, that’s why they are brittle
Cast irons
Glass
T/F: Brittle Materials are strong in tension but weak in compression
F
Under ____ any incipient cracks present are closed up
Compression
Technique developed that allowed the use of brittle materials in situations where tensile stress would normally occur
Use of pre-stressed concrete and
Glass-fibre-reinforced plastics in Pressure vessel construction
Are induced to counteract external stresses
Internal stresses
Curve downward
Load deflection
Horizontal side to side
Tendons stressed
Horizontal to center
Prestress forces
Curve upward to center
Prestress deflection
Indication of a material’s ability to resist wear
Hardness
Hardness is measure using
Brinell Madness Test
An important property if the equipment is being designed to handle abrasive solids, or liquids containing suspended solids that are likely to cause erosion
Hadness
Hard to hardest
Lead
Pure aluminium
Copper
Soft brass
Hardened aluminium
Mild steel
Annealed chisel steel
White cast iron
Nitrided surface
Glass
Rhenium diboride
T/F: The higher the impression diameter the lower the Brinell Number
True
Is likely to occur in equipment subject to cyclic loading
Fatigue
Examples where fatigue occurs
Cracks in bicycle frame
Helical gear
Spring
Steering arm
Gradual extension of a material under a steady tensile stress over a prolonged period of time
Creep
Usually only important at high temperatures like with steams and gas turbine blades
Creep
For a few materials like ____ the rate of creep is significant at moderate temperatures
Lead
_____ Will creep under its own weight at room temperature and ___ must be supported at frequent intervals
Lead
Lead linings
Reported as the stress to rupture in 100,000 hours at the test temperature
Creep strength
____ and ____ of metals decrease with increasing temperature
Tensile strength and elastic modulus
____ and ____ of metals decrease with increasing temperature
Tensile strength and elastic modulus
Tensile strength and elastic modulus of metals ____ with increasing temperature
Decrease
Tensile strength of mild steel (low carbon, C<0.25%) is 450 Pa at 25°C falling to ___ @500°C
210 Pa
Young’s Modulus of Mild steel is 200,000 Pa at 25°C and falls to _____ at 500°C
150,000 Pa
SA-285 Plain Carbon Steel plate cannot be used to construct a pressure vessel with design temperature
> 900°F or 482°C
If any pressure vessel designed to for use above 900°F, what must be used
Killed steel or Alloy
Maximum allowable stress used in design is always based on the?
Design temperature
Are superior in sufficient strength at the design temperature that gives an economic and mechanically feasible wall thickness
Stainless steel than carbon steels
Will be important if the material is subjected to high stresses at elevated temperatures
Creep resistance
Special alloys that are used for high temperature equipment such as furnace tubes in environments that do not contain silphur
Inconel or incoloy
A these temperatures, metals that are normally ductile can fail in a brittle manner
Less than 10°C
Serious disasters have occurred through the failure of this at low temperatures
Welded carbon steel vessels
The phenomenon of _____ is associated with the crystalline structure of the metals
Brittle failure
Are more liable to brittle failure
BCC
For this low temperature equipment, austenitic steel (FCC) or aluminium (Hex) should be specified
Cryogenic plant
Liquefied - gas storage