What will you do if Carbon Steel pipe is installed in place of LTCS

Introduction:
Low Temperature Carbon Steel (LTCS) is used in piping system when there is a possibility of process fluid temperature falling below -29 degree centigrade during operation. In typical refinery A 106 Gr B material is used for carbon steel and A 333 Gr 6 is used for LTCS in normal operation. There is no major difference in between these two materials in composition. Also no non-destructive testing is available which can ensure these two materials. So if by mistake CS and LTCS mixes up with one another and someone installs CS in place of LTCS without knowing the major operational impact whats the solution?
Reason for Mix up:
 
In construction sites sometimes the material mix up may occur. Someone may be wondering how Carbon steel (CS) and Low Temperature Carbon Steel (LTCS) material could mix up. The main reason is that no physical identification is possible and There are various possibilities which can arise in a construction site like:
1. Common surface preparation & painting yard for all materials.
2. In many cases, the colour coding of pipes (Positive Material Identification-PMI) was not followed due to schedule pressure.
3. On fittings, identification marks are written by low stress punch which was not visible after painting.
4. Common store/contractor/fabrication area in construction site.
5. Ignorance of all concerned about the criticality & impact of mix-up with normal carbon steel.
 
So what will you do in such situation?
Process piping code ASME B 31.3 provides a guidelines in such situations. There is a provision in ASME B 31.3 codes that is based on the stress ratio, the minimum allowable temperature of carbon steel materials can be further lowered without any impact testing.
So whats this stress ratio? 
Stress ratio can be defined as maximum of the
a) Nominal pressure stress divided by allowable stress at design minimum temperature.
b) For piping component with pressure ratings, the operating pressure divided by rated pressure at the design minimum temperature.
c) Combined longitudinal stress, without stress intensification factor, due to pressure, deadweight, and displacement strain divided by allowable stress at the design minimum temperature. (Coincident Conditions)
Note that Stress Ratio requires computed stresses at minimum temperature and coincident pressures and No stress intensification factor to be used for stress calculations.
So calculate stress ratio as per above guidelines.
Now the code provides a graph (reproduced above) from where you can calculate the amount of temperature reduction with respect to stress ratio. From the figure for a temperature reduction of -17 degree centigrade (to make it -29-17=-46 degree centigrade) the required stress ratio is 0.65. So if the calculated stress ratio is within 0.65 then not to be worried. In case the stress ratio exceeds 0.65 provide additional support to reduce stress ratio within that limit.
In this way you can reduce the probable huge impact of material changing (thereby cost) after the erection of piping is already over.
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Anup Kumar Dey

I am a Mechanical Engineer turned into a Piping Engineer. Currently, I work in a reputed MNC as a Senior Piping Stress Engineer. I am very much passionate about blogging and always tried to do unique things. This website is my first venture into the world of blogging with the aim of connecting with other piping engineers around the world.

12 thoughts on “What will you do if Carbon Steel pipe is installed in place of LTCS

  1. How you made = -46 Degree cel, what is the basis. I would like know more on this, my line is running on bridge my Nominal pressure stress + Bridge Displacement is no chance to get the 0.65.??

  2. This only works if the weld procedures also meet the LTCS requirements for impact test. All this allows you to do is use non LTCS. It does nothing for a welded system where the weld procedures were not designed for low temperatures.

  3. WARNING:/CAUTION:
    Good topic, however highly recommend you to include caution statement on this topic for use because it needs high attention on approval from operator perspective.Reading your post should not mislead LTCS can be replaced by CS grade(in any case). Which is wrong.

    If you dont mind, can you share your actual project experience? In terms operating temp..application….etc. LTCS used in design because of depresurrisation case …..

    My point, in first instance CS grade should not been installed where LTCS should be used which itself a default in Construction.It is a design integrity process safety issue.

  4. Would like to have your views on using this approach for inline piping items like valves, strainers etc. for which the geometries are convoluted. The B 31.3 code clearly mentions only pipes and blinds where the stress definitions are straightforward.

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