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What are the most important factors when selecting materials for a high-pressure pipeline system?

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High-pressure pipeline systems are essential for transporting fluids and gases in various industries, such as oil and gas, petrochemical, power, and water. However, designing and operating such systems pose significant challenges, especially in terms of selecting the right materials. In this article, you will learn about the most important factors that influence the material selection for high-pressure pipeline systems, and how to avoid common pitfalls.

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Saeed Moshayedi

Deputy Head Of Inspection Department at 6th Refinery of South Pars Gas Complex

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Milad Mojtahedi

Assistant Professor of Materials Science & Metallurgical Engineering, Razi University
Rafael Acosta

Sr. Project Director/Joint Venture Business

1 Pressure Rating

One of the first factors to consider when selecting materials for a high-pressure pipeline system is the pressure rating. The pressure rating indicates the maximum internal pressure that the pipeline can withstand without failing or leaking. The pressure rating depends on the material properties, such as strength, ductility, and toughness, as well as the pipe dimensions, such as wall thickness, diameter, and length. You should choose materials that have adequate pressure ratings for the intended application, and follow the relevant standards and codes, such as ASME B31.3 or API 5L.

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Saeed Moshayedi

Deputy Head Of Inspection Department at 6th Refinery of South Pars Gas Complex
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In high pressure piping according to ASME B31.3 impact test is essential. The point is that in high pressure piping, pipe is thick, therefore stress becomes three-dimensional (in Barlow's formula, radial stress is assuming zero) as well as probability for brittle fracture is considerable, which means we need higher toughness and impact test is a great index for that.

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2 Temperature Range

Another factor that affects the material selection for a high-pressure pipeline system is the temperature range. The temperature range refers to the minimum and maximum temperatures that the pipeline will be exposed to during operation. The temperature range influences the material behavior, such as thermal expansion, contraction, stress, and fatigue. You should choose materials that have suitable thermal properties, such as thermal conductivity, coefficient of thermal expansion, and heat capacity, and that can resist thermal shock and creep. You should also consider the effects of temperature on the corrosion resistance and chemical compatibility of the materials.

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Milad Mojtahedi

Assistant Professor of Materials Science & Metallurgical Engineering, Razi University
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A high-pressure piping system, as defined by ASME B31.3, is a system with a design pressure that exceeds the ASME B16.5 Class 2500 (PN 420). It needs specified material selection and design according to temperature. Carbon steel is a common material used in high-pressure piping systems, but it can only sustain temperatures below 427°C. Above this temperature, graphitization of carbon steel occurs, which makes it susceptible to failure. Stainless steel, on the other hand, can be used up to 550°C. For elevated temperatures up to 630°C, alloy steels with high chromium and molybdenum content are recommended.

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3 Corrosion Resistance

Corrosion resistance is a crucial factor for selecting materials for a high-pressure pipeline system, as corrosion can degrade the material performance, reduce the service life, and increase the risk of failure and leakage. Corrosion is the deterioration of the material due to chemical or electrochemical reactions with the environment, such as the fluid, gas, soil, or air. You should choose materials that have high corrosion resistance, such as stainless steel, nickel alloys, or titanium alloys, or that can be protected by coatings, linings, or cathodic protection. You should also consider the type and severity of corrosion, such as uniform, pitting, crevice, galvanic, or stress corrosion cracking.

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Riliwan Bakare

API 570 Piping Inspection|NDT Inspection|Asset Integrity Inspection|Corrosion management|
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Corrossion resistance is one of the important factors that can never be overlooked for selecting a material for high-pressure pipline system.As corrossion is the most mechanism responsible for material failure in materials engineering

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4 Chemical Compatibility

Chemical compatibility is another factor that influences the material selection for a high-pressure pipeline system, as chemical compatibility determines the suitability of the material for the specific fluid or gas that will be transported. Chemical compatibility is the ability of the material to resist chemical attack, degradation, or reaction with the fluid or gas. You should choose materials that have high chemical compatibility, such as polyethylene, polypropylene, or polyvinylidene fluoride, or that can be isolated by gaskets, seals, or valves. You should also consider the concentration, pH, and composition of the fluid or gas, as well as the presence of impurities, additives, or contaminants.

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5 Cost and Availability

The last factor to consider when selecting materials for a high-pressure pipeline system is the cost and availability. The cost and availability refer to the economic and practical aspects of the material selection, such as the initial investment, maintenance, replacement, and disposal costs, as well as the supply, demand, and delivery time of the materials. You should choose materials that have low cost and high availability, such as carbon steel, copper, or brass, or that can offer long-term benefits, such as reduced energy consumption, improved reliability, or enhanced safety. You should also consider the market trends, regulations, and environmental impacts of the materials.

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Saeed Moshayedi

Deputy Head Of Inspection Department at 6th Refinery of South Pars Gas Complex
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As high pressure pipings has more risks, %100 Radiographic Test (RT) is included for examination of material of construction in related codes and standard which might impose more cost to the project than normal pressure piping in which we could select randam RT.

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Rafael Acosta

Sr. Project Director/Joint Venture Business
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Materials and Equipment to match Operations parameters and Compatible with type of flow. All QA & QC Evaluation Criteria must match the Construction Process and the Regulatory Compliance along with Safety and Operational Impact to the business.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Paul Chamberlin, BSME

Project & Mechanical Engineer experienced in industrial facilities, e.g., lithium extraction, thermal power plants, oil & gas gathering, processing, pipelines, and compressor/pump stations. Western US only.
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As you get into the higher SMYS pipe materials the number of pipeline welders that are qualified to weld the high SMYS pipe decreases.

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What are the most important factors when selecting materials for a high-pressure pipeline system?

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1 Pressure Rating

2 Temperature Range

3 Corrosion Resistance

4 Chemical Compatibility

5 Cost and Availability

6 Here’s what else to consider

Chemical Engineering

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