j press stainless steel piping
Post on 13-Sep-2014
16 views
DESCRIPTION
TO learn more about stainless steel, piping technology and other questions, you may contact Pravin Goel at [email protected] J-PressTRANSCRIPT
1
Stainless Steel in Plumbing
Systems for Buildings and Industry
Pravin Goel Presentation to ADG, CPWD, Chandigarh
10th April, 2013
2
®
• Stainless Steel is an Alloy of Iron with
minimum 10.5 % Chromium
• Chromium forms a layer of Oxide which is
– Very Thin
– Passive
– Impervious
– Self Forming instantly on damage
What is Stainless Steel?
Stainless
Steel
Passive CrO Film
Steel / GI
Rust
3
®
Self Repairing surface
4
Important Properties
5
®
• Aesthetics
• Hygiene, Anti-Bacterial
• High Level of Clean-
ability
• High Strength to
Weight Ratio
• Fire Resistant
• High Temperature
Resistant
• Excellent Fabrication
properties
• Excellent Impact
resistance
• Long Maintenance
Free Life
• Cryogenic (Sub Zero)
Properties
• Different Finishes
Important Properties
6
®
High Resistance to Corrosion
• Suitable even for
environments
like coastal area.
Extremely Severe
Severe
Moderate
Mild
Negligible Corrosion map of India
7
®
Fire Rating
High Strength at High
Temperature
Minimum structural
deformation
Retains half the room
temperature strength at 500°C
No painting required, not
prone to fire
Fire testing: Darchem Engineering, NiDI
8
Stainless Steel Plumbing Systems
9
®
Competing Plumbing Materials in India
GI Galvanized Iron
PVC Polyvinyl chloride
(variants : cPVC, uPVC)
PPR Polypropylene Random
Copolymer
Cu Copper
Composites Metal – Aluminum/ Steel
lined with PVC
Stainless Steel 304, 316, 444
10
®
Global References
Taipei Financial Center Petronas Towers, Malaysia Aurora Residential Towers,
Australia
304 stainless steel pipes and Press Fitting Couplings are used in the Petronas towers,
the tallest buildings in the world, to accommodate High Pressures and Vibration.
Similarly, Taipai Financial Center and Aurora Towers have used these stainless steel
piping system for Fire protection and Hot and Cold Water Supply
Source: High pressure Urban water Distribution Nickel Vol20, number
2, March 2005
11
®
Global References
Lightweight Bridge to carry drinking water in Tokyo.
Source: Peter Cutler, NiDI, JSSA, Nickel Magazine Mar2005
• Lightweight bridges are used to
carry potable water and
pedestrians across river spans
up to 632 m in Japan
• 85% Type 304
• 10% Type 316
• Some 2205 near the coast
• No repainting
• 40% cheaper over 30 years
• First one built: 1983
• Max pipe diameter: 0.8 m
• There are now ~3000 such
bridges in Japan
12
®
• Raw water handing in Meltur Dam,
Cauvery River
• First stainless steel raw water pipe in
India (1998)
• 300 mm x 3 mm grade 304 stainless steel replaced 900 mm x 13 mm cast iron
• Lightweight meant easy installation in
hilly country
• >50 year life expected (2 replace-
ments of cast iron in that time)
• Smooth bore meant sustained low
pumping costs
• LCC analysis: 60% saving over 50
years
Mettur Dam, Tamil Nadu
Source: Peter Cutler, NiDI
13
®
Why Fire Sprinklers Fail?
Newly constructed HDIL Building on fire
18th Nov, 2010
3 persons Killed
Fire in “Bombay House” Tata group HQs
Feb 09, 2011,
14
®
Application in Fire Fighting Systems
15
®
• Cost Effective grade for
Sprinkler system
• Low Nickel Grades 439 or J4
• Cost of pipe competitive with
Tata “C” Class
– About 30% cheaper than SS
304 pipes
• Fittings of 304 grade
• Estimated installed cost
similar to Tata “C” class
pipes.
Special Grade for Fire Sprinklers
Advantages SS Sprinkler System: fast and reliable assembly of the system
without using an open fire,
resistance to high pressure – up to 16 bar,
low flow resistance in pipes and fittings,
low weight of pipes and fittings,
mechanical strength,
very good look of the system,
function of signalisation of not ready-pressed
connections.
16
®
Corrosion Resistance:
Ferritic vs Austenitic
Source: Ferritic Solutions by ISSF
17
®
Salt Spray Test Comparison
Source: Salt Spray Test and its use in ranking stainless
steel- ISSF, May 2008
In Salt spray Test Chloride concentration specified (3%)is hundred times more
than in drinking water (0.025%) and even more than in Sea Water (1.8%)
18
®
• Tests by JSSA on SS Piping
systems (joined by
mechanical coupling)
– Good & air tight
– Do not leak
• 21 storey high rise building
constructed
– Between 1st & 4th Floor, system
was designed to simulate
Earthquake shocks on 5th to 21st
Floor
• Source: Nickel Magazine, Volume 23,
• No. 4, October 2008 Issue
Earthquake Resistance
• The tests were part of a broad, 3-year
program designed to expand the use of long-
lasting stainless steel in residential high-rise
piping systems throughout Japan
19
®
Applications in Hospitals
Corrosion of copper pipe-work in
domestic hot and cold water services
in Hospitals in many areas of
Scotland, where water is soft and
contains high levels of sediment, has
led to increasing use of stainless steel
SS Pressfit System can be pressure tested up to 25 Bar
Source: Bright Future for SS Plumbing, Association of Plumbing and Heating contractors
Erosion in Copper Pipes
20
®
• ANSI Std. – NSF 51 – 2002
– Stainless Steel with min Cr 16% is
recommended for food contact
• European Std. for Food Compatibility
– Stainless Steel with min Cr 13 % recommended
for food contact
• ISSDA recommends SS Plumbing with SS
grades with min 16 % Cr
Food Grade Compatibility
21
®
• No general corrosion so no need for corrosion
allowance
• No Threading required, hence thinner – 1/3rd the
weight of GI pipe
• No need for protective coating
• No need to control water chemistry
• Water purity is maintained
• Lightweight
• Easy to Install
• Equipment is durable with Low Life Cycle Cost
SS Plumbing
22
®
Approvals to use stainless steels
• National approvals in EU Member States will
be replaced by European Acceptance Scheme
• USA:
– specified grades approved for public water supply
without restriction under ANSI/NSF 61
– approved under International Building Code
– approved under International Residential Code
• National approvals in Australia/New Zealand,
China, Malaysia
• India .....
23
®
• 2008 Uniform Plumbing Code – India
– Page No. 119, Clause 605.11
– Galvanised Iron:
• Water Pipes & Fittings made of galvanised
iron shall not be recommended in piping
systems used to convey potable water
Plumbing Code – India
24
®
• Pipe – SS Grade (AISI 304/ 316L or J4
grades)
• Fittings – Innovative Press Fit Design (AISI
304 / 316L grade)
– Sealing Ring
: EPDM
• Press fitting Tools
– Manual / Hydraulic
– Battery Operated
Product – Press Fit Technology
25
®
• Providing and fixing Stainless Steel Grade either AISI 316L or AISI 304 grade
pipes confirming to JIS 3448, JWWA G 116, complete with "Press-Fit" Type
joining system with V-Profile (double crimping), EPDM O-ring for Hot and Cold
water supply (brand “J-Press") capable to withstand temperature upto 110
degree centigrade, such as sockets, bends, elbows, tees, reducers, unions,
flanges, etc. necessary adapters for SS / GI/ Copper and CP fittings, jointing,
sundries, cutting holes in walls/ floors/ slabs and making good complete.
MAKE: J-PRESS
OD Thk
1/2" 15.88 x 0.8 Outer dia pipe
3/4" 22.22 x 1.0 Outer dia pipe
1" 28.56 x 1.0 Outer dia pipe
1.25" 34.0 x 1.2 Outer dia pipe
1.5" 42.7 x 1.2 Outer dia pipe
2" 48.6 x 1.2 Outer dia pipe
Specifications of SS Pipes (for tender)
26
®
Element Unit 304 316L 439 J4 (204)
Ni % 8 – 10.5 10 -14 0.5 1 – 2
Cr % 17.5 –
19.5
16 – 18 17-19 15 – 16.5
C % (max) 0.08 0.08 0.03 0.10
Mn % (max) 2 2 1.0 8.5 – 10
Mo % - 2 – 3
Cu % - 1.5 - 2.0
Si % (max) < 1
P % (max) < 0.045
S % (max) < 0.030
Fe % Balance
Composition of Various Grades
UTS Mpa 515 485 415 650
YS Mpa 205 170 220 325
Hardness HRB (max) 92 95 92 100
27
®
Introducing “V” Profile
Pressing at 3-locations, in front of, on top, and behind the sealing ring
makes joint gas and water-tight.
The latest and foolproof Double Compression pipe fittings
28
®
Press Fitting with V-Profile
Latest V-profile Fittings
29
Grooved Piping for Large
Diameter pipes
30
®
What is Grooved Piping System
• A Fast, Clean and Errorfree way to join
Pipes
– No Welding
– No Threading
– No Flanging
• The Joints are
Removable
31
®
Types of Grooved Fittings
32
®
Couplings
• Couplings are used
to join the Grooved
pipes and fittings.
• Couplings consists
of Gaskets to give a
Pressure-Tight pipe
system
33
®
Components of Grooved System
Housing Nut & Bolts Gasket
34
®
Grooves
• Grooves are rolled
or cut at the ends of
the pipes
• Fittings, Valves and
other components
are manufactured
with the same
grooves
35
Tests and Studies
36
®
Leakage Rate experience (Japan)
Relationship between Ratio of Stainless Steel piping to leakage rate
Source : JSSA
37
®
• If a pipe has been used for a long time, on condition that the same
water power slope, rate of flow will be gradually reduced due to
increase of surface roughness caused by corrosion.
• According to Kohl Brooke and White, the surface roughness of a pipe
increases in proportion to T (years in use).
ε = ε0 + αT
(α constant = 0.06 ~ 2.1mm per year)
Surface Roughness
Source : JSSA, The Society of Heating, Air-Conditioning and Sanitary
Engineers manual <the 13th edition> 121?122 pages.
Flow Qty comparison
(l/min)
SS Carbon Steel
Pipe size
=32 Su,
R=45
At Design
• l/min
C=150 C=100
101 49
After some time
• l/min
C=150 C=80
101 39
38
®
Demolition waste
During operation
During
construction
39
®
Durability Tests in Japan
40
®
Effect of water velocity on corrosion rate
http://www.nickelinstitute.org/index.cfm/ci_id/3080/la_id/1/document/1/re_id/0
Copper
Mild steel
Stainless steel Co
rro
sio
n r
ate
(m
py)
Flow rate (ft/sec)
0 4 8 12 16 20
0
32 28 24
0.003
0.006
0.012
0.009
0.018
0.015
41
®
• The use of SS for general service allows one to
select a smaller dia pipe for a given flow volume
vis a vis Carbon Steel pipes
• eg. 200A for v=3.5 m/s, 7000 l/min is equivalent to
300A, v= 2.0 m/s, 7000 l/min in Carbon Steel
pipes
Savings – Use Lower Dia in SS Piping
Design Manual for SS Plumbing (page 49)
42
®
Test Reports
Pressure Test
• Design for
25kgf/cm2
• Tested upto
95Kgf/cm2
without any
deformation
43
®
• Test for Joint Strength - Tensile
Strength - 3500N before joint slip
Test Report - UTS
SS GI Copper PPR
Material Tensile
Strength (Mpa)
>520 >290 >210 >49
Comparative Strength
44
®
Easy to install
Easy to use in Difficult areas
Time taken :
About 8 hrs against 2-3 days for
GI& Copper (1/3rd time). Expected to
come down further to 4-5 hrs.
45
®
Life Cycle Cost
Initial Installed Costs
+
Costs over the life of the structure
• Materials • Fabrication • Installation
• Maintenance • Replacement • Disruption
46
®
Estimated Cost of a Bathroom
Per Toilet (Internal): GI Rate GI Total SS Rate Discount SS Total
Usage C Class Cost 304 Price Cost
Pipe – Hot+Cold (m) 22 125.10 2752 162.47 146.22 3217 Elbow 15 25.40 381 79.34 71.41 1071 Tee 10 36.50 365 145.21 130.69 1307 Coupling 15 21.00 315 56.00 50.40 756 Threaded Adapter 8 21.00 168 233.95 210.55 1684 Material Cost/ Toilet 3981 8035 Labor Cost 8000 7000
Total Cost of Plumbing in a bathroom 11,981 15,035 100% 125%
Cost Comparison
47
®
Cost GI SS
• Material Cost 3,500 8,000
• Labor Cost 8,000 7,000
• Total Cost 11,000 15,000
• Average Life 10 years 50 years
• Replacement 4 times Nil
– Avg. Cost of Replacement 20,000 0
– Avg. Cost of interiors 30,000 0
Total Cost (4 times) 200,000 0
• Repair Cost 8,000 0
• Total Lifecycle Costs 219,000 15,000
Life Cycle Costs
48
®
Lifecycle costs
Built in 1972 with CS rebar;
corrosion began 2 years later.
first cost £28 million
By 1989, amount spent on repair. £45 million
By 2010, estimated amount that
would be spent on repair.
£120 million
Total amount that would be
spent by 2010
£165 million; (nearly 6
times the original cost !)
Additional first-cost of SS rebar
in critical locations (selective
use)
£3.4 million; (only 12%
increase in initial cost ).
Midlands Link Viaduct, UK
49
®
Summary Comparison Parameter GI PPR cPVC Copper SS Remarks
Corrosion Resistance * 5* 5* **** 5* 304 Grade SS
Hygiene * *** *** **** 5* Recommended for Food and Pharma equipment
Maintenance Free Life * *** ** *** 5* No need of replacement
Enhances Building Life * *** *** **** 5* No leakage, hence no damage to building
Strength of Pipes **** ** * *** 5* SS is the strongest Material
Ease of Installation ** ** *** ** 5* Fast installation with Low Skill worker
Earthquake Proof *** ** ** *** 5* Withstands the vibrations and shocks due to its ductile nature
Cleanability * ** ** **** 5* No deposit buildup due to smooth surface
Food Grade * ** ** **** 5* Meets all food grade standards
High temperature Application *** * * **** 5* Retains strength at high temperature
Low Temperature Application *** * * *** 5* Is not brittle at low temperature, unlike plastics or GI
Fire Resistant **** * * *** 5* Withstands High temperature.
Experience of Usage 5* * * 5* 5* Worldwide usage experinence of 30-40 years
Outside Painting Required * **** **** **** 5* No need of painting
Deposition of Algae ** * * *** 5* Smooth surface prevents algae buildup
Blockage Problem * ** ** **** 5* No deposit buildup hence no blockage
Damage due to Drilling **** ** * **** 5* Strongest material doesn't get damaged due to drilling
High Flow Rate of Water ** *** *** *** 5* Smooth and Wear resistant at High Flow rate
Low Roughness (less scaling) * *** *** **** 5* Smooth surface prevents deposition
Usage in Public Building * * * ** 5* Strong material not easily damaged
Wear Resistant * * * * 5* Not effected by sand or high flow rate
Joint Assurance System *** * * ** 5* No Welding or Solution joining. Permanent Mechanical Joint
Saves Pumping Energy * *** *** **** 5* Smooth surface need less electricity
Water Quality affect * **** **** **** 5* No change in water quality during storage
Pressure Rating *** ** * *** 5* Highest pressure rating of 25 bar
Joint Strength ** * * ** 5* Press fit joint has foolproof and high strength joint
Application Range *** ** ** **** 5* Used for Air, Water and Many Gases
Less conduiting (Jhiri) reqmt ** * * *** 5* As Pipe dia is less
High Wall Strength *** * * *** 5* Less Brick cutting for piping retains its strength
Saving in Labor Cost * **** **** ** 5* Fast installation with Low Skill worker
Saving in Installation Time * *** *** ** 5* Fast to install (approx 1/3rd time of GI piping)
Application in High Rise Buildings *** ** ** **** 5* Not affected by Vibration and Maintenance
Cost *** 5* 5* * ** Slightly more than GI and others
Low Diameter possible * * * **** 5* High flow rates allow for use of low diameter
Life Cycle cost * *** *** **** 5* Lowest lifecycle cost
Total 5 * 1 2 2 1 34 Highest Rating in most parameters
Scale : 1 Poor, 5- Best
50
®
A Big Builder, Mumbai
51
®
• Chennai Airport
• Ambedkar Hospital, Noida
• Crowne Plaza, Rohini
• Indus Hotel, Sahadhara
• AIIMS, Delhi
• Sugdha Hospital, Hisar
• Jindal Hospital, Hisar
• Govind Nursing Home, Hisar
• Heritage Hotel, Gwalior
• Houses – Punjabi Bagh,
Pitampura, Vasant Vihar,
Shanti Niketan, etc
• Farm Houses, Delhi
• Military Engineer Services
• Factories
• DLF- Magnolia, Golf Course,
Gurgaon
• Jindal Guest House, Delhi
• Sony Bakery, Delhi
• Orbit Flat, Mumbai
• Jalandhar
• Chandigarh
• Panchkula
• Ambala
• Haveli, Jalandhar
Some Major Users of SS PressFit Technology
52
Thank You
For more details please contact
PRAVIN GOEL
+91 8800304400,
P-20,FF, Uppals Southend, Sohna Road, Gurgaon
752, Sector 10, Panchkula