Stainless Steel in Plumbing Systems for Buildings and Industry

Pravin Goel
Parliament House Annexxe Project 03 September, 2012

What is Stainless Steel?

Stainless Steel is an Alloy of Iron with minimum 10.5 % Chromium Chromium forms a layer of Oxide which is Stainless
Passive CrO Film

Very Thin Passive Impervious Self Forming instantly on damage

Steel

Rust

Steel / GI

Self Repairing surface

Important Properties

Important Properties
Aesthetics Hygiene, Anti-Bacterial High Level of Cleanability 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

High Resistance to Corrosion

Suitable even for environments like coastal area.

Corrosion map of India

Extremely Severe Severe Moderate Mild Negligible

Fire Rating
High

Strength at High Temperature structural deformation half the room temperature strength at 500C painting required, not prone to fire

Minimum

Retains

No

Fire testing: Darchem Engineering, NiDI

Stainless Steel Plumbing Systems

Competing Plumbing Materials in India

GI
Galvanized Iron Polyvinyl chloride (variants : cPVC, uPVC) Polypropylene Random Copolymer

PVC

PPR

Cu

Copper
Metal Aluminum/ Steel lined with PVC

Composites

Stainless Steel

304, 316, 444

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

10

Global References
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

Lightweight Bridge to carry drinking water in Tokyo.

Source: Peter Cutler, NiDI, JSSA, Nickel Magazine Mar2005

11

Mettur Dam, Tamil Nadu

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 replacements of cast iron in that time) Smooth bore meant sustained low pumping costs LCC analysis: 60% saving over 50 years
Source: Peter Cutler, NiDI

12

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,

13

Application in Fire Fighting Systems

14

Special Grade for Fire Sprinklers

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.

15

Corrosion Resistance: Ferritic vs Austenitic

Source: Ferritic Solutions by ISSF

16

Salt Spray Test Comparison

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%)

Source: Salt Spray Test and its use in ranking stainless steel- ISSF, May 2008

17

Earthquake Resistance
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 The tests were part of a broad, 3-year
Source: Nickel Magazine, Volume 23, No. 4, October 2008 Issue

program designed to expand the use of longlasting stainless steel in residential high-rise piping systems throughout Japan

18

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
Erosion in Copper Pipes

SS Pressfit System can be pressure tested up to 25 Bar

Source: Bright Future for SS Plumbing, Association of Plumbing and Heating contractors

19

Food Grade Compatibility

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

20

SS Plumbing
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

21

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 .....

22

Plumbing Code India

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

23

Product Press Fit Technology

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

24

Specifications of SS Pipes (for tender)

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" 3/4" 1" 1.25" 1.5" 2" 15.88 x 0.8 22.22 x 1.0 28.56 x 1.0 34.0 x 1.2 42.7 x 1.2 48.6 x 1.2 Outer dia pipe Outer dia pipe Outer dia pipe Outer dia pipe Outer dia pipe Outer dia pipe

25

Composition of Various Grades

Element Ni Unit % 304 8 10.5 316L 10 -14 439 0.5 J4 (204) 12

Cr
C Mn Mo Cu

%
% (max) % (max) % %

17.5 19.5
0.08 2 -

16 18
0.08 2 23

17-19
0.03 1.0

15 16.5
0.10 8.5 10 1.5 - 2.0

Si P
S Fe

% (max) % (max)
% (max) %

<1 < 0.045

< 0.030 Balance

UTS
YS Hardness

Mpa
Mpa HRB (max)

515
205 92

485
170 95

415
220 92

650
325 100

26

Introducing V Profile
The latest and foolproof Double Compression pipe fittings

Pressing at 3-locations, in front of, on top, and behind the sealing ring makes joint gas and water-tight.

27

Press Fitting with V-Profile

Latest V-profile Fittings

28

Product Specifications Pipe

Specification: JIS G 3448 , JWWA G116
Designation OD mm Thickness mm

15
20 25 32

15.88
22.22 28.58 34

0.80
1 1 1.2

40
50

42.17
48.60

1.2
1.2

29

Pressing / Cutting Tools

Manual Pressing Tool

Pipe Cutter

30

Joining Systems
Fast, Clean & Safe No Soldering, Welding, or Screwing

Pressed Joint After Pressing

31

Grooved Piping for Large Diameter pipes

32

What is Grooved Piping System

A Fast, Clean and Errorfree way to join Pipes
No Welding No Threading No Flanging

The Joints are Removable

33

Types of Grooved Fittings

34

Couplings
Couplings are used to join the Grooved pipes and fittings. Couplings consists of Gaskets to give a Pressure-Tight pipe system

35

Components of Grooved System

Housing Gasket

Nut & Bolts

36

Grooves
Grooves are rolled or cut at the ends of the pipes Fittings, Valves and other components are manufactured with the same grooves

37

Tests and Studies

38

Leakage Rate experience (Japan)

Relationship between Ratio of Stainless Steel piping to leakage rate

Source : JSSA

39

Surface Roughness
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). = 0 ( constant = 0.06 2.1mm per year)
Flow Qty comparison (l/min) At Design l/min After some time l/min SS C=150 101 C=150 101 Carbon Steel C=100 49 C=80 39

Pipe size =32 Su, R=45

Source : JSSA, The Society of Heating, Air-Conditioning and Sanitary Engineers manual <the 13th edition> 121?122 pages.

40

Demolition waste During operation During construction

41

Durability Tests in Japan

42

Effect of water velocity on corrosion rate

0.018 Copper 0.015 0.012 Corrosion rate (mpy) 0.009 Mild steel 0.006 0.003 Stainless steel

0
0 4 8 12 16 20 24 28 32

Flow rate (ft/sec)

http://www.nickelinstitute.org/index.cfm/ci_id/3080/la_id/1/document/1/re_id/0

43

Savings Use Lower Dia in SS Piping

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

Design Manual for SS Plumbing (page 49)

44

Test Reports
Pressure Test Design for 25kgf/cm2 Tested upto 95Kgf/cm2 without any deformation

45

Test Report - UTS

Test for Joint Strength - Tensile Strength - 3500N before joint slip

Comparative Strength

SS Material Tensile Strength (Mpa) >520

GI >290

Copper >210

PPR >49

46

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.

47

Life Cycle Cost

Initial Installed Costs

Materials Fabrication Installation

+ Costs over the life of the structure

Maintenance Replacement Disruption

48

Life Cycle Costs

Cost Material Cost Labor Cost Total Cost Average Life
Repairs Replacement

GI 3,000 8,000 8,000 10 years

1 times 4 times

SS 8,000 7,000 14,000 50 years

Nil

Cost of Repair (5 times) 10,000

Cost of Replacement 60,000 Cost of Interiors 60,000 Total Lifecycle Costs 141,000

0
Nil

0 0 15,000

49

Lifecycle costs
Midlands Link Viaduct, UK
Built in 1972 with CS rebar; first cost 28 million corrosion began 2 years later. By 1989, amount spent on repair. 45 million By 2010, estimated amount that 120 million would be spent on repair. Total amount that would be 165 million; (nearly 6 spent by 2010 times the original cost !) Additional first-cost of SS rebar 3.4 million; (only 12% in critical locations (selective increase in initial cost ). use)

50

Parameter Corrosion Resistance Hygiene Maintenance Free Life Enhances Building Life Strength of Pipes Ease of Installation Earthquake Proof Cleanability Food Grade High temperature Application Low Temperature Application Fire Resistant Experience of Usage Outside Painting Required Deposition of Algae Blockage Problem Damage due to Drilling High Flow Rate of Water Low Roughness (less scaling) Usage in Public Building Wear Resistant Joint Assurance System Saves Pumping Energy Water Quality affect Pressure Rating Joint Strength Application Range Less conduiting (Jhiri) reqmt High Wall Strength Saving in Labor Cost Saving in Installation Time Application in High Rise Buildings Cost Low Diameter possible Life Cycle cost Total 5 *

Summary Comparison
GI * * * * **** ** *** * * *** *** **** PPR cPVC

5*
*** *** *** ** ** ** ** ** * * * * **** * ** ** *** *** * * * *** **** ** * ** * * **** *** **

5*
*** ** *** * *** ** ** ** * * * * **** * ** * *** *** * * * *** **** * * ** * * **** *** **

Copper **** **** *** **** *** ** *** **** **** **** *** ***

SS

Remarks

5*
* ** * **** ** * * * *** * * *** ** *** ** *** * * *** *** * * 1

5*
**** *** **** **** *** **** ** * ** **** **** *** ** **** *** *** ** ** **** * **** **** 1

5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5* 5*
**

5*
* *** 2

5*
* *** 2

5* 5*
34

304 Grade SS Recommended for Food and Pharma equipment No need of replacement No leakage, hence no damage to building SS is the strongest Material Fast installation with Low Skill worker Withstands the vibrations and shocks due to its ductile nature No deposit buildup due to smooth surface Meets all food grade standards Retains strength at high temperature Is not brittle at low temperature, unlike plastics or GI Withstands High temperature. Worldwide usage experinence of 30-40 years No need of painting Smooth surface prevents algae buildup No deposit buildup hence no blockage Strongest material doesn't get damaged due to drilling Smooth and Wear resistant at High Flow rate Smooth surface prevents deposition Strong material not easily damaged Not effected by sand or high flow rate No Welding or Solution joining. Permanent Mechanical Joint Smooth surface need less electricity No change in water quality during storage Highest pressure rating of 25 bar Press fit joint has foolproof and high strength joint Used for Air, Water and Many Gases As Pipe dia is less Less Brick cutting for piping retains its strength Fast installation with Low Skill worker Fast to install (approx 1/3rd time of GI piping) Not affected by Vibration and Maintenance Slightly more than GI and others High flow rates allow for use of low diameter Lowest lifecycle cost

Scale : 1 Poor, 5- Best

Highest Rating in most parameters

51

A Big Builder, Mumbai

52

Some Major Users of SS PressFit Technology

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

53

For more details please contact

PRAVIN GOEL +91 8800304400,

pravingoel@outlook.com P-20,FF, Uppals Southend, Sohna Road, Gurgaon JSteelSystems@gmail.com 752, Sector 10, Panchkula

Thank You
54