P a m p h l e t 9 4

S o d i u mH y d r o x i d e S o l u t i o n a n d P o t a s s i u m H y d r o x i d e S o l u t i o n ( C a u s t i c ) S t o r a g e E q u i p m e n t a n d P i p i n g S y s t e m s E d i t i o n 4

S e p t e m b e r 2 0 1 2

Table of Contents
1. INTRODUCTION................................................................................................................... 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3. SCOPE ............................................................................................................................... 1 CHLORINE INSTITUTE STEWARDSHIP PROGRAM ................................................................... 1 DEFINITIONS AND ACRONYMS .............................................................................................. 1 SAFETY PROGRAMS ............................................................................................................ 3 DISCLAIMER ........................................................................................................................ 3 APPROVAL .......................................................................................................................... 3 REVISIONS .......................................................................................................................... 3 REPRODUCTION .................................................................................................................. 4 PRODUCT DATA - SODIUM HYDROXIDE AND POTASSIUM HYDROXIDE SOLUTIONS (CAUSTIC) . 4 CAUSTIC IN TRANSPORTATION ............................................................................................. 4 REACTIVITY AND COMPATIBILITY DATA................................................................................. 4 PERSONAL PROTECTION INFORMATION ................................................................................ 5 SPILL PREVENTION PROGRAM ............................................................................................. 5 RELATED INSTITUTE PUBLICATIONS ..................................................................................... 5 REGULATORY AND INSURANCE REQUIREMENTS ................................................................... 5

GENERAL INFORMATION .................................................................................................. 4

EMERGENCY RESPONSE .................................................................................................. 5 3.1 EMERGENCY PLANNING....................................................................................................... 5 3.2 CHEMTREC AND CANUTEC ............................................................................................. 6 3.3 REPORTING OF RELEASE..................................................................................................... 6

4.

STORAGE TANKS ............................................................................................................... 8 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 GENERAL ............................................................................................................................ 8 TANK CAPACITY .................................................................................................................. 9 SAFETY ............................................................................................................................ 10 SECURITY ......................................................................................................................... 10 OPERATIONAL CONSIDERATIONS ....................................................................................... 11 DESIGN ............................................................................................................................ 11 TANK ATTACHMENTS AND OPENINGS (APPURTENANCES) ................................................... 16 SPILL CONTAINMENT ......................................................................................................... 17 INSPECTION AND MAINTENANCE ........................................................................................ 18 GENERAL .......................................................................................................................... 19 PIPING LAYOUT ................................................................................................................. 19 PIPE AND PIPING COMPONENTS ........................................................................................ 21 VALVES ............................................................................................................................ 31 OTHER COMPONENTS ....................................................................................................... 43 INSTRUMENTATION ............................................................................................................ 44 INSPECTION AND MAINTENANCE ........................................................................................ 44

5.

PIPING SYSTEMS .............................................................................................................. 19 5.1 5.2 5.3 5.4 5.5 5.6 5.7

6.

OTHER EQUIPMENT ......................................................................................................... 46 6.1 PUMPS ............................................................................................................................. 46 6.2 HEAT EXCHANGERS .......................................................................................................... 47 6.3 AGITATORS AND MIXERS ................................................................................................... 47

7.

REFERENCES.................................................................................................................... 49 7.1 7.2 7.3 7.4 7.5 7.6 INSTITUTE PUBLICATIONS .................................................................................................. 49 API STANDARD SPECIFICATIONS ....................................................................................... 49 ASME CODES AND STANDARDS ........................................................................................ 49 ASTM STANDARD SPECIFICATIONS ................................................................................... 50 NACE CORROSION DATA .................................................................................................. 51 OTHER REFERENCES ........................................................................................................ 51

APPENDIX A .............................................................................................................................. 54 APPENDIX B .............................................................................................................................. 58 APPENDIX C .............................................................................................................................. 59 APPENDIX D .............................................................................................................................. 60 APPENDIX E .............................................................................................................................. 61 APPENDIX F .............................................................................................................................. 71

ii

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

1. 1.1

INTRODUCTION SCOPE This publication is intended to provide useful information concerning the storage and piping of sodium hydroxide and potassium hydroxide solutions. This pamphlet's objective is to offer practical suggestions in the design, construction and operation of systems suitable for 50% (and less) plus 73% solutions of sodium hydroxide, and for 50% (and less) solutions of potassium hydroxide. The requirements of anhydrous sodium hydroxide and potassium hydroxide have not been considered.

1.2

CHLORINE INSTITUTE STEWARDSHIP PROGRAM The Chlorine Institute (CI) exists to support the chlor-alkali industry and serve the public by fostering continuous improvements to safety and the protection of human health and the environment connected with the production, distribution and use of chlorine, sodium and potassium hydroxides, and sodium hypochlorite; and the distribution and use of hydrogen chloride. This support extends to giving continued attention to the security of chlorine handling operations. Institute members are committed to adopting CIs safety and stewardship initiatives, including pamphlets, checklists, and incident sharing, that will assist members in achieving measurable improvement. For more information on the Institutes stewardship program, visit CIs website at www.chlorineinstitute.org.

1.3

DEFINITIONS AND ACRONYMS In this pamphlet, the following meanings apply unless otherwise noted: Alloy 20 ANSI API ASME ASTM CANUTEC caustic caustic embrittlement one of the so-called super stainless steels that was designed for maximum resistance to acid attack. American National Standards Institute American Petroleum Institute American Society of Mechanical Engineers American Society for Testing and Materials Canadian Transport Emergency Centre generic term for either caustic soda or caustic potash a term that describes the stress corrosion cracking (intercrystalline cracking) of steel caused by exposure of caustic solutions while under tensile stress.

2
caustic potash caustic soda CERCLA CFR CHEMTREC CPVC DOT ECTFE EPDM FEP FRP Hastelloy HAZCOM Inconel Institute kPa Monel MSDS OSHA PFA psig

PAMPHLET 94

solutions of varying concentration of potassium hydroxide (KOH) solutions of varying concentration of sodium hydroxide (NaOH) Comprehensive Environmental Response, Compensation and Liability Act of 1980. Code of Federal Regulations (U.S.) Chemical Transportation Emergency Center chlorinated polyvinyl chloride U.S. Department of Transportation copolymer of ethylene and chlorotrifluoroethylene ethylene propylene diene monomer or ethylene propylene diene terpolymer fluorinated ethylene propylene fiberglass reinforced plastic a registered trademark of Haynes International, Inc. Hazard Communication (see 29 CFR 1910.1200) a registered trademark of Haynes International, Inc. The Chlorine Institute kilopascal a registered trademark of Special Metals Corporation Material Safety Data Sheet U.S. Occupational Safety and Health Administration, Department of Labor perfluoroalkoxy pounds per square inch gauge

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

PTFE PVC release SCC spill TC transfer site WHMIS 1.4 SAFETY PROGRAMS

polytetrafluoroethylene polyvinyl chloride any loss of caustic to soil or water systems from the containment (primary or secondary) vessel, pipe or equipment stress corrosion cracking any loss of caustic from primary containment vessel, pipe or equipment but not to soil or water systems Transport Canada any facility where product is loaded and/or unloaded Workplace Hazardous Material Information System (Canada)

Every site handling caustic should have an ongoing safety program. Periodic training sessions and safety inspections must be conducted in accordance with DOT and OSHA regulations and equivalent Canadian requirements. Special attention should be paid to the appropriateness of emergency procedures and to equipment to be used in an emergency. Additional information on safety programs is available from the Institute and from caustic suppliers. 1.5 DISCLAIMER The information in this pamphlet is drawn from sources believed to be reliable. The Institute and its members, jointly and severally, make no guarantee, and assume no liability, in connection with any of this information. Moreover, it should not be assumed that every acceptable procedure is included, or that special circumstances may not warrant modified or additional procedure. The user should be aware that changing technology or regulations may require a change in the recommendations herein. Appropriate steps should be taken to ensure that the information is current when used. These recommendations should not be confused with federal, state, provincial, municipal or insurance requirements, or with national safety codes. 1.6 APPROVAL The Institute's Health, Environmental, Safety, and Security Issue Team approved Edition 4 of this pamphlet on September 4, 2012. 1.7 REVISIONS Suggestions for revisions should be directed to the Secretary of the Institute. 1.7.1 Significant Revisions in Current Edition There are no significant revisions to Edition 4 of this pamphlet.

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1.8 REPRODUCTION

PAMPHLET 94

The contents of this pamphlet are not to be copied for publication, in whole or in part, without prior Institute permission. 2. 2.1 GENERAL INFORMATION PRODUCT DATA - SODIUM HYDROXIDE AND POTASSIUM HYDROXIDE SOLUTIONS (CAUSTIC) Sodium hydroxide solution and potassium hydroxide solution are the proper shipping names for these products. However, this pamphlet will henceforth use the generic product names caustic soda and caustic potash (or caustic to mean both). Personnel handling caustic solutions should be thoroughly familiar with the chemical and physical properties as well as the health hazards and first aid procedures appropriate for these products. It is highly recommended that the reader review the safe handling practices outlined in the data sheets found in Appendix A. 2.2 CAUSTIC IN TRANSPORTATION Caustic soda and caustic potash are classified for transportation by DOT and TC as Class 8 (corrosive materials). They are shipped as solutions in bulk containers. However, due to relatively high freezing points (Appendices B and D) the materials may solidify during transportation if shipping precautions are not taken into consideration. Caustic soda is generally shipped as 50% concentration, while caustic potash is shipped at a concentration of 45% to 50%. "Fifty-percent caustic soda" is the commercial designation for caustic concentrations typically 48% to 52%. For purposes of consistency, all references to 50% caustic in this pamphlet are intended to include concentrations typically 48% to 52%. All persons handling bulk transports must be familiar with all applicable regulations and safety procedures for the particular product and its concentration. Higher concentrations of caustic soda, typically at 73%, are generally shipped at elevated temperatures that require special handling. 2.3 REACTIVITY AND COMPATIBILITY DATA Under normal use and conditions, caustic is generally regarded as stable. However, caustic will rapidly attack and destroy such materials as leather, wool and the metals and the alloys of aluminum, zinc, and tin. In addition, the reaction with these metals may generate flammable hydrogen gas. The reaction of caustic with aluminum is particularly vigorous and contact should be avoided. Both caustic soda and caustic potash are strongly alkaline and may react violently with acidic solutions. These reactions will generate heat and could cause splattering of the liquid. Caustic will also react vigorously with many organic chemicals and due caution is required. Neither caustic soda nor caustic potash form hazardous decomposition products nor contribute to hazardous polymerization. Considerable heat is generated when caustic is diluted with water. Proper handling procedures must be followed to prevent vigorous boiling, spattering or violent eruption of the diluted solution.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

2.4

PERSONAL PROTECTION INFORMATION Detailed requirements for personal protective equipment should be established on a site specific basis. Handling caustic requires adequate personal protective equipment to protect the handler/user against product hazards. This topic is addressed in the Occupational Safety and Health Standard in 29 CFR 1910 Subpart I PPE. Users of this pamphlet should be familiar with these regulations and incorporate their requirements into the training of those involved in caustic handling. Proper caustic compatible protective equipment (which may include hard hat, chemical splash goggles, full face shields, gloves, rubber boots, etc.) should be worn when handling caustic. Safety showers and eye wash facilities should be located in the immediate work area. Additional information about protective equipment for handling caustic can be found in CI Pamphlet 65 Personal Protective Equipment for Chlor-Alkali Chemicals (7.1).

2.5

SPILL PREVENTION PROGRAM All transfer and handling facilities must have a documented spill prevention and containment program for all hazardous materials. See Section 4.8 for recommendations on caustic spill containment. Consideration must be given to the containment of caustic spills and leaks to comply with applicable federal, state and local regulations. (7.6 and Appendix A).

2.6

RELATED INSTITUTE PUBLICATIONS For related information regarding physical properties, handling, protective equipment, tank cars and tank motor vehicle the reader should refer to Section 7.1 and Appendix A.

2.7

REGULATORY AND INSURANCE REQUIREMENTS The location, capacity, design, maintenance and operation of caustic storage installations may be subject to local, state or provincial regulations and to insurance company requirements. Installations shall fully comply with all applicable requirements.

3. 3.1

EMERGENCY RESPONSE EMERGENCY PLANNING Emergency/contingency plans should be in place for all areas of caustic handling and transportation. These plans should identify hazards, develop systems for accident prevention, and procedures for minimizing loss and damage resulting from accidents. Copies of the plan should be on file as required by regulation.

PAMPHLET 94

Transfer Sites All personnel responsible for transfer operations should be completely familiar with the site emergency plan for handling spills and leaks of caustic. Refer to OSHA regulations 29 CFR 1910.120 for emergency response training. Each site should have proper emergency response equipment on hand. Transportation The DOT and TC have specific training requirements applicable to handling of hazardous materials. Shippers and consumers must familiarize themselves with these specific requirements, and the emergency response communication standards and OSHA/WHMIS requirements for off-site responder training. 3.2 CHEMTREC AND CANUTEC For transportation-related incidents in the U.S., one should utilize CHEMTREC, the Chemical Transportation Emergency Center in Washington, DC, as the dispatch agency. CHEMTREC operates around the clock - 24 hours a day, seven days a week to receive calls from any point in the United States and Canada at 800-424-9300. CHEMTREC provides immediate advice for those at the scene of emergencies, then promptly contacts the appropriate shipper and others as required. Registration with CHEMTREC is provided through the American Chemistry Council. In Canada, CANUTEC, the Canadian Transport Emergency Centre in Ottawa, should be used as the dispatch agency. Their telephone number is 613-996-6666 (call collect) or *666 from a mobile phone in Canada only. CANUTEC is administered by Transport Canada and operates in a manner that is similar to CHEMTREC. 3.3 REPORTING OF RELEASE Sodium hydroxide and potassium hydroxide are identified as hazardous substances in Table 302.4 - List of Hazardous Substances and Reportable Quantities of 40 CFR 302.4. CERCLA requires immediate notification of a release equal to or in excess of the reportable quantity. The reportable quantity of both substances is currently 1,000 pounds (454 Kg). The 1,000 pound reportable quantity is based on a 100% basis (i.e. a 50% caustic soda solution contains 6.4 lbs. per U.S. gallon.). Should a reportable release occur in the U.S., the law requires these agencies be notified as soon as possible: National Response Center (1-800-424-8802) State Emergency Response Commission Local Emergency Planning Committee

In addition, state and local laws may require reporting to the appropriate state and/or local environmental agencies. While the laws/regulations do not require direct notification of the Coast Guard, many facilities have found it mutually beneficial to directly notify the Coast Guard regarding releases that might affect the use of a waterway.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

In most cases, the initial report will be by telephone for expediency. A follow up written report is also required. It is suggested that the following information be given during the telephone report: Name of company involved Name of caller Plant location Chemical released Date, time, and duration of release Release quantity estimate Information as to whether or not the release is continuing or has been stopped The medium or media into which the release occurred (air, water, land) Any known or anticipated acute or chronic health risks associated with the emergency and, where appropriate, advice regarding medical attention for exposed individuals (Health Hazard Data and First Aid information from the current caustic Material Safety Data Sheet (MSDS) may be utilized.) Precautions taken as a result of the release Wind speed and direction Name and telephone number of person to contact for further information

If any agency notified has emergency response capabilities and/or responsibilities, you should also inform them of any assistance you need. A written follow-up emergency notice is required as soon as practicable after a reportable release. This document should: Set forth and update the verbal information given previously Discuss actions taken to respond to and contain the release Discuss any known or anticipated acute or chronic health risks associated with the release Where appropriate, give advice regarding medical attention for exposed individuals.

It is also suggested, but not required, that the final report list the cause and corrective actions, with a timetable if appropriate. If the report is mailed, it is recommended to be sent by certified mail, return receipt requested.

PAMPHLET 94

3.3.1

Federal Reporting Requirements In addition to reporting to the National Response Center, certain facilities are required to make annual reports of hazardous substances and releases (See 40 CFR 370).

3.3.2

State Reporting Requirements Varies from state to state, but usually includes: State Emergency Response Commission in addition to the immediate reporting notification

Immediate notification required: 3.3.3 State Environmental Department or environmentally responsible agency. This may be more than one agency. Reporting time limits vary. State Police. Reporting time limits vary.

Local Reporting Requirements In addition to reporting to the Local Emergency Planning Committee, immediate notification may be required to the following. Reporting time limits vary. Town or city leadership groups Local police or sheriff Local fire department(s) Local health department

4. 4.1

STORAGE TANKS GENERAL The guidelines in this section are intended to provide sound engineering practices for the design, fabrication, operation and maintenance of above ground caustic storage tanks. Caustic storage tanks are available in several shapes, and in both a vertical and a horizontal orientation. However, the most common design is a vertical cylindrical design, using a flat bottom and a closed top. This pamphlet will concentrate its comments on the vertical cylindrical design. The guidelines in this section can be considered independent of the shape selected.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

This pamphlet will address storage of caustic up to and including concentrations of 73%. The storage of anhydrous caustic is not covered. Prior to designing a safe, secure and reliable caustic storage facility the expected service conditions, product quality, safety and security requirements must be completely defined. Service conditions to be defined shall include the capacity, temperature ranges and pressure ranges. Product quality parameters to be defined shall include caustic concentration, product contamination, and dilution effects. These parameters provide the information required for the selection of shape, and the materials of construction. Safety requirements that can affect the design include containment needs, environmental protection, personnel safety, and local codes. Operational considerations to be defined shall include utilities, loading and offloading, lighting, freeze protection, operation logic, and maintenance. Site assessment must include soil analysis, ambient conditions including wind, snow, flood, and seismic rating for the area.

4.2

TANK CAPACITY General The caustic storage system capacity should be the minimum that satisfies: operation maintenance inspection inventory and shipping requirements of the facility environmental risks

Storage Capacity It is suggested that the size of a consumer's storage tank be one and one half times the size of the delivered transport container. This ratio is often reduced for large capacity tanks. If a continuous supply of caustic is being consumed at the site, at least two tanks should be considered to facilitate filling and gauging for product transfer, inspection, and maintenance. If carbon steel construction is used, the amount of iron pick-up can be minimized by keeping the contact area of metal with caustic solution to a minimum. From this standpoint, a height-to-diameter ratio of 1/1 is optimal. In addition to minimal surface area per unit volume, problems related to heating and insulation are minimized.

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PAMPHLET 94

4.3

SAFETY Consideration should be given in locating the caustic tank to minimize the potential exposure to workers. However, in locating the tank in a remote area of the facility, security concerns may be elevated. The tank area should be well-marked with the appropriate warning signs and labels, as identified in the HAZCOM plans. If located in heavy traffic areas, consideration should be given to controlled access. In the U.S., the federal OSHA Hazard Communication regulations 29 CFR 1910.1200 requires all manufacturing plants to label hazardous chemical vessels and ensure that all employees are trained concerning the hazards involved. State and local government regulations may require more specific labeling. In Canada, federal regulation WHMIS (Workplace Hazardous Material Information System) is applicable.

4.4

SECURITY Security concerns should be addressed including potential for breach, consequences and mitigation. As with the other components of a risk assessment, the community may be asked to participate in the design process. In identifying security requirements, all the potential methods of breaching security must be identified, the consequences of sabotage and the methods to reduce these security risks should be evaluated and where appropriate implemented into the design of the site. Caustic storage facility security concerns must be considered by having the proposed site and facility design reviewed by those having security expertise. Design issues addressed should include: Physical location relative to other facility components and the surrounding community Clear visibility; open/clear areas Lighting Surveillance including security personnel, motion detectors and cameras Locked compounds and equipment (valves, pumps, etc.) Fencing, bollards, trenches, entrance/exit points Access control system

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

11

4.5

OPERATIONAL CONSIDERATIONS Essential utilities such as air, water, steam, and power should be provided in the storage area. A potable water supply should be included for eye wash fountains and safety showers. Non-potable water can be used for flushing the tank, lines, etc. A steam supply to the caustic tank area may be used for freeze protection by maintaining the tank temperature above 60oF (15.6oC) and for thawing and transferring caustic without the use of a pump from some types of railcars. If loading or off-loading of tank trucks or railcars is considered, the tank site must be sized large enough for safe maneuvering and positioning of the vehicles. The tank area should be well lighted, even if night operations are not planned, to facilitate the efficient management of a potential emergency that could occur day or night. An automatically controlled lighting system is preferred and should include emergency lighting in critical working areas such as pump rooms, valve areas, etc. in case of power failure. Because of the high freezing point of 50% caustic (see Appendices B and D), it is desirable to locate these tanks in heated buildings maintained above 60oF (15.6oC). However, this may not be practical for large storage facilities where the tank must be placed outdoors with a source of heat supplied to prevent freezing and flow problems. The tank layout and access should consider tank openings (inlet and outlet), maintenance, instrumentation, logic such as level indication/controls and spill containment. All personnel responsible for operating the caustic storage facility must also be trained on security issues protocol.

4.6 4.6.1

DESIGN General The storage tank design should be performed by persons experienced in the area of storage tank design. All the users requirements including the location and security (accessibility) assessment should provide the basis of the tank design.

4.6.2

Design Standard The basis of the design for metallic vertical cylindrical tanks can be either API 12F, or API 620, or API 650 standard (7.2). The design parameters will govern the standard selected. ASME Section VIII is an appropriate design standard for metallic horizontal tanks. ASME RTP-1 (7.3.1) is an appropriate design standard for reinforced thermoset plastic vessels. The design of the storage tank will require complete documentation. The documentation should include the process description, piping and instrument design, definition of the standards employed, design calculations, certified tank drawings, materials of construction and record of proof testing. If the storage tank has an internal supported roof, the open structural shapes are preferred over pipe for the supports, because all surface areas can be visually inspected for corrosion.

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PAMPHLET 94

4.6.3

Materials of Construction General The selection of material or combination of materials should take into consideration the caustic concentrations, temperature and purity control. Carbon steels, carbon steel with protective coatings or linings, carbon steel with clad alloys, stainless steels, nickel, and nickel alloys have all been successfully utilized as materials of construction for storage tanks. Refer to Appendix C, Caustic Soda Service Graph. Appendix C is also applicable to caustic potash based on membership experiences. Carbon steel is common at lower concentrations ( 51%) and temperatures ( 120oF (48.9oC)) where iron contamination is not a concern. At higher o o concentrations and temperatures over 120 F (48.9 C), carbon steel will experience accelerated corrosion and stress corrosion cracking (sometimes referred to as "caustic embrittlement"). Carbon steel can be protected with the application of various lining or coating systems. The success of the liners is typically a function of temperature. There is a wide range of liners in service that include various rubbers, coating systems, metal cladding and thermoplastic linings. Stainless steels have been used successfully, but possible failure from exterior chloride cracking should be considered. Nickel and nickel alloys can be used at any combination of temperature and concentration. The use of these materials is typically found in high temperature, high concentrations, or critical purity applications. Acceptable alternatives also include nickel or nickel alloy clad to the carbon steel. When this option is used, additional precaution in the welding and joining of the dissimilar metals is necessary. FRP fabricated storage tanks for caustic are not commonly used, but may be considered if metal contamination of the caustic is a significant concern. Important parameters in selection are structural strength, ability to heat trace as compared to metal construction, and corrosion barrier. Because caustic can readily attack the glass fibers, synthetic surfacing veils, with an appropriate corrosion barrier, should be specified. The proper selection of a corrosion barrier is critical. Some of the vinyl ester and epoxy resins have good resistance for caustic service within certain temperature and concentration limits. The resin selection should be carefully reviewed for any potential FRP applications, especially if the process caustic concentration is greater than 20%. The selection of a corrosion allowance is very important. Steels and stainless steels can be attacked from inside or outside the tank. For floors and walls, a minimum corrosion allowance of 1/8 inch (3 mm) is typical for carbon steel. Corrosion rates must be carefully considered for the tank roof, and for any internal support system for the roof.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

13

50% and Less Caustic Storage Tanks Temperature 120oF 160oF For caustic solutions maintained below 120oF (48.9oC), the most common material for tank construction is carbon steel. The plate joints should be welded with appropriate rods, such as those containing 1/2% molybdenum. The potential for stress corrosion cracking (SCC) can be minimized by reducing stresses in the steel. If service temperatures above 120oF (48.9oC) are expected, stress relieving of welds and bends should be considered, see Appendix C. Temperature above 160oF At temperatures above 160oF (71.1oC), more corrosion resistant materials such as alloys of nickel should be considered. The austenitic stainless steels, primarily 304L and 316L have been used successfully in caustic service. The low carbon content austenitic grade provides improved protection of the weld area (heat affected zone) against corrosion. However both general corrosion rates and the risk of stress corrosion cracking increase at higher temperatures. Therefore, in the absence of specific experience in a particular application, a general upper limit of 200oF (95oC) should be observed, see Appendix C. Cracking may result from stress corrosion cracking (generally internal to the equipment) or chloride attack (generally external to the equipment).

73% Caustic Storage Tanks From a corrosion point of view, nickel is the material of choice for 73% liquid caustic storage. However, nickel clad or lined steel tanks have been used successfully. Linings Tank linings may be used to minimize corrosion and iron pick-up. Factors to consider for lining selection are chemical compatibility, temperature resistance, and physical properties such as thermal shock, impact resistance, permeability, and wear resistance. Before selecting a lining material for a caustic environment, both the lining supplier and the caustic supplier service representatives should be consulted. Silica-containing materials such as glass, brick and tile are attacked by caustic liquors and should not be used. Nickel and Nickel Alloys Nickel and nickel alloys are much more resistant to attack by caustic than carbon steels and the extra cost may be justified. Where high purity product must be maintained or a storage tank temperature in excess of 160oF (71.1oC) is expected, nickel, nickel-clad, or nickel-lined tanks should be considered.

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PAMPHLET 94

Plastics Generally, plastics should only be used for lining of metal or FRP tank structures; lined equipment affords higher levels of safety than unsupported plastic material. Many plastics have chemical resistance to caustic solution, up to their temperature limits. Materials such as PVC, CPVC, polypropylene, polysulfone and the fluorocarbon resins (PFA, FEP, PTFE, and ECTFE) will normally not be degraded by 50% caustic soda. Plastic liners can fail if maximum temperatures are exceeded. Therefore, design should take into consideration the maximum process temperature. Resins Epoxy resins and some vinyl resins have been successfully used for tank linings. The supplier of the resin should be asked about the suitability of a given material for a specific service and requested to make recommendations for qualified applicators. Elastomers Certain rubbers, such as natural rubber, neoprene and chlorobutyl rubber have proven successful in some applications at varying temperature limits. The manufacturer of the elastomer should be consulted for a recommendation for a specific application. Coating Systems Selected coating systems have successfully been used as a barrier in preventing iron contamination of the caustic. The manufacturer of the coating system should be contacted for a recommendation for a specific application. 4.6.4 Foundations The detailed design and construction of the tank foundation can only be done after careful assessment of the site surface, subsurface, and climatic conditions to ensure adequate tank support. Foundations for vertical tanks should be a uniformly supporting design. A reinforced concrete foundation or ring wall with an impervious material inside the wall should be considered. Moisture intrusion beneath the tank can cause external corrosion. Appropriate design to prevent moisture intrusion should be considered. A leak detection system should also be considered. 4.6.5 Tank Heating and Insulation Caustic storage tank heating requirements are determined by the caustic concentration in storage and its corresponding freezing point. See Appendices B and D. It is desirable to place higher concentration caustic tanks (higher freezing points) in heated buildings that are maintained at a temperature greater than 60oF (15.6oC). However, this is usually only practical for smaller tanks. Storage tanks located outdoors should be insulated and/or heated if sustained temperatures below 60oF (15.6oC) are expected.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

15

For internal tank heating, a nickel bayonet-type, or coil-type heat exchanger should be considered. Care must be taken to prevent overheating to temperatures above those recommended for the materials of construction. Automatic temperature control or regulation of the steam source within temperature and material limitations should be considered. A temperature controller including a high temperature alarm and a thermocouple at the same liquid level as the steam coil should be considered. Field indication of temperature is desirable. If a source of steam is not available, the storage tank can be heated using an electrical horizontal bayonet-type heat exchanger similar to the one described above. Wall heating can be accomplished with steam coils or electrical heating tape. Wall heating systems must be designed to avoid the creation of hot spots which can exceed the design limits of the vessel. The temperature of the caustic solution can be maintained or increased slowly using electrical heat-tracing tape attached to the outside of the storage tank. If electrical heat-tracing tape is the only source of heat, the storage tank should be wellinsulated to minimize heat loss from the caustic solution. Not as common but also used are hot water circulation in external coils made of carbon steel separated from the tank with spacers. Temperatures of the storage tank can also be maintained by circulating the contents through an external heat exchanger (See Section 6.2). 4.6.6 Tank Exterior Painting All carbon steel tanks, including insulated tanks, should have an appropriate paint system to minimize corrosion of the vessels exterior. 4.6.7 Instrumentation Appropriate instrumentation along with safe operating procedures will greatly reduce the risks of overfilling as well as temperatures and pressure excursions. All instrumentation should be routinely checked for reliability and accuracy. Tank Level Redundant liquid level indicators with audible and visible high level alarms should be considered. The first stage alarm should provide adequate time for the operator to take appropriate action before a second high level alarm or overflow is reached. For the second stage (high high-level) alarm system, a sensor independent of the tank level instrument should be considered. CAUTION: Due to specific gravity differences, the level transmitters that measure liquid head will vary dramatically as the caustic solution is diluted.

16

PAMPHLET 94

Consideration should be given to automatic shutdown of the tank fill operation if the second stage alarm is activated. This alarm should be set far enough below the actual tank overflow, giving the operator sufficient time to react. The tank may also be provided with a low level alarm to prevent overheating if the liquid level was to drop below the heat source, e.g., steam coil, or, if not heated, the pump suction line. Sight glasses should not be used on caustic storage tanks unless materials of construction compatible with caustic are used and it is well protected. Glass materials should be avoided. Tank Temperature For heated storage, the temperature of the caustic storage tank contents should be controlled within the limitations of the materials of construction. See Appendices B and D. Automatic control is preferred. A local temperature indicator should also be considered. Temperature sensors are typically installed in thermowells for ease of maintenance. 4.7 TANK ATTACHMENTS AND OPENINGS (APPURTENANCES) General All welding carried out on any attachment to the tank must be done by qualified welders using proven welding procedures in accordance with Section IX of the ASME Code. Reinforcement requirements at attachments and openings should be determined by the tank design code used. If stress relieving is required it should be carried out in accordance with the applicable code. When possible, all connections at the top of the tank should be located to permit servicing. Flanged type connections are preferred. ASME flanges should be considered, if not required, by the applicable code. Alloy construction should be considered for lap-joint flanges. All valves installed on the tank should be of a design that will allow secure locking of the operating mechanism. Specific considerations for certain tank openings are a follows: Manways A manway should be considered for entry for cleaning, washing, linings, coatings inspection and bottom non-destructive examination testing and maintenance. Vents The tank vent, open to atmosphere at all times, should have a cross-sectional area sufficient to prevent overpressure or vacuum. Valves should never be installed on the vent line.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

17

Overflows Overflow lines should extend from the top of the shell of the tank to an adequate elevation above ground level. A dedicated overflow, routed safely to a containment vessel should be installed. Flow detection instrumentation should be considered with the installation of the overflow. Inlet Fill Connection Consideration should be given to locating the fill line connection above the tank overflow level. An isolation valve should be installed in the nearest practical location. Material and design of the valve should be in accordance with the recommendations in Section 5.4. Outlet Connection An isolation valve should be located at the tanks outlet connection, or as close as possible. Drain Connection A drain connection at the lowest point of the tank should be considered to facilitate flushing and cleaning. Spare Nozzles Future welding on the tank after caustic is introduced is difficult, therefore, spare nozzles should be considered in the initial design. Access Platforms, walkways, and access should be provided so routine operator and maintenance activities at valves, connections, sample points, instrumentation, etc. can be performed on items that are located above grade. 4.8 SPILL CONTAINMENT As part of the risk assessment process, all new caustic storage facilities must consider spill containment for the storage tank system. Containment can be gained by use of sumps or reservoirs, double wall tankage, or by diking. The containment system should not allow disposal of collected material without prior confirmation of the contents. If the material is recovered into the process, confirmation may not be required. All existing systems should be evaluated on an individual basis with respect to industry best practices. Emergency provisions including the recovery and disposal of any caustic spilled, should be developed. Personnel must be thoroughly trained to handle emergencies effectively. Design layout in design of the diked area should consider the potential for mixing of incompatible materials.

18
4.9 4.9.1

PAMPHLET 94

INSPECTION AND MAINTENANCE General A well-managed inspection and maintenance program for the caustic storage tank(s) will ensure a safe and reliable operation. Guidelines outlined in API Standard 653 - Tank Inspection, Repair, Alterations and Reconstruction should be adopted where appropriate (7.2.6). All repair work and inspections should be thoroughly documented for future reference.

4.9.2

Commissioning Before a new caustic storage tank is put into service, its integrity must be proven through an inspection and testing process. The tank should not be insulated until this process is complete and the tank is accepted by the owner/operator. Following a thorough cleaning of the tank, the floor and roof welds should be tested in accordance with applicable codes. Next, the tank should be filled with water for leak testing. For large outdoor tanks, its settling should be surveyed and documented as it undergoes the initial water fill. A carbon steel tank which has been exposed to a corrosive atmosphere for an extended period may require descaling. It must be inspected to ensure integrity in caustic service. Once descaled, it should be filled with caustic as soon as possible to passivate the surface.

4.9.3

Inspection A formal in-service and out-of-service inspection program should be well-established for caustic storage tanks. The tank inspections should be carried out by certified inspectors. The intervals between inspections can be determined by service history and corrosion rates measured during previous inspections. Local regulatory requirements may also dictate the frequency of inspections. In addition to determining the integrity of the tank proper, the foundation structural integrity, shell plumbness, appurtenances, heater, instruments, and dikes drainage system should be routinely inspected. Visual A good visual inspection can be a very effective component of the program. The wall area next to the floor on large tanks can experience significant loads and should be given special attention. Any white, crystallized residue on the tank may indicate leakage. Ultrasonic Thickness Check Portable ultrasonic thickness gauges can be used during tank inspection to measure the tank wall thickness. Measurement can be obtained without disturbing the tank contents. Corrosion inspection points should be labeled and clearly identified.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

19

Cracked Weld Areas (carbon steel and stainless steel tanks) Weld areas that are not stress relieved become more susceptible to stress corrosion cracking. If the service temperature is frequently above the 120oF (48.9oC) range, these areas should be carefully inspected by proven crack detection techniques. Magnetic particle and liquid penetrant tests can detect surface cracks very well. 4.9.4 Maintenance A well-established preventive maintenance program will predict and minimize major repair work and caustic tank outage. The Inspection program previously discussed will play a key role in determining the extent of repair work required on the tank. All tank repair work should be done in accordance with the applicable code by qualified personnel. Cleaning and neutralizing of metal surfaces exposed to caustic in preparation for welding is critical to prevent sensitizing the heat-affected zone. 5. 5.1 PIPING SYSTEMS GENERAL The guidelines in this section are intended to provide sound practices for the design and construction of piping systems. In general, the industry follows the requirements contained in the ASME B31.3 code (7.3.4). Caustic is a hazardous material and therefore the piping systems for caustic service should be designed carefully. The expected service conditions must first be thoroughly defined before a safe and reliable design can be engineered. The designer should consider variability in operating conditions, including start-ups, shutdowns, process upsets and system cleaning. Material selection must be based on expected service temperatures, pressures, concentrations and intended caustic purity. The piping systems for anhydrous caustic soda are not covered in this section. For more information on storing and handling dry caustic soda, consult your supplier's technical representative. 5.2 PIPING LAYOUT Proper piping layout can enhance safety, reduce maintenance time and provide efficient operations at effective costs. The following are several important considerations in designing piping layout. General Practices Avoid low point traps which will make clearing the line for maintenance or freeze protection more difficult. If traps are unavoidable, drains should be provided or procedures should be developed that will allow the line to be blown clear or washed with the least amount of exposure to personnel and the environment.

20

PAMPHLET 94

If pigging will be used to clear piping systems, proper components should be used to allow passage of the pig. Long radius elbows, guide bars, and full port valves are some of the components typically used in a piping system that will be pigged. Pipe loops are preferred (horizontal plane) for lines requiring provision for linear thermal expansion. Piping systems should be installed to allow complete drainage. High point vents and low point drains should be provided. However, in some circumstances high point vents collect oxygen, which leads to internal corrosion. Do not install more high point vents than are required. Piping systems should include the appropriate number of fittings to facilitate hydrotesting, clean-out, and maintenance. On flange connections, flange guards may be considered especially in cases where there is risk of splashing personnel with product. Caustic lines should be clearly identified. Pipe routing should be kept to a minimum, especially outdoors where the caustic solutions can easily freeze if heating equipment malfunctions. All process piping should be heat traced and insulated if caustic temperatures are anticipated to be 60oF (15.5oC) or lower. Caustic (50%) freezes at temperatures below 60oF (15.5oC). In most cases this means that caustic pipelines must be insulated, and frequently they must be heat traced, as well. Electric heat tracing is strongly preferred to steam heat tracing. Self-limiting electric tracing is preferred in those cases where it is practical to use it. In all cases the heat input must be controlled to avoid high metal temperatures that would result in caustic stress corrosion cracking. Use caution in the placement of the temperature measurement device so that it does not indicate a false low reading if the layout of the piping system is such that the pipeline may be hotter in some sections than it is in other sections.

Clearances Road and walkway clearances should be set to minimize the possibility of impact damage. Barriers or guard rails should be considered. Railroad and roadway clearances may be regulated by federal, state, provincial, or local laws. Supports Piping should be designed with adequate support to avoid excessive deflection between adjacent supports and not allow metal to metal wear or corrosion. If located in an area where seismic activity can be significant, the local code requirements should be reviewed. In general, pipes should be supported with hangers, shoes or saddles, pipe clamps or U-bolts. Do not hang other piping from a caustic line and do not hang caustic lines from other piping. For new construction weld-on shoes are preferred over clampon shoes since metal to metal connections provide crevices that tend to corrode. This is especially true in climates that have high humidity levels.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

21

Routing Aboveground installations are preferred for in-plant piping. When routing caustic piping over equipment, the potential for caustic leaks should be considered. In general, caustic lines should be routed on the lower elevation of the pipe rack. Valves and Controls Accessibility should be considered when locating all valves and controls to facilitate their operation and maintenance. Block valves should be located in branch lines, preferably at the main header. When locating block valves, consider such factors as accessibility and the ability to isolate piping equipment and tanks. Block valves located below the normal liquid level should be close to or at the tank nozzles. 5.3 PIPE AND PIPING COMPONENTS This section provides recommended minimum specifications for pipe and piping components for caustic. All parts of this pamphlet should be consulted before deciding on the components of a piping system. 5.3.1 Metallic Piping Systems Piping systems, including pipe, fittings, gaskets, nuts and bolts, valves, and other items have been organized into three groups (Tables 5.1, 5.2 and 5.3) according to the following construction breakdown: Threaded construction Threaded construction should be limited to pipe systems two inches in diameter or less. Threaded construction reduces the wall thickness of the pipe and can add stress points which may be a disadvantage. Threaded connections are susceptible to leaks in caustic service due to the very low surface tension of caustic soda solutions. Threaded joint leaks are especially prone to occur at line pressures exceeding about 60 psig. Socket Weld Construction Socket weld construction is sometimes used for pipe systems two inches in diameter or less. However, failure can occur if proper fit-up and welding procedures are not followed. Crevice corrosion is also cause for concern, and for this reason the use of socket welded pipe construction is not a very good choice for permanent systems that are expected to stay in service for long time periods. Socket welded systems are more acceptable for piping systems that are intended to be of a temporary nature.

22

PAMPHLET 94

Butt Weld Construction Butt welding and flanged joints are recommended for all sizes.

Within the three construction groups listed above, there are several material groups which can be selected. The characteristics of the various materials of construction are as follows: Carbon Steel Carbon steel is a common material of construction within limited temperature and caustic concentration ranges. At temperatures above 120oF (49oC) at 50% caustic soda, carbon steel is susceptible to stress corrosion cracking. Refer to Appendix C. Stainless The austenitic low carbon stainless steels, primarily 304L and 316L have been used successfully in caustic service. The low carbon content austenitic grades provide improved protection of the weld area (heat affected zone) against corrosion. However both general corrosion rates and the risk of stress corrosion cracking (SCC) increase at higher temperatures and concentrations. Therefore, in the absence of specific experience in a particular application, a general upper limit of 200oF (95oC) should be observed, see Appendix C. Cracking may result from SCC (generally internal to the equipment) or chloride attack (generally external to the equipment). Temperatures above 212F (100oC) tend to create product quality issues with both color and with high iron concentrations. Temperatures above 248F (120oC) are susceptible to caustic SCC. External chloride SCC can occur at much lower temperatures (even at ambient temperatures) if the atmosphere or the pipe insulation contains chlorides. Chloride SCC is generally not a problem on the inside of the pipe due to the high pH levels that are normally present. Monel Monel is used in caustic applications up to 73% and is more resistant to stress corrosion cracking than stainless steel. However, when compared to nickel, Monel has a higher corrosion rate at elevated temperatures. Nickel Nickel is the common material for caustic piping at high temperatures and concentrations. It is resistant to stress corrosion cracking and has a very low corrosion rate minimizing metal ion contamination. Nickel provides the greatest corrosion resistance of the metallic materials listed in this section.

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Table 5.1: Threaded Construction [See Note 7]

ITEM NOMINAL PIPE SIZE (NPS) <=50% CAUSTIC <=120oF(48.9oC) [See Note 1] <=175 PSIG(1207 kPa) CARBON STEEL [See Note 2] [Through 1-1/2"] ASTM A106 Grade B Sch 80 Carbon Steel Seamless ASME B36.10 <=50% CAUSTIC <=200oF(95oC) [See Note 1] <=175 PSIG (1207 kPa) STAINLESS STEEL [See Notes 2, 3 and 8] [Through 2"] ASTM A312 Grade TP304 Sch 40S Stainless Steel Seamless or Welded ASME B36.19 [See Note 11] <=73% CAUSTIC <=260oF(126.7oC) [See Note 1] <=175 PSIG (1207 kPa) MONEL [See Note 2] [Through 1"] ASTM B165 UNS N04400, Annealed Sch 40, Seamless or ASTM B725 UNS N04400, Annealed Sch 40 Welded ASME B36.19 [1-1/2" and Larger] Not Recommended [See Note 11] <=73% CAUSTIC <=350oF(176.7oC) [See Note 1] <=175 PSIG (1207 kPa) NICKEL [See Notes 2 and 8] [Through 1"] ASTM B161 UNS N02200, Annealed Sch 40 Seamless or ASTM B725 UNS N02200, Annealed Sch 40 Welded ASME B36.19 [1-1/2" and Larger] Not Recommended [See Note 11]

PIPE

See Material Group

[2"] ASTM A53 Grade B Sch 40 Carbon Steel Seamless or Welded ASME B36.10 FITTINGS Through 1" ASTM A105 Class 3000 Forged Carbon Steel Threaded Ends ANSI B16.11 ASTM A351 Grade CF8 Class 150 Cast SS or ASTM A182 Grade F304 Class 3000 Forged SS Threaded Ends ANSI B16.11 [See Note 5]

ASTM A494 Grade M35-2 Class 150 Cast Monel or ASTM B366 (B564/B164) Grade WPNC Class 3000 Forged Monel, Annealed Threaded Ends ANSI B16.11 [See Note 5] Not Recommended

ASTM A494 Grade CZ-100 Class 150 Cast Nickel or ASTM B366 (B564/B160) Grade WPN Class 3000 Forged Nickel, Annealed Threaded Ends ANSI B16.11 [See Note 5] Not Recommended

1-1/2" to 2"

ASTM A105 Class 3000 Forged Carbon Steel Threaded Ends ANSI B16.11

ASTM A351 Grade CF8 Class 150 Cast SS or ASTM A182 Grade F304 Class 3000 Forged SS Threaded Ends ANSI B16.11 [See Note 5] ASTM A351 Grade CF8 Class 150 Cast SS or ASTM A182 Grade F304 Class 3000 Forged SS Ground Joint Seat Threaded Ends [See Note 5]

UNIONS

Through 1"

ASTM A105 Class 3000 Forged Carbon Steel Ground Joint Seat Threaded Ends

ASTM A494 Grade M35-2 Class 150 Cast Monel or ASTM B366 (B564/B164) Grade WPNC Class 3000 Forged Monel, Annealed Ground Joint Seat Threaded Ends [See Note 5] Not Recommended

ASTM A494 Grade CZ-100 Class 150 Cast Nickel or ASTM B366 (B564/B160) Grade WPN Class 3000 Forged Nickel, Annealed Ground Joint Seat Threaded Ends [See Note 5] Not Recommended

1-1/2" to 2"

ASTM A105 Class 3000 Forged Carbon Steel Ground Joint Seat Threaded Ends

ASTM A351 Grade CF8 Class 150 Cast SS or ASTM A182 Grade F304 Class 3000 Forged SS Ground Joint Seat Threaded Ends [See Note 5]

24

PAMPHLET 94

Table 5.1: Threaded Construction [See Note 7]

ITEM NOMINAL PIPE SIZE (NPS) <=50% CAUSTIC <=120oF(48.9oC) [See Note 1] <=175 PSIG(1207 kPa) CARBON STEEL [See Note 2] ASTM A105 Class 150 Forged Carbon Steel Raised Face Threaded ASME B16.5 <=50% CAUSTIC <=200oF(95oC) [See Note 1] <=175 PSIG (1207 kPa) STAINLESS STEEL [See Notes 2, 3 and 8] ASTM A182 Grade F304 Class 150 Forged Stainless Steel Raised Face Threaded ASME B16.5 <=73% CAUSTIC <=260oF(126.7oC) [See Note 1] <=175 PSIG (1207 kPa) MONEL [See Note 2] ASTM B164/B564 UNS N04400 Class 150 Forged Monel, Annealed Raised Face Threaded ASME B16.5 Not Recommended <=73% CAUSTIC <=350oF(176.7oC) [See Note 1] <=175 PSIG (1207 kPa) NICKEL [See Notes 2 and 8] ASTM B160/B564 UNS N02200 Class 150 or Class 300 Forged Nickel, Annealed Raised Face Threaded ASME B16.5 [See Note 6] Not Recommended

FLANGES

Through 1

1-1/2" to 2"

ASTM A105 Class 150 Forged Carbon Steel Raised Face Threaded ASME B16.5 PTFE Gasket With Various Fillers or EPDM Non-Asbestos [See Note 4] ASTM A193 Grade B7 Alloy Steel Quenched and Tempered Stud Bolts and Cap Screws ASME B18.2.1 [See Notes 9 and 10] ASTM A194 Grade 2H Carbon Steel Heavy Hex Nuts ASME B18.2.2 [See Note 9]

ASTM A182 Grade F304 Class 150 Forged Stainless Steel Raised Face Threaded ASME B16.5 PTFE Gasket with Various Fillers or EPDM or NonAsbestos [See Note 4 ] ASTM A193 Grade B7 Alloy Steel Quenched and Tempered Stud Bolts and Cap Screws ASME B18.2.1 [See Notes 9 and 10] ASTM A194 Grade 2H Carbon Steel Heavy Hex Nuts ASME B18.2.2 [See Note 9]

GASKETS

All Sizes

PTFE Gasket with Various Fillers Non-Asbestos [See Note 4] ASTM A193 Grade B7 Alloy Steel Quenched and Tempered Stud Bolts and Cap Screws ASME B18.2.1 [See Notes 9 and 10] ASTM A194 Grade 2H Carbon Steel Heavy Hex Nuts ASME B18.2.2 [See Note 9]

PTFE Gasket with Various Fillers or Non-Asbestos [See Note 4] ASTM A193 Grade B7 Alloy Steel Quenched and Tempered Stud Bolts and Cap Screws ASME B18.2.1 [See Notes 9 and 10] ASTM A194 Grade 2H Carbon Steel Heavy Hex Nuts ASME B18.2.2 [See Note 9]

BOLTS

All Sizes

NUTS

All Sizes

Note 1. Note 2.

Piping material selection should be based on a combination of caustic concentration and temperature, refer to Appendix C for material selection. Higher pressures may be acceptable based on ANSI/ASME specifications for the temperature - pressure application. The maximum listed are based on the ANSI/ASME specifications and Appendix C. The specifications listed are typical for 304 stainless steel. Type 316 (regular or low carbon grades) may be substituted, with corresponding appropriate specifications or the L grades. PTFE gaskets with various fillers and expanded PTFE have been used successfully.

Note 3.

Note 4.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

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Note 5.

Fittings and unions in stainless steel, Monel and nickel can be Class 150 or Class 3000. Selection of the proper fitting should be based on design parameters of application. Check pressure-temperature ratings of flanges. The pressures and temperatures listed in the table are based on current applications of caustic suppliers and users. Stainless steel and nickel threads are susceptible to galling. Threads shall be to ASME B1.1. Bolts shall have a Class 2A fit and nuts shall have a Class 2B fit. Stud bolts are preferred on in-line piping components that do not have tapped threads. Cap screws may be used for tapped piping components and instrumentation. Welded pipe has increased susceptibility to galling when threaded.

Note 6. Note 7. Note 8. Note 9. Note 10.

Note 11.

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PAMPHLET 94

Table 5.2: Socket Weld Construction [See Note 7]

ITEM NOMINAL PIPE SIZE (NPS) <=50% CAUSTIC <=120oF(48.9oC) [See Note 1] <=175 PSIG (1207 kPa) CARBON STEEL [See Note 2] [Through 1-1/2"] ASTM A106 Grade B Sch 80 Carbon Steel Seamless ASME B36.10 <=50% CAUSTIC <=200oF(95oC) [See Note 1] <=175 PSIG (1207 kPa) STAINLESS STEEL [See Notes 2 and 3] [Through 1"] ASTM A312 Grade TP304 Sch 40S Stainless Steel Seamless or Welded ASME B36.19 <=73% CAUSTIC <=260oF(126.7oC) [See Note 1] <=175 PSIG (1207 kPa) MONEL [See Note 2] [Through 1"] ASTM B165 UNS N04400, Annealed Sch 40, Seamless or ASTM B725 UNS N04400, Annealed Sch 40 Welded ASME B36.19 [1-1/2" and Larger] Not Recommended <=73% CAUSTIC <=350oF(176.7oC) [See Note 1] <=175 PSIG (1207 kPa) NICKEL [See Note 2] [Through 1"] ASTM B161 UNS N02200, Annealed Sch 40 Seamless or ASTM B725 UNS N02200, Annealed Sch 40 Welded ASME B36.19 [1-1/2" and Larger] Not Recommended

PIPE

See Material Group

[2"] ASTM A53 Grade B Sch 40 Carbon Steel Seamless or Welded ASME B36.10 FITTINGS Through 1 ASTM A105 Class 3000 Forged Carbon Steel Socket Weld Ends ANSI B16.11

[1-1/2" and Larger] Not Recommended

ASTM A351 Grade CF8 Class 150 Cast SS or ASTM A182 Grade F304 Class 3000 Forged SS Socket Weld Ends ANSI B16.11 [See Note 5]

ASTM A494 Grade M35-2 Class 150 Cast Monel or ASTM B366 (B564/B164) Grade WPNC Class 3000 Forged Monel, Annealed Socket Weld Ends ANSI B16.11 [See Note 5] Not Recommended

ASTM A494 Grade CZ-100 Class 150 Cast Nickel or ASTM B366 (B564/B160) Grade WPN Class 3000 Forged Nickel, Annealed Socket Weld Ends ANSI B16.11 [See Note 5] Not Recommended

1-1/2" to 2"

ASTM A105 Class 3000 Forged Carbon Steel Socket Weld Ends ANSI B16.11 ASTM A105 Class 3000 Forged Carbon Steel Ground Joint Seat Socket Weld Ends

Not Recommended

UNIONS

Through 1

ASTM A351 Grade CF8 Class 150 Cast SS or ASTM A182 Grade F304 Class 3000 Forged SS Ground Joint Seat Socket Weld Ends [See Note 5]

ASTM A494 Grade M35-2 Class 150 Cast Monel or ASTM B366 (B564/B164) Grade WPNC Class 3000 Forged Monel, Annealed Ground Joint Seat Socket Weld Ends [See Note 5] Not Recommended

ASTM A494 Grade CZ-100 Class 150 Cast Nickel or ASTM B366 (B564/B160) Grade WPN Class 3000 Forged Nickel, Annealed Ground Joint Seat Socket Weld Ends [See Note 5] Not Recommended

1-1/2" to 2"

ASTM A105 Class 3000 Forged Carbon Steel Ground Joint Seat Socket Weld Ends

Not Recommended

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

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Table 5.2: Socket Weld Construction [See Note 7]

ITEM NOMINAL PIPE SIZE (NPS) <=50% CAUSTIC <=120oF(48.9oC) [See Note 1] <=175 PSIG (1207 kPa) CARBON STEEL [See Note 2] ASTM A105 Class 150 Forged Carbon Steel Raised Face Socket Weld ASME B16.5 <=50% CAUSTIC <=200oF(95oC) [See Note 1] <=175 PSIG (1207 kPa) STAINLESS STEEL [See Notes 2 and 3] ASTM A182 Grade F304 Class 150 Forged Stainless Steel Raised Face Socket Weld ASME B16.5 <=73% CAUSTIC <=260oF(126.7oC) [See Note 1] <=175 PSIG (1207 kPa) MONEL [See Note 2] ASTM B164/B564 UNS N04400 Class 150 Forged Monel, Annealed Raised Face Socket Weld ASME B16.5 Not Recommended <=73% CAUSTIC <=350oF(176.7oC) [See Note 1] <=175 PSIG (1207 kPa) NICKEL [See Note 2] ASTM B160/B564 UNS N02200 Class 150 or Class 300 Forged Nickel, Annealed Raised Face Socket Weld ASME B16.5 (See Note 6) Not Recommended

FLANGES

Through 1

1-1/2" to 2"

ASTM A105 Class 150 Forged Carbon Steel Raised Face Socket Weld ASME B16.5 PTFE Gasket With Various Fillers or EPDM or NonAsbestos [See Note 4] ASTM A193 Grade B7 Alloy Steel Quenched and Tempered Stud Bolts and Cap Screws ASME B18.2.1 (See Notes 8 and 9) ASTM A194 Grade 2H Carbon Steel Heavy Hex Nuts ASME B18.2.2 (See Note 8)

Not Recommended

GASKETS

All Sizes

PTFE Gasket With Various Fillers or EPDM or NonAsbestos [See Note 4] ASTM A193 Grade B7 Alloy Steel Quenched and Tempered Stud Bolts and Cap Screws ASME B18.2.1 (See Notes 8 and 9) ASTM A194 Grade 2H Carbon Steel Heavy Hex Nuts ASME B18.2.2 (See Note 8)

PTFE Gasket With Various Fillers or NonAsbestos [See Note 4] ASTM A193 Grade B7 Alloy Steel Quenched and Tempered Stud Bolts and Cap Screws ASME B18.2.1 (See Notes 8 and 9) ASTM A194 Grade 2H Carbon Steel Heavy Hex Nuts ASME B18.2.2 (See Note 8)

PTFE Gasket With Various Fillers or NonAsbestos [See Note 4] ASTM A193 Grade B7 Alloy Steel Quenched and Tempered Stud Bolts and Cap Screws ASME B18.2.1 (See Notes 8 and 9) ASTM A194 Grade 2H Carbon Steel Heavy Hex Nuts ASME B18.2.2 (See Note 8)

BOLTS

All Sizes

NUTS

All Sizes

Note 1. Note 2.

Piping material selection should be based on a combination of caustic concentration and temperature, refer to Appendix C for material selection. Higher pressures may be acceptable based on ANSI/ASME specifications for the temperature - pressure application. The maximum listed are based on the ANSI specifications and Appendix C. The specifications listed are typical for 304 stainless steel. Type 316 (regular or low carbon grades) may be substituted, with corresponding appropriate specifications or the >L= grades.

Note 3.

28
Note 4. Note 5.

PAMPHLET 94

PTFE gaskets with various fillers and expanded PTFE have been used successfully. Fittings and unions in stainless steel, Monel and nickel can be Class 150 or Class 3000. Selection of the proper fitting should be based on design parameters of application. Check pressure-temperature ratings of flanges. The pressures and temperatures listed in the table are based on current applications of caustic suppliers and users. Threads shall be to ASME B1.1. Bolts shall have a Class 2A fit and nuts shall have a Class 2B fit. Stud bolts are preferred on in-line piping components that do not have tapped threads. Cap screws may be used for tapped piping components and instrumentation.

Note 6. Note 7. Note 8. Note 9.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

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Table 5.3: Butt Weld Construction [See Note 6]

ITEM NOMINAL PIPE SIZE (NPS) <=50% CAUSTIC <=120oF(48.9oC) [See Note 1] <=175 PSIG(1207 kPa) CARBON STEEL [See Note 2] [Through 1-1/2"] ASTM A106 Grade B Sch 80 Carbon Steel Seamless ASME B36.10 <=50% CAUSTIC <=200oF(95oC) [See Note 1] <=175 PSIG (1207 kPa) STAINLESS STEEL [See Notes 2 and 3) [Through 3/4"] ASTM A312 Grade TP304 Sch 40S Stainless Steel Seamless or Welded ASME B36.19 <=73% CAUSTIC <=260oF(126.7oC) [See Note 1] <=175 PSIG (1207 kPa) MONEL [See Note 2] [Through 3/4"] ASTM B165 UNS N04400, Annealed Sch 40, Seamless or ASTM B725 UNS N04400, Annealed Sch 40 Welded ASME B36.19 [1" to 4"] ASTM B165 UNS N04400, Annealed Sch 10, Seamless or ASTM B725 UNS N04400, Annealed Sch 10 Welded ASME B36.19 [6" and Larger] Monel UNS N04400 ASTM and Thickness Per Application ASTM A403 Grade WP304 or WP304-W 304 SS Seamless or Welded (bore to match pipe) ASME B16.9 ASTM A403 Grade WP304 or WP304-W 304 SS Seamless or Welded (bore to match pipe) ASME B16.9 ASTM A182 Grade F304 Forged Stainless Steel (bore to match pipe) ASTM A182 Grade F304 Class 150 Forged Stainless Steel Raised Face (bore to match pipe) Weldneck or Slip-on ASME B16.5 ASTM B366 Grade WPNC or WPNC-W Monel, Annealed Seamless or Welded (bore to match pipe) ASME B16.9 Monel UNS N04400 ASTM Per Application (bore to match pipe) <=73% CAUSTIC <=350oF(176.7oC) [See Note 1] <=175 PSIG (1207 kPa) NICKEL [See Note 2] [Through 3/4"] ASTM B161 UNS N02200, Annealed Sch 40 Seamless or ASTM B725 UNS N02200, Annealed Sch 40 Welded ASME B36.19 [1" to 4"] ASTM B161 UNS N02200, Annealed Sch 10 Seamless or ASTM B725 UNS N02200, Annealed Sch 10 Welded ASME B36.19 [6" and Larger] Nickel UNS N02200 ASTM and Thickness Per Application ASTM B366 Grade WPN or WPN-W Nickel, Annealed Seamless or Welded (bore to match pipe) ASME B16.9 Nickel UNS N02200 ASTM Per Application (bore to match pipe)

PIPE

See Material Group

[2" to 10"] ASTM A53 Grade B Sch 40 Carbon Steel Seamless or Welded ASME B36.10

[1" and Larger] ASTM A312 Grade TP304 Sch 10S Stainless Steel Seamless or Welded ASME B36.19

[12" and Larger] ASTM A53 Grade B Std Wt Carbon Steel Seamless or Welded ASME B36.10 FITTINGS Wrought Through 4" ASTM A234 Grade WPB or WPB-W Carbon Steel Seamless or Welded (bore to match pipe) ASME B16.9 ASTM A234 Grade WPB or WPB-W Carbon Steel Seamless or Welded (bore to match pipe) ASME B16.9 ASTM A105 Forged Carbon Steel (bore to match pipe) ASTM A105 Class 150 Forged Carbon Steel Raised Face Weldneck or Slip-on (bore to match pipe) ASME B16.5

6" and Larger

FITTINGS Forged

All Sizes

ASTM B564 UNS N04400 Forged Monel (bore to match pipe) ASTM B164/B564 UNS N04400 Class 150 Forged Monel, Annealed Raised Face Weldneck or Slip-on (bore to match pipe) ASME B16.5

ASTM B160/B564 UNS N02200 Forged Nickel (bore to match pipe ASTM B160/B564 UNS N02200 Class 150 or Class 300 Forged Nickel, Annealed Raised Face Weldneck or Slip-on (bore to match pipe) ASME B16.5 [See Note 5]

FLANGES

All Sizes

30

PAMPHLET 94

Table 5.3: Butt Weld Construction [See Note 6]

ITEM NOMINAL PIPE SIZE <=50% CAUSTIC <=120oF(48.9oC) [See Note 1] <=175 PSIG(1207 kPa) CARBON STEEL [See Note 2] PTFE Gasket With Various Fillers or EPDM or NonAsbestos [See Note 4] ASTM A193 Grade B7 Alloy Steel Quenched and Tempered Stud Bolts and Cap Screws ASME B18.2.1 (See Notes 7 and 8) ASTM A194 Grade 2H Carbon Steel Heavy Hex Nuts ASME B18.2.2 (See Note 7) <=50% CAUSTIC <=200oF(95oC) [See Note 1] <=175 PSIG (1207 kPa) STAINLESS STEEL [See Notes 2 and 3) PTFE Gasket With Various Fillers or EPDM or NonAsbestos [See Note 4] ASTM A193 Grade B7 Alloy Steel Quenched and Tempered Stud Bolts and Cap Screws ASME B18.2.1 (See Notes 7 and 8) ASTM A194 Grade 2H Carbon Steel Heavy Hex Nuts ASME B18.2.2 (See Note 7) <=73% CAUSTIC <=260oF(126.7oC) [See Note 1] <=175 PSIG (1207 kPa) MONEL [See Note 2] PTFE Gasket With Various Fillers or EPDM or NonAsbestos [See Note 4] ASTM A193 Grade B7 Alloy Steel Quenched and Tempered Stud Bolts and Cap Screws ASME B18.2.1 (See Notes 7 and 8) ASTM A194 Grade 2H Carbon Steel Heavy Hex Nuts ASME B18.2.2 (See Note 7) <=73% CAUSTIC <=350oF(176.7oC) [See Note 1] <=175 PSIG (1207 kPa) NICKEL [See Note 2] PTFE Gasket With Various Fillers or EPDM or NonAsbestos [See Note 4] ASTM A193 Grade B7 Alloy Steel Quenched and Tempered Stud Bolts and Cap Screws ASME B18.2.1 (See Notes 7 and 8) ASTM A194 Grade 2H Carbon Steel Heavy Hex Nuts ASME B18.2.2 (See Note 7)

GASKETS

All Sizes

BOLTS

All Sizes

NUTS

All Sizes

Note 1. Note 2.

Piping material selection should be based on a combination of caustic concentration and temperature, refer to Appendix C for material selection. Higher pressures may be acceptable based on ANSI/ASME specifications for the temperature - pressure application. The maximum listed are based on the ANSI/ASME specifications and Appendix C. The specifications listed are typical for 304 stainless steel. Type 316 (regular or low carbon grades) may be substituted, with corresponding appropriate specifications or the >L= grades. PTFE gaskets with various fillers and expanded PTFE have been used successfully. Check pressure-temperature ratings of flanges. The pressure and temperatures listed in table one based on current applications of caustic suppliers and users.

Note 3.

Note 4. Note 5. Note 6.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

31

Note 7. Note 8.

Threads shall be to ASME B1.1. Bolts shall have a Class 2A fit and nuts shall have a Class 2B fit. Stud bolts are preferred on in-line piping components that do not have tapped threads. Cap screws may be used for tapped piping components and instrumentation.

5.3.2

Other Piping Systems Nonmetallic piping systems including lined pipe, FRP, dual laminate FRP, PVC, CPVC, polypropylene and other materials have been successfully used for many applications at varying concentrations. Each application is unique and therefore the conditions should be carefully considered before selection of the material of construction.

5.4

VALVES Valving for caustic service requires special attention by all associated with the application, including the manufacturer, the supplier, the installer, the operator, and the maintainer. An understanding by all involved of the following subsections will provide for a successful application. This section will discuss the types of valves currently in service, the criteria for selection of valve features, valve selection tables and materials of construction tables. The information presented is based on experience of the Institutes membership and relevant information furnished by valve manufacturers. There is no intention to exclude the use of other valve types or materials provided there is adequate experience and sufficient testing to ensure their safe operation.

5.4.1

General Caustic Service Valves The types of valves commonly employed in caustic service are the globe, ball, plug, gate, butterfly and diaphragm. Each type is available in several basic body patterns and with different design features often unique to a particular service and/or installation. Specific advantages and disadvantages are listed in the following section. Globe Valves Globe valves offer several important safety features, including tight shut off in both directions (bidirectional seating) without trapping liquid inside cavities, multi-turn operation that prevents quick (and sometimes accidental) opening and closing, and a positive means to verify valve position (open or closed). The recommended configuration includes a blow-out proof stem, a bolted bonnet employing four bolts minimum, and a gland with outside screw and yoke (OS&Y) for external packing gland adjustment. Either metal-to-metal seating employing hard-facing, or soft-seating using a fluoropolymer insert will provide satisfactory service. A bellows seal can be chosen for extended service life. Similar results may be achieved with special stuffing box designs incorporating a live-loaded packing gland.

32
Ball Valves

PAMPHLET 94

Ball valves can provide tight shutoff with minimum resistance to flow when fully open. They are generally easier to operate than plug valves of equal size. Some maintain that the 1/4-turn stem movement lends itself to an inherently more reliable stem seal design than the rising stem valve. Ball valves should incorporate a blow-out proof stem design and a means to externally adjust the stem seal. The sealing material generally is a fluoropolymer resin, although fluroelastomer O-rings are sometimes employed as the outer secondary seal. Glass reinforced fluropolymer seals should not be used in caustic service. Ball valves may be furnished either full-bore or reduced-bore. Flanged valves may have either a long (standard) or short body pattern. Full-bore ball valves have openings throughout the length of the valve with a diameter equal to their nominal pipe size. Two designs of ball valves generally used are the metal bodied type with fluoropolymer resin seats and the fully lined type utilizing a fluoropolymer resin-lined body and overmolded ball. Selection should be based on a complete understanding of the pressure, temperature, and concentration of the application. Plug Valves Plug valves can be used for caustic service and have generally provided satisfactory service. Their primary drawback is a need to balance turning torque and shutoff sealing capability. Like the ball valve, this valve can provide tight shutoff and, with the 1/4-turn stem movement, lends itself to an inherently more reliable stem seal design than the rising stem valve. Plug valves have an inherent blow-out proof stem design and should be provided with a means to externally adjust the stem seal. The sealing material generally employed is a fluoropolymer resin. Two designs of plug valves generally used are the metal type with a fluoropolymer resin sleeve body and metal plug, and the fully lined type, utilizing a fluoropolymer resin-lined body and overmolded plug. While these valves provide good shutoff sealing, they require substantial torques to operate them. This torque requirement tends to increase as the valve liner ages or deforms. The use of gear operators on 4 inch valves and larger is strongly recommended. In some cases, gear operators may be needed on 3 inch valves, as well. Gate Valves Gate valves have provided satisfactory service in caustic applications. Gate valves utilizing a rising stem design may require additional maintenance and packing adjustments to avoid shaft leakage. Material selection should be based on the specific application, with regards to the concentration and temperature. Metal-to-metal seating or soft-seating using a fluoropolymer resin insert will provide satisfactory service.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

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Rubber-Lined Butterfly Valves Rubber-lined butterfly valves have been used in caustic applications employing elastomers such as EPDM or chlorosulphonated-polyethylene for the body liner (seat). Commonly supplied with a metal disc overmolded with these same rubber materials or a fluoropolymer resin may also be used. An advantage of this type of valve is that the body, shafts, bearings, and packing are non-wetted parts. In certain applications, these valves may not provide adequate shutoff sealing. In those cases where positive shut off is important, other valve choices should be considered. Fluorocarbon Resin-Lined Butterfly Valves Fluorocarbon resin-lined butterfly valves can provide tight shutoff in both directions without trapping fluid, and with the 1/4-turn stem movement, lends itself to an inherently more reliable stem seal design than the rising stem valve. It should incorporate a blowout proof stem design. Soft-Seated "High-Performance" Butterfly Valves Soft-seated, high-performance butterfly valves have been used in caustic applications, particularly in larger pipe sizes. These valves are distinguished from rubber and fluoropolymer-lined butterfly valves by their ANSI rated pressure capability. With these valves, the metal body and disc come in contact with the media; hence, material selection must be made with regards to concentration and temperature of the caustic. Most soft-seated high-performance butterfly valves use an adjustable packing design, a wetted shaft/disc arrangement and a one-piece soft-lip seal. Soft-seated high performance butterfly valves can provide tight shut-off, and with the 1/4-turn stem movement, lends itself to an inherently more reliable stem seal design than the rising stem valve. Diaphragm Valves Diaphragm valves have been used in caustic applications. This type of valve employs a variety of body materials (unlined metal and plastic or elastomer and plastic-lined) in conjunction with an elastomer or fluoropolymer diaphragm. The body and diaphragm are the only parts exposed to the media. Diaphragm valves can provide tight shut-off in both directions without trapping fluid, multi-turn operation that prevents quick (sometimes accidental) opening and closing, and can be provided with a positive means to verify position (open or closed). 5.4.2 Valve Selection Guide A valve selection guide is provided in Tables 5.4.2.1 through 5.4.2.8. These tables are intended for use in selecting various types of valves that have been found satisfactory in caustic service. It is not intended to prevent the use of valve types other than those designated as "satisfactory" in a particular service class. However, the user is cautioned against such practice unless ample testing (with documentation) has been conducted, to assure safe operation.

34

PAMPHLET 94

Table 5.4.2.1: Globe Valves

NOMINAL PIPE SIZE (NPS) COMMON END CONNECT PRIMARY FORM AND MINIMUM RATING Forged API Class 800 or Cast ASME Class 150 Forged API Class 800 or Cast ASME Class 150 Forged API Class 800 or Cast ASME Class 150 Forged API Class 800 or Cast ASME Class 150 Forged or Cast ASME Class 150 <=50% CAUSTIC <=120oF(48.9oC) <=175 PSIG (1207 kPa) CARBON STEEL <=50% CAUSTIC <=200oF(95oC) <=175 PSIG (1207 kPa) STAINLESS STEEL <=73% CAUSTIC <=260oF(126.7oC) <=175 PSIG (1207 kPa) MONEL <=73% CAUSTIC <=350oF(176.7oC) <=175 PSIG (1207 kPa) NICKEL [See Note 2]

Through 1"

Threaded [See Note 1]

1-1/2" to 2"

Threaded [See Note 1]

Not Recommended

Not Recommended

Through 1"

Socket Welded

1-1/2" to 2"

Socket Welded

Not Recommended

Not Recommended

Not Recommended

All Sizes

Flanged

Legend: Note 1. Note 2.

S = Satisfactory Except for connections to transportation equipment, specific instruments, and special process equipment, flanged valves are recommended. An ASME Class 150 nickel valve has a rating of 140 psig at 350oF (176.7oC) and an ASME Class 300 nickel valve has a rating 360 psig at 350oF (176.7oC). When using a nickel system, caution should be taken in selecting the correct valve rating.

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Table 5.4.2.2: Ball Valves

NOMINAL PIPE SIZE (NPS) COMMON END CONNECT PRIMARY FORM AND MINIMUM RATING Forged or Cast ASME Class 150 Forged or Cast ASME Class 150 Forged or Cast ASME Class 150 Forged or Cast ASME Class 150 Forged or Cast ASME Class 150 [See Note 3] <=50% CAUSTIC <=120oF(48.9oC) <=175PSIG(1207kPa) CARBON STEEL <=50% CAUSTIC <=200oF(95oC) <=175 PSIG (1207 kPa) STAINLESS STEEL <=73% CAUSTIC <=260oF(126.7oC) <=175 PSIG (1207 kPa) MONEL <=73% CAUSTIC <=350oF(176.7oC) <=175 PSIG (1207 kPa) NICKEL [See Note 2] SC

Through 1"

Threaded [See Note 1] Threaded [See Note 1] Socket Welded Socket Welded Flanged

1-1/2" to 2"

Not Recommended

Not Recommended

Through 1"

SC

1-1/2" to 2"

Not Recommended

Not Recommended

Not Recommended

All Sizes

SC

Legend:

S = Satisfactory SC = Satisfactory under specific conditions, consult manufacturer for details.

Note 1. Note 2.

Except for connections to transportation equipment, specific instruments, and special process equipment, flanged valves are recommended. An ASME Class 150 nickel valve has a rating of 140 psig at 350oF (176.7oC) and an ASME Class 300 nickel valve has a rating of 360 psig at 350oF (176.7oC). When using a nickel system, caution should be taken in selecting the correct valve rating. Fluoroplastic lined ball valves are satisfactory only under specific conditions. Consult the manufacturer for details.

Note 3.

36
Table 5.4.2.3: Plug Valves
NOMINAL PIPE SIZE (NPS) COMMON END CONNECT PRIMARY FORM AND MINIMUM RATING Cast ASME Class 150 Cast ASME Class 150 Cast ASME Class 150 Cast ASME Class 150 Cast ASME Class 150 [See Note 3]

PAMPHLET 94

<=50% CAUSTIC <=120oF(48.9oC) <=175 PSIG (1207 kPa) CARBON STEEL

<=50% CAUSTIC <=200oF(95oC) <=175 PSIG (1207 kPa) STAINLESS STEEL

<=73% CAUSTIC <=260oF(126.7oC) <=175 PSIG (1207 kPa) MONEL

<=73% CAUSTIC <=350oF(176.7oC) <=175 PSIG (1207 kPa) NICKEL [See Note 2] S Not Recommended SC Not Recommended

Through 1" 1-1/2" to 2" Through 1" 1-1/2" to 2" All Sizes

Threaded [See Note 1] Threaded [See Note 1] Socket Welded Socket Welded Flanged

S S S S

S S S Not Recommended

S Not Recommended S Not Recommended

Legend:

S = Satisfactory SC = Satisfactory under specific conditions, consult manufacturer for details.

Note 1. Note 2.

Except for connections to transportation equipment, specific instruments, and special process equipment, flanged valves are recommended. An ASME Class 150 nickel valve has a rating of 140 psig at 350oF (176.7oC) and an ASME Class 300 nickel valve has a rating of 360 psig at 350oF (176.7oC). When using a nickel system, caution should be taken in selecting the correct valve rating. Fluoroplastic lined plug valves are satisfactory only under specific conditions. Consult the manufacturer for details.

Note 3.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

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Table 5.4.2.4: Gate Valves

NOMINAL PIPE SIZE (NPS) COMMON END CONNECT PRIMARY FORM AND MINIMUM RATING <=50% CAUSTIC <=120oF(48.9oC) <=175 PSIG (1207 kPa) CARBON STEEL <=50% CAUSTIC <=200oF(95oC) <=175 PSIG (1207 kPa) STAINLESS STEEL <=73% CAUSTIC <=260oF(126.7oC) <=175 PSIG (1207 kPa) MONEL <=73% CAUSTIC <=350oF(176.7oC) <=175 PSIG (1207 kPa) NICKEL [See Note 2] S

Through 1"

Threaded [See Note 1] Threaded [See Note 1] Socket Welded Socket Welded Flanged

Forged API Class 800 or Cast ASME Class 150 Forged API Class 800 or Cast ASME Class 150 Forged API Class 800 or Cast ASME Class 150 Forged API Class 800 or Cast ASME Class 150 Forged or Cast ASME Class 150

1-1/2" to 2"

Not Recommended

Not Recommended

Through 1"

1-1/2" to 2"

Not Recommended

Not Recommended

Not Recommended

All Sizes

Legend: Note 1. Note 2.

S= Satisfactory Except for connections to transportation equipment, specific instruments, and special process equipment, flanged valves are recommended. An ASME Class 150 nickel valve has a rating of 140 psig at 350oF (176.7oC) and an ASME Class 300 nickel valve has a rating of 360 psig at 350oF (176.7oC). When using a nickel system, caution should be taken in selecting the correct valve rating.

38

PAMPHLET 94

Table 5.4.2.5: Rubber Lined Butterfly Valves

NOMINAL PIPE SIZE (NPS) 2" and Larger 2" and Larger COMMON END CONNECT Wafer Lug PRIMARY FORM AND MINIMUM RATING Cast 150 psig Cast 150 psig <=50% CAUSTIC <=120oF(48.9oC) <=175 PSIG (1207 kPa) CARBON STEEL SC SC <=50% CAUSTIC <=200oF(95oC) <=175 PSIG (1207 kPa) STAINLESS STEEL SC SC <=73% CAUSTIC <=260oF(126.7oC) <=175 PSIG (1207 kPa) MONEL Not Recommended Not Recommended <=73% CAUSTIC <=350oF(176.7oC) <=175 PSIG (1207 kPa) NICKEL Not Recommended Not Recommended

Legend:

S= Satisfactory SC= Satisfactory under specific conditions. Consult manufacturer for details.

Table 5.4.2.6: Fluoropolymer Lined Butterfly Valves

NOMINAL PIPE SIZE (NPS) 2" and Larger 2" and Larger COMMON END CONNECT Wafer Lug PRIMARY FORM AND MINIMUM RATING Cast 150 psig Cast 150 psig <=50% CAUSTIC <=120oF(48.9oC) <=175 PSIG (1207 kPa) CARBON STEEL SC SC <=50% CAUSTIC <=200oF(95oC) <=175 PSIG (1207 kPa) STAINLESS STEEL SC SC <=73% CAUSTIC <=260oF(126.7oC) <=175 PSIG (1207 kPa) MONEL SC SC <=73% CAUSTIC <=350oF(176.7oC) <=175 PSIG (1207 kPa) NICKEL SC SC

Legend:

S= Satisfactory SC= Satisfactory under specific conditions, consult manufacturer for details.

Table 5.4.2.7: High Performance Butterfly Valves

NOMINAL PIPE SIZE (NPS) COMMON END CONNECT PRIMARY FORM AND MINIMUM RATING Cast ASME Class 150 Cast ASME Class 150 <=50% CAUSTIC <=120oF(48.9oC) <=175 PSIG (1207 kPa) CARBON STEEL S S <=50% CAUSTIC <=200oF(95oC) <=175 PSIG (1207 kPa) STAINLESS STEEL S S <=73% CAUSTIC <=260oF(126.7oC) <=175 PSIG (1207 kPa) MONEL S S <=73% CAUSTIC <=350oF(176.7oC) <=175 PSIG (1207 kPa) NICKEL [See Note 1] SC SC

2" and Larger 2" and Larger

Wafer Lug

Legend:

S = Satisfactory SC = Satisfactory under specific conditions, consult manufacturer for details.

Note 1.

An ASME Class 150 nickel valve has a rating of 140 psig at 350oF (176.7oC) and an ASME Class 300 nickel valve has a rating of 360 psig at 350oF (176.7oC). When using a nickel system, caution should be taken in selecting the correct valve rating.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

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Table 5.4.2.8: Diaphragm Valves

NOMINAL PIPE SIZE (NPS) COMMON END CONNECT PRIMARY FORM AND MINIMUM RATING Cast 150 psig Cast 150 psig Cast 150 psig Cast 150 psig Cast ASME Class 150 [See Note 3] <=50% CAUSTIC <=120oF(48.9oC) <=175 PSIG (1207 kPa) CARBON STEEL SC SC SC SC SC <=50% CAUSTIC <=200oF(95oC) <=175 PSIG (1207 kPa) STAINLESS STEEL SC SC SC Not Recommended SC <=73% CAUSTIC <=260oF(126.7oC) <=175 PSIG (1207 kPa) MONEL SC Not Recommended SC Not Recommended SC <=73% CAUSTIC <=350oF(176.7oC) <=175 PSIG (1207 kPa) NICKEL (See Note 2) SC Not Recommended SC Not Recommended SC

Through 1" 1-1/2" to 2" Through 1" 1-1/2" to 2" All Sizes

Threaded (See Note 1) Threaded (See Note 1) Socket Welded Socket Welded Flanged

Legend:

S = Satisfactory SC = Satisfactory under specific conditions. Consult manufacturer for details.

Note 1. Note 2.

Except for connections to transportation equipment, specific instruments and special process equipment, flanged valves are recommended. An ASME Class 150 nickel valve has a rating of 140 psig at 350oF (176.7oC) and an ASME Class 300 nickel valve has a rating of 360 psig at 350oF (176.7oC). When using a nickel system, caution should be taken in selecting the correct valve rating. Ratings for diaphragm valves are dependent upon size and materials of construction. Consult manufacturer for specific applications.

Note 3.

5.4.3

Valve Material Selection Guide Table 5.4.3.1 lists materials that have proven to be suitable for valve parts in caustic service. Materials are listed by the applicable standard/material designations. This guide is not intended to prevent the substitution of other materials known to be suited for the specific service as agreed upon between the manufacturer and purchaser.

40

PAMPHLET 94

Table 5.4.3.1: Valve Material Selection Guide

PRODUCT FORM VALVE PART <=50% CAUSTIC <=120oF(48.9oC) <=175 PSIG (1207 kPa) CARBON STEEL ASTM A216 Grade WCB ASTM A395 [See Notes 1 and 8] ASTM A126 [See Note 1] ASTM A105, ASTM A182 Grade F1 ASTM A516 Grade 70 ASTM A307 Grade B (See Note 9) ASTM A193 Grade B7 ASTM A563 ASTM A194 Grade 2H 316 Stainless Steel, Alloy 20, Monel 400 and 405 (UNS N04400 and UNS N04405), Hastelloy B and C <=50% CAUSTIC <=200oF(95oC) <=175 PSIG (1207 kPa) STAINLESS STEEL [See Note 5] ASTM A351 Grade CF8 ASTM A395 [See Note 1] <=73% CAUSTIC <=260oF(126.7oC) <=175 PSIG (1207 kPa) MONEL ASTM A494 Grade M-30-2 ASTM A395 [See Note 1] <=73% CAUSTIC <=350oF(176.7oC) <=175 PSIG (1207 kPa) NICKEL [See Note 8] ASTM A494 Grade CZ-100 [See Note 9] ASTM A395 [See Note 1] ASTM B160/B564 Grade N02200 [See Note 8] ASTM B162 Grade UNS N02200 [See Note 8] ASTM A307 Grade B,(See Note 9) ASTM A193 Grade B7 ASTM A563 ASTM A194 Grade 2H Nickel 200 (UNS N02200)

Castings [See Note 8]

Bodies, Bonnets and Covers

Forgings

Bodies, Bonnets and Covers Bodies, Bonnets and Covers Machine Bolts and Stud Bolts [See Note 9] Nuts

ASTM A182 Grade F304 ASTM A240 Type 304 ASTM A307 Grade B (See Note 9) ASTM A193 Grade B7 ASTM A563 ASTM A194 Grade 2H 316 Stainless Steel, Alloy 20, Monel 400 and 405 (UNS N04400 and UNS N04405), Hastelloy B and C, Inconel, Nickel 200 (UNS N02200) 316 Stainless Steel, Alloy 20, Monel 400 and 405 (UNS N04400 and UNS N04405), Hastelloy B and C, Inconel, Nickel 200 (UNS N02200) [See Note 2] Monel 400 and 405 (UNS N04400 and UNS N04405), Hastelloy B and C Hard Faced [See Note 3] [See Note 4]

ASTM B164/B564 Grade N04400 [See Note 2] ASTM B127 Grade UNS N04400 [See Note 2] ASTM A307 Grade B,(See Note 9) ASTM A193 Grade B7 ASTM A563 ASTM A194 Grade 2H Monel 400 and 405 (UNS N04400 and UNS N04405), Hastelloy B and C, Inconel, Nickel 200 (UNS N02200)

Rolled Plates and Shapes Body, Bonnet and Cover Bolting [See Note 6]

Other Metal Parts [See Note 4]

Stems (Shafts)

Balls, Discs and Tapered Plugs

316 Stainless Steel, Alloy 20, Monel 400 and 405 (UNS N04400 and UNS N04405), Hastelloy B and C [See Note 2]

Monel 400 and 405 (UNS N04400 and UNS N04405), Hastelloy B and C, Inconel, Nickel 200 (UNS N02200) [See Note 2] Monel 400 and 405 (UNS N04400 and UNS N04405), Hastelloy B and C Hard Faced [See Note 3] [See Note 4]

Nickel 200 (UNS N02200) [See Note 2]

Bellows

Monel 400 and 405 (UNS N04400 and UNS N04405), Hastelloy B and C Hard Faced [See Note 3] [See Note 4]

Nickel Alloy [See Note 8]

Seats, Discs and Wedge Facings Other Parts

Hard Faced [See Note 3] [See Note 4]

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

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Table 5.4.3.1: Valve Material Selection Guide

PRODUCT FORM VALVE PART <=50% CAUSTIC <=120oF(48.9oC) <=175 PSIG (1207 kPa) CARBON STEEL EPDM, Chlorosulphonated Polyethylene, Virgin or Reinforced PTFE, PFA PTFE, PFA, FEP, ETFE, ECTFE PTFE, Graphite, Graphite Filled PTFE, Non-Asbestos PTFE, Graphite, Graphite Filled PTFE, Non-Asbestos <=50% CAUSTIC <=200oF(95oC) <=175 PSIG (1207 kPa) STAINLESS STEEL [See Note 5] Chlorosulphonated Polyethylene, Virgin or Reinforced PTFE, PFA <=73% CAUSTIC <=260oF(126.7oC) <=175 PSIG (1207 kPa) MONEL Virgin or Reinforced PTFE, PFA <=73% CAUSTIC <=350oF(176.7oC) <=175 PSIG (1207 kPa) NICKEL [See Note 8] Virgin or Reinforced PTFE, PFA

Non-metallic Parts

Seats, Sleeves, Diaphragms and Seals Fluoropolymer Linings Packing

PTFE, PFA, FEP, ETFE, ECTFE PTFE, Graphite, Graphite Filled PTFE, Non-Asbestos PTFE, Graphite, Graphite Filled PTFE, Non-Asbestos

PTFE, PFA, FEP, ETFE, ECTFE PTFE, Graphite, Graphite Filled PTFE, NonAsbestos PTFE, Graphite, Graphite Filled PTFE, NonAsbestos

PTFE, PFA, FEP, ETFE, ECTFE PTFE, Graphite, Graphite Filled PTFE, Non-Asbestos PTFE, Graphite, Graphite Filled PTFE, Non-Asbestos

Gasketing

The complete titles of specifications are listed in Section 7. Note 1. Ductile Iron to ASTM A395 and Cast Iron to A126 may be lined for use as rubber lined butterfly and diaphragm valves; fluoropolymer resin ball, plug, butterfly, and diaphragm valves; and fluoropolymer resin sleeved plug valves. Use annealed Monel 400 per ASTM B564 Grade N04400 for forgings and ASTM B127 Grade N04400 for plates. Hard-faced seating surfaces of Stellite 6, 12 and/or 21 are recommended for metal seating surfaces prone to the combined effects of corrosion and erosion. Monel K500 (UNS NO5500) also possesses good hard-facing properties. Various metals are used as base materials for over molded parts such as plugs, balls, and discs. The specifications listed are typical for 304 stainless steel. Type 316 may be substituted, with corresponding appropriate specifications or the >L= grades of 304 and 316.

Note 2. Note 3.

Note 4. Note 5.

42

PAMPHLET 94

Note 6.

Other parts (such as yokes, yoke nuts, glands, gland bushings, studs, and handwheels) shall be constructed of a material suitable for the service and as agreed upon between manufacturer and purchaser. If environmental conditions are such that chloride stress corrosion cracking is possible, then Series 300 stainless steels should be avoided for bolts, studs and nuts. Generally, Series 300 stainless steel bolts, studs, and nuts should be avoided, as chloride stress cracking can occur as a result of seep leaks as well as from chlorides in the atmosphere. These piping components are very highly stressed during their fabrication, making them especially subject to stress corrosion cracking from both chlorides and from caustic (even at ambient temperatures). Ductile Iron to ASTM A395 and Cast Iron to A126 may be used for pressure reducing valves and for fluorocarbon resin sleeved plug valves within this system. The valve manufacturer should be consulted on the appropriate nickel alloy for use in this system. ASTM A307 Grade B bolting on valves shall be restricted to bonnet or cover bolting only for Class 300 and lower rated valves provided the service o o temperature is limited to 400 F (204 C). When required, ASTM A563 nuts shall be used with ASTM A307 Grade B bolts and ASTM A194 Grade 2H nuts shall be used with ASTM A193 Grade B7 bolts.

Note 7.

Note 8. Note 9.

5.4.4

Check Valves All of the standard types of check valves are suitable for caustic service. The body and trim material should be consistent with the general piping specifications. For check valves that utilize springs, Monel or Inconel should be specified for the spring material.

5.4.5

Pressure Relief Valves Caustic systems should be designed to avoid the use of pressure relief valves if at all possible. If the use of a pressure relief device is unavoidable, the materials of construction of the device should be consistent with those of the piping system. For temperatures above 140oF (60oC), Monel or Inconel springs should be specified. The pressure relief valve vent system should be adequately sized and piped to a containment system. The relief device and its associated piping should be protected from freezing. Both caustic soda and caustic potash will become very viscous at 80oF (26.7oC) and will freeze at temperatures below 60oF (15.6oC).

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5.5

OTHER COMPONENTS Expansion Joints Caustic piping systems shall have sufficient flexibility to prevent failure of the piping system due to thermal expansion or contraction. When flexibility cannot be introduced into the system through pipe routing, bellows expansion joints can be employed to absorb the differential expansion while containing the system pressure. These joints are engineered products which should not be purchased and used as commodity items. Expansion joints shall be kept to a minimum, but when required shall be metallic with minimum bellows metallurgy of Monel alloys 400 and R405 (UNS N04400 and N04405) nickel or PTFE and shall comply with ASME B31.3 (7.3.4). The expansion joint in piping between the storage tank and its transfer pump should always be located downstream of the first storage tank block valve. This allows isolation of the storage tank in case of an expansion joint failure. Hoses Hoses are utilized for temporary connections in caustic service. selected based on chemical compatibility and mechanical integrity. Loading Arms Loading arms are utilized for loading and unloading caustic. Piping and joints should be selected based on chemical compatibility and technical integrity. Insulation and Heat Tracing Caustic solutions, dependent on concentration, freeze at temperatures below 60oF (15.5oC) and therefore the piping system should be heat traced and insulated when these conditions are anticipated. Self-regulating electric tracing is recommended over steam tracing which can in turn result in stress cracking and ultimately premature pipe failure. The following should be considered when designing the heat trace/insulation system:

Hose should be

If the material of construction of the piping system is carbon steel, the heat tracing should not allow the piping temperature to exceed 120oF (48.9oC) as corrosion rates are elevated at this temperature resulting in iron contamination of the caustic and susceptibility to stress corrosion cracking. If the material of construction of the piping system is stainless steel (type 304L or 316L), the heat tracing should not allow the piping temperature to exceed 200oF (95oC). At temperatures above 200oF (95oC) type 304L and 316L stainless steel in caustic service experience increased general corrosion rates and higher susceptibility to stress cracking. Steam tracing of caustic piping is not generally recommended, however, in situations where it is used, standoffs should be employed to prevent hot tubing from contacting directly with the pipe and exceeding the pipe material temperature limits.

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Some insulation materials if high in chloride content can promote external stress corrosion cracking of stainless steel at elevated temperatures. Use of alternate insulation systems or protection of the stainless steel surface is necessary.

5.6

INSTRUMENTATION Proper instrumentation can be a key factor in safe operations of caustic piping systems. Isolation of instrument devices from the process may be accomplished by materials of construction or diaphragm protection. If direct reading pressure sensing devices are used, they should be equipped with Alloy 20, Monel, nickel, or Hastelloy C bourdon tubes. Pressure sensing instruments may be protected from the caustic process by a liquid-filled seal. The process connection can be carbon steel, Monel, Alloy 20, nickel, or Hastelloy C. The diaphragm should be Monel, Alloy 20, nickel, or Hastelloy C. Temperature sensing devices should be equipped with thermowells of suitable material, such as Monel, Alloy 20, nickel, or Hastelloy C, to permit replacement of the temperature element without a shutdown. Many types of level devices including pressure, displacement, proximity, and capacitance types can be used if designed for caustic service. Glass devices are attacked by caustic. Differential pressure sensing devices must be calibrated to the correct caustic concentration or the measured level will be incorrect. Many types of flow devices including orifice flanges, magmeters, vortex shedding meters, turbine meters, coreolis meters, etc., can be used if designed for caustic service. Flow devices should be made of corrosion resistant materials such as stainless steel, Alloy 20, Monel, nickel, or Hastelloy C. Control valve materials and design should follow guidelines presented in Section 5.4. Due to cycling, stem sealing is a more important consideration than with manual valves and care must be exercised in seal selection. Aluminum, magnesium, zinc, brass, copper, and tantalum are materials that are attacked by caustic and must be avoided. Shutoff or isolation valves are recommended to permit service of the instruments while in use.

5.7

INSPECTION AND MAINTENANCE Routine Maintenance Written procedures specific to caustic piping maintenance should be used to ensure long term integrity of the system. Personnel that work on caustic piping systems should be trained in the proper maintenance procedures. After maintenance, the affected area of piping should be checked for leaks.

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Cleaning and neutralizing of metal surfaces exposed to caustic in preparation for welding is critical in order to avoid caustic SCC of the welded heat-affected zone. Periodic Inspections Caustic piping systems should be inspected on a regular basis. The inspections will help to find problems prior to failure. Criteria for initiating replacement or repair should be developed for each facility. There are multiple ways to inspect these systems. Useful methods include visual inspections and nondestructive test checks. A visual inspection is by far the most important inspection that can be done. Other methods can be used as a supplement. Nondestructive testing can be used in measuring corrosion rates. The results of all inspections should be well documented. Preventive Maintenance As part of a good overall preventive maintenance program, consideration should be given to ensuring that the following items be checked periodically and corrected as needed: flange bolt condition and tightness valve packing adjustment valve operation condition of supports paint condition heat tracing functionality insulation condition Transfer hoses and connections should be inspected any time they are going to be used. These are non-repairable items and should be replaced any time there is leakage, fraying, deformation, or corrosion.

Consideration should be given to repainting on a regular basis, with timing determined by individual site conditions. Visual A visual inspection should include a leak check of all flanges, valves and other fittings and attachments. Particular areas of concern should include such things as pipe supports and areas with paint or insulation damage. Where insulation is damaged further inspection is warranted. Special note should be taken of weld areas, as these areas corrode most quickly. Any significant observed pitting or wall loss should be investigated further, and should be corrected as necessary. Nondestructive Testing Nondestructive testing methods detect pipe wall thickness, pit depths, and internal and external erosion/corrosion. These methods include ultrasonic thickness measurements and radiographic measurements.

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PAMPHLET 94

Due to normal variations in pipe dimensions, it is important that the same points be measured each time they are tested. This can be accomplished by developing "maps" or isometric sketches of the system, with test points clearly identified and marked. Routine testing will show the corrosion rates typical for the system, so that predictive maintenance can be estimated. Consideration should be given to checking areas of high fluid velocity more frequently due to possible internal erosion. Radiographic techniques are available to check pipe wall thickness through insulation. This permits checking piping systems without breaking the vapor barrier of the insulation. If test methods are used which require the removal of insulation, care must be taken to restore the insulation vapor barrier integrity. Inspection Records Written records should be maintained. These records should include the initial inspection report, as well as recommended further inspections and corrective actions. Documentation of all follow-up actions should be appended to the initial original report. 6. 6.1 OTHER EQUIPMENT PUMPS Centrifugal pumps are recommended for transferring caustic solutions from storage to the point of use, however, positive displacement and other types of pumps are used for specific conditions. Ductile iron pumps or stainless steel may be used for caustic solutions below 120oF (49oC). Alloy 20, CD4M, Monel or other nickel alloy pumps will provide a longer service life at temperatures above 120oF (49oC). Caustic transfer pumps may be equipped with a high pressure/low pressure switch or low flow switch cutoff to prevent continued operation when the pump is dead-headed or running dry. A minimum flow recycle line will also help to prevent pump damage from dead-heading. The centrifugal pump shaft seal can be a packing gland, a mechanical seal and/or a repeller equipped seal-less pump. If dilution of caustic is a concern, double mechanical seal or repeller equipped seal-less pump should be considered. The gland area of the pump should be shielded for personnel protection. A magnetically-coupled pump eliminates the need for seals. Aluminum, magnesium, zinc, brass, copper, and tantalum are materials that are attacked by caustic and are to be avoided in pump construction. Piping connections for washing and draining for pump maintenance should be provided. Pump location should receive careful consideration. The pump should be easily accessible for operation and maintenance. The area adjacent to the pump should be designed to minimize personnel exposure and environmental contamination should the pump develop a leak.

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For pumps in 50% caustic service where ambient temperatures are below 60oF, the pump casing may be heat traced and insulated to prevent caustic freezing. 6.2 HEAT EXCHANGERS Heat exchangers are used either to remove the heat of dilution from caustic (usually to permit storage in carbon steel tanks) or to add heat to caustic to prevent it from freezing. Two types of heat exchangers are commonly used, shell and tube, and plate and frame type. For the shell and tube heat exchanger, steam is normally introduced to the shell side for heating while cooling water is introduced to either the shell or tube side for cooling. Use of cooling water on the tube side has the advantage of easy access for cleaning. The shell and tube heat exchanger can be installed either vertically or horizontally for either heating or cooling. As an alternative to internal heating of caustic storage tank (4.6.4), the heat exchanger is used for heating externally. External heating has the advantage of easy inspection and maintenance of the heat exchanger, and minimizes the possibility of local hot spots on the tank. The latter is especially important for lined or coated storage tank. In selecting the heat exchanger materials of construction, the maximum temperature of the heating medium must be considered. Typically, nickel 200 is used on the process (caustic) side of the heat exchanger. Steam pressure of 15 psig (103 kPa) is typically used for heating. The 15 psig steam is to minimize the potential of boiling caustic in the heat exchangers. The plate and frame type heat exchanger is commonly used for removing heat from caustic dilution than the shell and tube type. Stainless steel plate such as 304 and 316 has been used successfully. However, increased general corrosion rates at the higher temperatures generally limit the practical upper temperature to 140oF (60oC), as the plates typically have minimal corrosion allowance. Above 140oF (60oC), Monel 400 or nickel 200 should be considered. Rubber gaskets have been successfully used. Contact the heat exchange manufacturer for alternative gasket materials. All plate and frame heat exchangers should be equipped with an OSHA approved safety shroud to protect operating personnel against being sprayed if there is gasket leak. 6.3 AGITATORS AND MIXERS Agitation is needed to maintain a uniform concentration during caustic dilution. The normal practice of agitation and mixing is by an in-line static mixer, an internal tank mixing eductor or a circulation loop from the diluted caustic transfer pump. The 316 stainless steel in-line static mixer is suitable for temperatures below 140oF (60oC). For temperatures above 140oF (60oC) nickel or nickel alloy or fluorocarbon resin-lined static mixer, should be considered due to induced stresses which may be present in fabricated stainless mixers.

48

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Internal tank mixing eductors have proven very effective for mixing. They require an external recirculation pump. However, this can be combined with an external heating or cooling system or the diluted caustic transfer pump. For a properly sized system, the eductors can completely mix a storage tank in two to four hours following receiving new material into the tank. The eductors are normally of stainless or CPVC construction depending on the temperature. A recirculation loop from the diluted caustic transfer pump can also be used for mixing. The recirculation line should be routed to the tank 180o from the pump suction nozzle for better mixing.

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7. 7.1

REFERENCES INSTITUTE PUBLICATIONS The following publication is specifically referenced in CI Pamphlet 94. The latest editions of CI publications may be obtained at http://www.chlorineinstitute.org. Pamphlet # 65 Title Personal Protective Equipment for Chlor-Alkali Chemicals, ed. 5; Pamphlet 65; The Chlorine Institute: Arlington, VA, 2008.

7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.3 7.3.1 7.3.2

API STANDARD SPECIFICATIONS Specification for Shop Welded Tanks for Storage of Production Liquids, API 12F; The American Petroleum Institute: Washington, DC, 2008. Valve Inspection And Testing, API 598; The American Petroleum Institute: Washington, DC, 2009. Butterfly Valves: Double Flanged, Lug, and Wafer Type; API 609; The American Petroleum Institute: Washington, DC, 2009. Design and Construction of Large, Welded, Low-Pressure Storage Tanks, API 620; The American Petroleum Institute: Washington, DC, 2008. Welded Steel Tanks for Oil Storage, ed. 11; API 650; The American Petroleum Institute: Washington, DC, 2007. Tank Inspection, Repair, Alteration, And Reconstruction, API 653; The American Petroleum Institute: Washington, DC, 2009 ASME CODES AND STANDARDS Reinforced Thermoset Plastic Corrosion Resistant Equipment, (Fiberglass Construction); ASME RTP-1; American Society of Mechanical Engineers: New York, NY, 2011. Rules for Construction of Pressure Vessels - Section VIII, Division I, ASME Boiler and Pressure Vessel Code, ASME BPVC-VIII-I; The American Society of Mechanical Engineers: New York, NY, 2010. Welding And Brazing Qualifications, Section IX, ASME Boiler and Pressure Vessel Code, ASME BPVC-IX; The American Society of Mechanical Engineers: New York, NY, 2010. Process Piping, ASME Code for Pressure Piping, ANSI/ASME B 31.3; The American Society of Mechanical Engineers: New York, NY, 2010.

7.3.3

7.3.4

50
7.3.5 7.3.6 7.3.7 7.4 7.4.1

PAMPHLET 94

Pipe Flanges and Flanged Fittings, ASME B16.5, an ANSI Standard; The American Society of Mechanical Engineers: New York, NY 2009. Face-to-Face And End-to-End Dimensions of Valves, ASME B16.10; an ANSI Standard; The American Standard of Mechanical Engineers: New York, NY 2009 Valves - Flanged Threaded and Welding End, ASME B16.34, an ANSI Standard; The American Standard of Mechanical Engineers: New York, NY 2005. ASTM STANDARD SPECIFICATIONS Pipe, Steel, Black and Hot Dipped, Zinc-Coated, Welded and Seamless, Book of ASTM Standards; A 53; American Society of Testing and Materials: West Conshohocken, PA, 2012. Carbon Steel Forgings for Piping Applications, Book of ASTM Standards; A 105; American Society of Testing and Materials: West Conshohocken, PA, 2011. Seamless Carbon Steel Pipe for High-temperature Service, Book of ASTM Standards; A 106; American Society of Testing and Materials: West Conshohocken, PA, 2011. Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings and Valves and Parts For High-Temperature Service, Book of ASTM Standards; A 182; American Society of Testing and Materials: West Conshohocken, PA, 20011 Alloy-Steel And Stainless Steel Bolting Materials For High-Temperature Service, Book of ASTM Standards; A193; American Society of Testing and Materials: West Conshohocken, PA, 2012. Piping Fittings of Wrought Carbon Steel And Alloy Steel For Moderate And Elevated Temperatures, Book of ASTM Standards; A 234; American Society of Testing and Materials: West Conshohocken, PA, 2011. Low and Intermediate Tensile Strength Carbon Steel Plates, Book of ASTM Standards; A 283; American Society of Testing and Materials: West Conshohocken, PA, 2007. Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength, Book of ASTM Standards; A 307; American Society of Testing and Materials: West Conshohocken, PA, 2010. Seamless and Welded Austenitic Stainless Steel Pipes, Book of ASTM Standards; A 312; American Society of Testing and Materials: West Conshohocken, PA, 2011.

7.4.2 7.4.3 7.4.4

7.4.5

7.4.6

7.4.7 7.4.8 7.4.9

7.4.10 Nickel Rod and Bar, Book of ASTM Standards; B160; American Society of Testing and Materials: West Conshohocken, PA, 2009. 7.4.11 Nickel Seamless Pipe and Tube, Book of ASTM Standards; B161; American Society of Testing and Materials: West Conshohocken, PA, 2009. 7.4.12 Factory-Made Wrought Nickel and Nickel Alloy Fittings, Book of ASTM Standards; B366; American Society of Testing and Materials: West Conshohocken, PA, 2010.

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

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7.5 7.5.1 7.6 7.6.1

NACE CORROSION DATA Corrosion, Data Survey, Metals Section; Ed. 6, National Association of Corrosion Engineers: Houston, TX. OTHER REFERENCES Code of Federal Regulations, Title 49. Parts 100-185. Office of the Federal Register National Archives and Records Administration. U.S. Government Printing Office: Washington, DC, (revised annually). North American Emergency Response Guidebook, Office of Hazardous Material Transportation: Washington, DC, 2008. Code of Federal Regulations, Title 40. Part 150. Office of the Federal Register National Archives and Records Administration. U.S. Government Printing Office: Washington, DC, (revised annually).

7.6.2 7.6.3

For further assistance and information on items referenced, contact: American Chemistry Council 700 2nd Street, NE Washington, DC 20002 202-249-7000202-249-6100 (Fax) http://www.americanchemistry.com American National Standards Institute (ANSI) 1899 L Street, NW 11th Floor Washington, DC 20036 202-293-8020 202-293-9287 (Fax) http://www.ansi.org American Society of Mechanical Engineers (ASME) Three Park Avenue New York, NY 10016-5990 800-843-2763 http://www.asme.org Association of American Railroads (AAR) 425 Third Street, SW Washington, DC 20024 202-639-2100 http://www.aar.org

American Petroleum Institute (API) 1220 L Street, NW Washington, DC 20005-4070 202-682-8000 800-854-7179 (Order Desk) http://www.api.org American Society of Testing and Materials (ASTM) 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959 610-832-9500 610-832-9555 (Fax) http://www.astm.org

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Canadian Chemical Producers Association (CCPA) 350 Sparks Street, Suite 805 Ottawa, Ontario K1R 7S8 (CANADA) 613-237-6215 613-237-4061 (Fax) http://www.ccpa.ca

Canadian General Standards Board Place du Portage Phase III, 6B1, 11 Laurie Street Gatineau, Quebec K1A0S5 (CANADA) http://www.pwgsc.gc.ca/cgsb (Regulation Purchases) 819-956-4802 613-954-5779 (Fax) 800-565-7757 (Fax) http://publications.pwgsc.gc.ca Chemical Transportation Emergency Center (CHEMTREC) 2900 Fairview Drive Falls Church, VA 22042-4513 800-262-8200, 703-741-5525 (Information) 703-741-6037 (Fax) http://www.chemtrec.org CSA International 178 Rexdale Boulevard Toronto, Ontario M9W 1R3 (CANADA) 416-747-4000 1-800-463-6727 416-747-4149 (Fax) 416-747-4044 (Standard Purchases) http://www.csa-international.org National Archives and Records Admin. Director, Office of the Federal Register 8601 Adelphi Road College Park, MD 20740-6001 1-866-272-6272 301-837-0483 (Fax) http://www.archives.gov National Board of Boiler and Pressure Vessel Inspectors 1055 Crupper Avenue Columbus, OH 43229-1183 614-888-8320 614-888-0750 (Fax) http://www.nationalboard.org National Tank Truck Carriers, Inc. 950 N. Glebe Road, Ste. 520 Arlington, VA 22203-4183 703-838-1960 703-838-8860 (Fax) http://www.tanktruck.org

Canadian Transport Emergency Centre (CANUTEC) 330 Sparks Street Office 1415 Ottawa, Ontario K1A ON5 (CANADA) 613-992-4624 (Information) 613-954-5101 (Fax) http://www.tc.gc.ca/canutec Compressed Gas Association 14501 George Carter Way, Ste. 103 Chantilly, VA 20151 703-788-2700 703-961-1831(Fax) http://www.cganet.com

ICC International Compliance Center Ltd. 205 Matheson Boulevard, East, Unit 7 Mississauga, Ontario L4Z 1X8 (CANADA) 416-890-7227 416-890-7070 (Fax) http://www.thecompliancecenter.com National Association of Corrosion Engineers NACE International 1440 South Creek Drive Houston, TX 77084-4906 281-228-6223 281-228-6300 (Fax) http://www.nace.org National Fire Protection Association 1 Batterymarch Park Quincy, MA 02169-7471 617-770-3000 617-770-0700 (Fax) http://www.nfpa.org

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Occupational Safety and Health Administration (OSHA) U.S. Department of Labor 200 Constitution Avenue, NW Washington, DC 20210 800-321-6742 http://www.osha.gov

Ministry of Transportation & Communications Land Transport Directorate Hazardous Materials & Waste Directorate Avenida Xola, esquina con Eje Central S/N, Col. Narvarte Del. Benito Juarez, MEXICO 52-55-572-39300 http://www.sct.gob.mx Superintendent of Documents Government Printing Office 732 North Capitol Street, NW Washington, DC 20401 202-589-0249 (Sales) http://www.gpo.gov The Chlorine Institute 1300 Wilson Boulevard, Ste. 525 Arlington, VA 22209 703-894-4140 703-894-4130 (Fax) http://www.chlorineinstitute.org

Society of Automotive Engineers (SAE) 400 Commonwealth Drive Warrendale, PA 15096-0001 724-776-4841 724-776-4841 (Fax) http://www.sae.org Transport Canada 330 Sparks Street Ottawa, Ontario K1A ON5 (CANADA) 613-990-2309 613-954-4731 (Fax) http://www.tc.gc.ca

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APPENDIX A DATA SHEET A-1 NAME: Sodium Hydroxide Solution TRADE NAME: Caustic Soda SYNONYMS: Liquid Caustic, Lye Solution, Caustic, Lye, Soda Lye PHYSICAL DATA Boiling Point: 288oF (142oC) 50% Solution 371oF (189oC) 73% Solution Vapor Pressure: Per producer data Vapor Density: Per producer data Appearance: Colorless or slightly colored, clear or opaque CHEMICAL FORMULA: NaOH

Solution in water: 100% Sp. Gravity: 1.53 @ 60oF (15.6oC) 50% Solution 1.706 @ 194oF (90oC) 73% Solution

Odor: Odorless FIRE AND EXPLOSION HAZARD DATA Flash Point: None

Molecular Weight: 40.0

Flammable Limits:

LFL: N/A UFL: N/A

Fire and Explosion Hazards:

In water solution caustic can react with amphoteric metals (such as aluminum) generating hydrogen which is flammable and/or explosive when ignited.

REACTIVITY DATA Stability: INCOMPATIBILITY Hazardous Material Decomposition: Dilution with water evolves large amount of heat. Product is strong caustic alkali. May react violently with acid and a number of organic compounds. Caustic reacts rapidly with aluminum, tin, and zinc. It will also react with bronze and brass. Product absorbs water and carbon dioxide from the air.

HEALTH HAZARDS Eye: May cause severe irritation with corneal injury and result in permanent impairment of vision, even blindness. Dusts may irritate eyes. Short single exposure may cause severe skin burns.

Skin Contact:

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Ingestion:

May cause gastrointestinal irritation or ulceration and severe burns of the mouth and throat. Dusts or mists may cause severe irritation to upper respiratory tract.

Inhalation:

HANDLING AND STORAGE PRECAUTIONS Ventilation: Control airborne concentrations below the exposure guideline. Good general ventilation sufficient for most operations. In misty atmospheres, use an approved mist respirator. If respiratory irritation is experienced, use an approved airpurifying respirator. Use protective clothing impervious to this material. Selection of specific items such as gloves, boots, apron, hard hat with face shield, or full-body suite will depend on operation. Remove contaminated clothing immediately, wash skin area with soap and water, and launder clothing before reuse. Use chemical goggles. Full-face shield in addition to goggles may be desirable to protect face. Maintain eye wash fountain and safety shower at or near work area.

Respiratory Protection:

Skin Protection:

Eye Protection;

ADDITIONAL INFORMATION: Special Precautions to be Taken in Handling and Storage: Prevent eye and skin contact. Do not breathe dusts or mists. Avoid storing next to strong acids. Caustic should be stored in clean, dry areas. Do not store in underground tanks. Product absorbs water and CO2 from air. Keep containers closed and sealed. Special Precautions for Diluting Caustic Soda Solution: ALWAYS add caustic soda solution to water with constant agitation. NEVER add water to the caustic soda solution. The water should be lukewarm (80-100oF) (27-38oC). NEVER start with hot or cold water. The addition of caustic soda to liquid will cause a rise in temperature. If caustic soda becomes concentrated in one area, or is added too rapidly, or is added to hot or cold liquid, a rapid temperature increase can result in DANGEROUS mists or boiling or spattering which may cause immediate VIOLENT ERUPTION.

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APPENDIX A DATA SHEET A-2 NAME: Potassium Hydroxide Solution TRADE NAME: Caustic Potash SYNONYMS: PHYSICAL DATA Boiling Point: 290oF (143oC) Vapor Pressure: Per producer data Vapor Density: Per producer data Appearance: Clear liquid CHEMICAL FORMULA: KOH

Solution in water: 100% Sp. Gravity: 1.53 @ 60oF (15.6oC) 50% Solution 1.706 @ 194oF (90oC) 73% Solution

Odor: Odorless FIRE AND EXPLOSION HAZARD DATA Flash Point: None

Molecular Weight: 56.1

Flammable Limits:

LFL: N/A UFL: N/A

Fire and Explosion Hazards: REACTIVITY DATA Stability: INCOMPATIBILITY Hazardous Material Decomposition: Avoid direct contact with water. This product may be added slowly to water or acids with dilution and agitation to avoid a violent exothermic reaction. Avoid contact with aluminum, tin, zinc, and alloys containing these metals. Avoid contact with leather, organic halogen compounds, organic nitre compounds, acid, and wool. Under normal conditions, the material is stable.

HEALTH HAZARDS Eye: Is destructive to eye tissues on contact. Will cause severe burns that result in damage to the eyes and even blindness. Is destructive to tissues contacted and produces severe burns. A latent period may exist between exposure and sense of irritation. May cause severe burns and complete tissue perforation of mucous membranes of the mouth, throat, esophagus, and stomach.

Skin Contact:

Ingestion:

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Inhalation:

Mists or spray may cause damage to the upper respiratory tract and even to the lung tissue proper which could produce chemical pneumonia, depending on severity of exposure.

HANDLING AND STORAGE PRECAUTIONS Ventilation: Respiratory Protection: Use with adequate ventilation. When exposure to dust, mist or spray is possible, employ respiratory protection. Use protective clothing impervious to this material. Selection of specific items such as gloves, boots, apron, hard hat with face shield or full-body suit will depend on operation. Remove contaminated clothing immediately, wash skin area with soap and water, and launder clothing before reuse. Use chemical goggles. Full-face shield in addition to goggles may be desirable to protect face. Maintain eye wash fountain and safety shower at or near work area.

Skin Protection:

Eye Protection:

ADDITIONAL INFORMATION: Special Precautions to be Taken in Handling and Storage: Prevent eye and skin contact. Do not breathe dusts or mists. Avoid storing next to strong acids. Caustic should be stored in clean, dry areas. Do not store in underground tanks. Product absorbs water and CO2 from air. Keep containers closed and sealed. Special Precautions for Diluting Caustic Soda Solution: ALWAYS add caustic potash solution to water with constant agitation. NEVER add water to the caustic potash solution. The water should be lukewarm (80-100oF) (27-38oC). NEVER start with hot or cold water. The addition of caustic potash to liquid will cause a rise in temperature. If caustic potash becomes concentrated in one area, or is added to rapidly, or is added to hot or cold liquid, a rapid temperature increase can result in DANGEROUS mists or boiling or spattering which may cause immediate VIOLENT ERUPTION.

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APPENDIX B FREEZING POINT CURVE FOR CAUSTIC SODA SOLUTIONS Reprinted from the Caustic Soda Solution Handbook, The Dow Chemical Company: Midland, MI, 2010

Note: The curve indicates the point at which crystals exist in contact with solution. From T.P. Hou, Manufacture of Soda Ash, 2 Ed. N.Y., Reinhold Publishing Corp., 1942. From Industrial Engineering Chemistry, Vol. 46, No. 11, p. 2401.

nd

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APPENDIX C CAUSTIC SODA SERVICE GRAPH Reprinted from Corrosion Data Survey - Metals Section, Sixth Edition. Copyright 1985 by NACE International. All Rights Reserved by NACE; reprinted with permission.

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APPENDIX D Freezing Points of Aqueous KOH Solutions Reprinted from Occidental Chemical Corporation Caustic Potash Handbook, Reprinted with permission.

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APPENDIX E Alloy Selection for Caustic Soda Service, by C.M. Schillmoller NiDI Technical Series No10 019 Reprinted with permission from the Nickel Development Institute

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PAMPHLET 94

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

69

70

PAMPHLET 94

SODIUM HYDROXIDE SOLUTION AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) STORAGE EQUIPMENT AND PIPING SYSTEM

71

APPENDIX F PAMPHLET 94 CHECKLIST This checklist is designed to emphasize major topics for someone who has already read and understood the pamphlet. Taking recommendations from this list without understanding related topics can lead to inappropriate conclusions. Place a check mark () in the appropriate box below:
Yes No N/A

1. Is the reactivity and compatibility information from Section 2.3 incorporated in procedures and programs? 2. Does the facility have a Spill Prevention Program in place? 3. Were the materials of construction outlined in Section 4 taken into consideration when specifying caustic storage tank? 4. Has material selection considered the potential for external chloride corrosion? 5. Has material selection considered the compatibility of glass with caustic? 6. Have metal surfaces exposed to caustic been cleaned before welding? 7. Is piping layout and design appropriate for the intended caustic service? 8. Are materials of construction for piping and valves appropriate for temperature and caustic concentrations? 9. Are gaskets used on caustic equipment compatible with caustic? 10. Are instrumentation components consistent with Institute recommendations? 11. Has heat tracing and line clearing methods been designed to prevent stress corrosion cracking? 12. Has a Preventive Maintenance program been established for caustic storage area?

{2.3}

{2.5}

{4.6.3} {4.6.4, 4.6.6}

{4.6.7, 5.6}

{4.9.4}

{5.2}

{5.3}

{5.3}

{5.6}

{5.5}

{5.7}

REMINDER: Users of this checklist should document exceptions to the recommendations contained in this pamphlet.

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