PIPING SYSTEM

Walker Services offers a few selections to choose from when it comes to making your piping extend its life in the harshest of environments. The tabs below go into greater detail about each product.
The Poly Pipe is a premium product generally outlasting steel pipe by a factor of four. It also outlasts rubber lined pipe. Its lightweight characteristics permits easy rotation of long lengths. Poly pipe has an outstanding resistance to nearly all acids, caustics, salt solutions, and other corrosive liquids and gases.
Hard Core X that will give you the maximum life out of your Steel Piping, is a tough one-piece ductile abrasion resistant hardened steel pipe. Engineered for maximum life in highly abrasive applications. With HARD CORE X 600 Brinell Ld. and 300 BHN outer hardness HARD CORE X provides the toughness required to handle the worst conditions industry can dish out.
Callay piping is superior to ceramics in many applications due to its high impact resistance and ease of installation. Callay piping is available in 4” ID minim, to 40” ID maximum with length of 20’. When extended economical service life is the need, Callay is the answer.

For our Steel Coat Piping Click Here

A COMPLETE PIPING PACKAGE TO MEET INDUSTRIAL NEEDS

Poly Pipe can be provided as a complete piping package to meet industrial needs by providing the highest quality polyethylene pipe with matching precision fittings that meet all applicable ASTM specifications. A wide range of diameters and walls to meet varying conditions are also offered.

Applications

  • Slurry lines
  • Mud lines
  • Irrigation lines
  • Cooling Water
  • Sand transport lines
  • Corrosive waste
  • Dredging lines
  • Sludge lines
  • Acid lines
  • Fly ash lines
  • Caustic lines
  • Dewatering lines

ADVANTAGES

  • CORROSION RESISTANCE: POLY PIPE has an outstanding resistance to nearly all acids, caustics, salt solutions, and other corrosive liquids and gases. POLY PIPE can be buried in acid or alkaline, wet or dry soil. The pipe does not scale or pit; it does not rot, rust or corrode. It also resists the growth of bacteria, algae and fungi that could impede flow or cause offensive odors. It is resistant to marine biological attack.
  • LIGHT WEIGHT: POLY PIPE is 10% to 30% of the weight of most other pipes of the same size. Significant cost savings can be realized by reduced manpower and lighter equipment for handling and installation of the pipe.
  • FLEXIBILITY: the inherent flexibility of POLY PIPE allows it to be used in difficult conditions of terrain. The combination of flexibility and lightweight allows the pipe to be assembled in flat or other ideal areas and be pulled over hills to the installation point. This same combination allows the use of
    narrower trenches since the pipe can be assembled above ground and rolled into the trench. Usually the pipe can be bent to a minimum radius of 10-20 times the pipe diameter. This allows contouring the pipe around obstacles without the use of fittings.
  • ABRASION RESISTANCE: POLY PIPE can handle a wide variety of slurries and other abrasive materials. Generally the pipe will outlast steel pipe by a factor of four. It also outlasts rubber lined pipe. Its lightweight characteristics permits easy rotation of long lengths.
  • FLOW CHARACTERISTICS: POLY PIPE has an extremely smooth inner surface which offers very low resistance to flow.
  • RESILIENCY: POLY PIPE can be deformed percussively without permanent damage under and increasing external load to more than half its original diameter. The pipe will flex with impact loads over a wide temperature range from – 180°F to 180°F without brittleness. The expansive force of water freezing in the pipe will not crack POLY PIPE.
  • COST SAVINGS: Compared to conventional jointed pipe, the use of POLY PIPE can result in significant cost savings in installation, labor and equipment, reduced maintenance over the life of the pipeline and freedom in design.
  • MATERIAL DESIGNATION: POLY PIPE is made of high density, high molecular weight polyethylene. The polyethylene base resin meets all requirements of ASTM 0-1248 for Type 111, Grade P34, Category 5, and has a PPI rating of PE3408 by the Plastic Pipe Institute. The average physical property values for POLY PIPE and fittings at 73.4°F are shown on pages to follow.

GET THE MAXIMUM LIFE OUT OF YOUR STEEL PIPE

 A tough one piece ductile abrasion resistant hardened steel pipe. Engineered for maximum life in highly abrasive applications. With HARD CORE X 600 Brinell Ld. and 300 BHN outer hardness HARD CORE X provides the toughness required to handle the worst conditions industry can dish out. HARD CORE X overcomes the brittleness of NI-HARD and the rigidity of Basalt lining piping systems. HARD CORE X can also be fabricated in Ts, Ys, sweep and elbows. Special induction bending practices maintain wall thickness and precision quality.

SPECIFICATIONS

LENGTHS: 20 and 40 foot standard; custom lengths available
COUPLING METHODS: Most common methods used for carbon steel piping apply
CUTTING: Fixed mount or hand held commercial abrasive disc saw or plasma arc.
WELDING: Standard low hydrogen 7018 rod; welding procedures available

View a PDF Chart for Sizes

Sizes

NOMINAL THICKNESS OD INCHES OD mm INCHES mm mm lbs./ft. kg/m
2-1/2 SCH 80 2.87 73 .267 .01 8 11
3 SCH 80 3.50 89 .300 7.62 10 15
4 SCH 80 4.50 114 .337 8.56 151 22
5 SCH 80 5.56 141 .375 9.53 21 31
6 SCH 40 6.63 168 .280 7.11 19 28
6 SCH 80 6.63 168 .432 10.97 29 43
8 SCH 40 8.63 219 .322 8.18 29 43
8 SCH 80 8.63 219 .500 12.7 43 65
10 SCH 40 10.75 273 .365 9.27 40 61
10 XH 10.75 273 .500 12.7 55 82
12 STD 12.75 324 .375 9.53 50 74
12 XH 12.75 324 .500 12.7 65 97
14 STD 14 356 .3275 9.53 55 81
14 XH 14 356 .500 12.7 72 107
16 STD 16 406 .375 9.53 63 93
16 XH 16 406 .500 12.7 83 123
18 STD 18 457 .375 9.53 71 105
20 STD 20 508 .375 9.53 79 117
22 STD 22 559 .375 9.53 87 129
24 N/A 24 610 .438 11.13 110 164

Applications

POWER GENERATION

Coal Slurry
Transport Fly Ash Systems
Pulverized Fuel Systems

MINING AND PROCESSING

Phosphate Transport
Prepping and Cleaning Plants

OTHER INDUSTRIES

Wood Chip Conveyance
Foundry
Sand Handling

MICRO-STRUCTURE

  • The phases of carbon steel are austenite, ferrite, pearlite, bainite and martensite. Austenite occurs at temperatures above 750°C where the carbon is fully soluble in the iron. Austenite cools to form perlite, bainite, martensite or a combination, depending on the chemistry of a particular steel and its cooling rate.

  • A soft perlitic structure is formed when carbon steel is slow cooled. This structure formed through diffusion is a mixture of ferrite and layers of carbides. As quenching of steel becomes more severe, the time for carbon diffusion becomes less. Upon cooling to an intermediate temperature (300°C to 500°C) and holding for a long period of time, bainite is formed. This phase is produced by a “shear” (distortion of the atomic structure) reaction followed by diffusion.

  • Upon instantaneous cooling (as in the case of a vigorous water quench) a “shear” reaction occurs in the place of a diffusion reaction. The resulting product is martensite, an extremely hard phase which can reach hardness in excess of 600 Brinell.

  • HARD CORE X’s yield strength follows metallurgical phases through the pipe wall. The yield follows a predictable curve to a strength of 75,000 psi on the outer layer. The strength of the outer layer is more than twice that of conventional carbon steel. The implications for long-term operation are clear: pipe of a reduced wall thickness can be operated safely.

  • HARD CORE X exhibits remarkable ductility – a 20-inch 00 ring can be compressed by 1.33 inches (33.8 mm). Upon release of compression, the ring will return to its original state, free from cracking.

  • Conclusion: HARD CORE X demonstrates a high degree of both ductility and strength.

MANUFACTURING PROCESS

  • Close process control of hardening and internal quenching is required to consistently achieve the correct micro-structure and to produce the hard martensite on the inside and the soft pear-lite on the outside.

  • The pipe is heated by electrical induction. A current is oscillated at high frequencies through the pipe wall. The resistance of the material to the electron flow converts the electrical energy to heat energy which is closely regulated and monitored by optical pyrometers.

  • The speed of the pipe and power is precisely controlled to achieve heat balance at the required temperature.

  • The pipe is then subjected to internal quenching by a specially designed water quenching system. This achieves the different cooling rates required at the different points through the pipe wall to achieve the necessary material properties of inner and outer zones with a well graded transition.

  • HARD CORE is also available with same above process but with a 425-575 BHN 1.0.

CHROME CARBIDE OVERLAY WEAR PIPE

Callay is an ultra hard, impact-abrasion resistant chrome carbide composite alloy formed by metallurgical bonding a granular chromium carbide powder to a steel substrate. The result is the ultimate wear resistant properties available for the heaviest abrasion/impact application. The uniform high concentration of carbide per square inch throughout the matrix yields wear resistant qualities far exceeding those of typical wear piping,

Callay piping is superior to ceramics in many applications due to its high impact resistance and ease of installation. Callay piping is available in 4” ID minimum, to 40” ID maximum with length of 20’. When extended economical service life is the need, Callay is the answer.

Compare our physical properties and Chemistry with your current source, if you can get it! The chemistry and physical properties gives Callay the competitive edge.

ANALYSIS

Chemical Properties may very according to mill mix.

CARBON MANGANESE MOLYBDENUM CHROMIUM SILICON NICKEL PHOSPHORUS SULFUR
4.03 3.75 1.62 32.71 .048 .5 .015 .015

Physical Properties

CARBIDE HARDNESS 90 HRC SCALE
MATRIX HARDNESS 62 HRC SCALE
BEAD WIDTH 1 1/4”
BASE PLATE 1/4” TO 1 1/2”
SINGLE PASS 1/8”, 3/16”, 1/4”
DOUBLE PASS 1/4”, 3/8”

Advantages

• Superior Abrasion / Impact Resistant
• Cost Effective
• Extended Service Life
• Stress Relieved
• Unaffected by operating temperature to 1250°F
• Can supply pipe to a minimum of 4” Ld.

Cutting; Air Arc, Plasma Arc, Caldo Mini Torch
Welding rod cap; 2134

Allow Walker Services to cast or fabricate your consumable wear part and wear proof with our products.

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