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Revision: 0
Effective: September-2014
Document ID SP-2161
Security Restricted
Owner UEOC
Version 0
Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole
nor any part of this document may be disclosed to others or reproduced, stored in a retrieval system,
or transmitted in any form by any means (electronic, mechanical, reprographic recording or
otherwise) without prior written consent of the owner.
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Description
(see Revision Record for
details)
Author
(name)
Approved
(name)
September-14
Pedro Rincon
Steve Jones
Janardhan Saithala
Cheng Ai Khoo
Nasser Behlani
Issu
e No
Revision Record
Issue No
0
Description of Revision
Original Issue under PDO SP-2161
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Table of Contents
1
INTRODUCTION...................................................................................................................................... 6
1.1
1.2
1.3
1.4
1.5
1.6
PURPOSE .............................................................................................................................. 6
SCOPE................................................................................................................................... 6
SPECIFICATION OWNERS RESPONSIBILITY............................................................................. 7
REVISION AND CHANGES TO THE DOCUMENT ....................................................................... 7
DEFINITION OF TERMS.......................................................................................................... 7
ABBREVIATIONS & ACRONYMS ........................................................................................... 8
GENERAL ........................................................................................................................... 11
TECHNICAL INTEGRITY ASPECTS ........................................................................................ 11
Health safety and environment .......................................................................................... 11
Sustainable development ................................................................................................... 11
Philosophy ......................................................................................................................... 11
INTRODUCTION ............................................................................................................. 37
General .............................................................................................................................. 37
VESSELS AND PIPING .......................................................................................................... 37
PIPING, FITTINGS VALVES AND OTHER COMPONENTS.......................................................... 40
SMALL BORE INSTRUMENT, HYDRAULIC AND CHEMICAL INJECTION TUBING ...................... 40
HEAT EXCHANGERS ............................................................................................................ 40
Shell-and-tube heat exchangers......................................................................................... 40
Plate coolers ...................................................................................................................... 42
Air cooled heat exchangers ............................................................................................... 43
Compact coolers (printed circuit heat exchangers)........................................................... 44
GLYCOL DEHYDRATION SYSTEM ........................................................................................ 44
FLARE & RELIEF SYSTEMS .................................................................................................. 44
ROTATING EQUIPMENT ....................................................................................................... 44
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6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
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Introduction
1.1
Purpose
The document provides the requirements on the process of materials selection and corrosion control
for surface equipment that shall be used during project life cycle to ensure technically proven and
economically acceptable materials selection for PDO projects. This specification also addresses
some of the roles and responsibilities of projects, function, designers, contractors and vendors to
ensure materials are designed, manufactured, procured and constructed to meet Company specified
technical requirements within agreed delivery timeframe.
The objective of this document is to achieve designs where materials are selected to maximise the
likelihood of no loss of containment for the design life at lowest life cycle cost by:
1.
2.
3.
4.
Materials selection and corrosion control are elements of corrosion management, and this guideline
develops further clarification and interpretation of CP-208 Corrosion Management Code of Practice
and DCAF requirements.
This Specification is intended for use by Petroleum Development Oman LLC (PDO), its
Contactors/Subcontractors and Design Consultants and vendors for all PDO equipment and facilities.
This specification covers all surface equipment from the connecting flanges to the Christmas tree.
If you are reading a hard copy of this standard, you should consider it uncontrolled and refer
instead to the version currently on the PDO intranet live link or appropriate search database.
1.2
Scope
The scope of this specification is to cover the surface facility materials selection for different phases
of the project from identify to operate phase.
This specification shall be read in conjunction with other Company, Shell and International standards
such as DEP 39.01.10.11-Gen, 39.01.10.12-Gen and DEP.30.10.02.15 . This document provides
further requirements on other company specifications (SPs), Shell DEPs and MESC SPEs and
International Standards for materials selection process and requirements.
In case of any conflict between this specification and other standards, this specification shall take
precedence.
This standard defined the minimum Company requirements for selecting materials of construction
and corrosion control measures to support the corrosion management strategy for a facility within the
company. It addresses requirement for identifying and evaluating all applicable corrosion threats,
materials deterioration mechanisms, selecting optimum materials of construction, corrosion control
measures and appropriate corrosion monitoring measures and the data necessary to ensure the
requirements of this standard are effectively implemented.
This standard does not cover downhole materials selection requirements. For downhole materials
selection, refer to DEP 39.01.10.02-Gen, DEP 30.10.02.15-Gen and WS 38.80.31.31-Gen.
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The owner of this specification, UEOC, as CFDH Materials and Corrosion, is responsible for
authorising all proposed deviations or amendments to the specification and for the instigation of
periodic reviews and updates in accordance with Clauses 1.2 and 1.5.
The requirements of this specification shall remain in force indefinitely unless superseded by an
authorized revision.
The range of business areas and various life cycle stages of projects to which this standard applies
as below:
All PDO Development/Projects
Business Segment
Stage
1.4
Upstream
Identify
Assess
Select
Define
Execute
Operate
This specification will be reviewed and updated as and when required. The review authority will be
UEOC, (CFDH Materials and Corrosion).
1.5
Definition of Terms
Company
Contractor
The party which carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project, or
operation or maintenance of a facility.
Shall
Should
UEOC
Sour Service
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Definition
AC
Atmospheric Corrosion
ALARP
BfD
CAPEX
Capital Expenditure
CE
Carbon Equivalent
CFDH
CMF
CORRAT
CP
Cathodic Protection
CRA
CS
Carbon Steel
CSCC
CUI
DEP
EFC
FEED
FMEA
GRP
HE
Hydrogen Embrittlement
HEMP
HIC
HRC
Rockwell Hardness
HSE
HV
Vickers Hardness
HYDROCOR
HRC
Rockwell Hardness
MatHelp
MCI
MDMT
NACE
OCTG
OPEX
Operating Expenditure
OPMG
OR&A
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Term
Definition
PDO
PFP
PTE
PWC
RAM
S-RBI
SCC
SLC
SME
SOHIC
SSC
SWC
TOL
Top Of Line
WPS
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HIERARCHY OF STANDARDS
1.
2.
3.
PDO Standards
SP-2161 (2014): Materials Selection and Corrosion Control for Surface Operating
Process
SP-1246: Specification for Painting and Coating of Oil and Gas Production Facilities
DEPs
DEP 30.10.02.15-Gen: Materials for Use in H2S Containing Environment in Oil and
Gas Production (Amendments/Supplements to ISO 15156:2009)
International Standards
ISO 15156-1: Petroleum and natural gas industries-Materials for use in H2Scontaining environments in oil and gas production-Part 1: General principles for
selection of cracking-resistant materials
ISO 15156-2: Petroleum and natural gas industries-Materials for use in H2Scontaining environments in oil and gas production-Part 2: Cracking-resistant carbon
and low alloy steels, and the use of cast irons
ISO 15156-3: Petroleum and natural gas industries-Materials for use in H2Scontaining environments in oil and gas production-Part 3: Cracking-resistant CRAs
(corrosion-resistant alloys) and other alloys
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General
3.2
3.2.1
Materials selection shall be in accordance with the HSE Hazards and Effect Management Process
(HEMP). This process identifies and assesses HSE hazards, implements control and recovery
measures, and maintains a documented demonstration that major HSE risks have been reduced to a
level that is As Low as Reasonably Practicable (ALARP). This shall be done for the full lifecycle of
assets and operations and uses the Risk Assessment Matrix (RAM). For High Risk and/or Severity
hazards bow tie diagrams with links to relevant details should be used to demonstrate tolerability and
ALARP.
3.2.2
Sustainable development
Sustainable development principles shall be applied as part of the materials selection process.
During the past decade it has become clear that the availability of materials and the manufacturing
capacity for materials and products is rapidly becoming a major constraint on construction
capabilities and hence, on energy production and development. Therefore, it is important to use
materials that are readily available and in ways that facilitate standardisation. Thus, one of the
considerations should be to avoid mixing materials in such a way that they cannot be separated
easily as this downgrades their value and limits their availability in the longer term.
3.2.3
Philosophy
Materials selection shall be based on the project life cycle and Basis for Design (BfD) document as
defined in Section 4.1 of this standard.
Materials of construction shall be selected to achieve a balance of minimum CAPEX with reduced
operating costs (OPEX) to maximise project value and minimise risks. The CAPEX shall be the raw
material and fabrication/construction costs. The OPEX shall be the corrosion protection and
inspection/maintenance cost.
The materials selection process shall reflect the overall philosophy regarding design and operating
conditions, design life time, cost profile (CAPEX/OPEX), inspection and maintenance philosophy,
safety and environmental profile, failure risk evaluations, remnant life assessments of existing similar
equipment, lessons learnt via integrity studies, compliance with local and international regulations
and other specific project requirements.
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General Principles
A high level materials selection, aimed at identifying unusually high cost materials is carried out
during the project Select phase and feeds into the Level 1 (CAPEX and OPEX) cost estimate (+40
%/25 %). For main process stream items, initial materials selection is carried out in the Select phase
of a project. Materials selection for secondary process streams is usually carried out in the project
Define phase as part of the Front End Engineering Design (FEED). During the FEED, materials
selection may be optimised, with the approval of the Materials and corrosion Function, as more
information becomes available in order to reduce costs to a minimum in line with specific project
parameters and risk philosophy. At this stage, more refined judgements on corrosion rates, life
predictions and risk assessments shall be carried out to ensure that the proposed materials selection
will be fit for purpose. For long-lead and/or bulk items (e.g. Line pipe), key materials decisions should
be made as early as possible in the project, preferably during the Select phase, i.e., ahead of FEED.
If the new project will make use of and tie into existing installations, the materials in place and their
current condition should be ascertained in the Select phase. Operations personnel shall be included
in the project team or consulted for these types of developments.
Materials selection is a risk based decision making process with the aim of selecting materials that
give rise to major accident hazard risks that are tolerable and ALARP. The tools of materials
selection decision making and the means of assuring (calibrating) the decision are summarised in the
diagram from SP-2062. - HSE Specification: Specifications for HSE Cases:
Figure 1: Risk based decision making process
The materials selection philosophy should be one that will not require PDO values to be called upon,
i.e. acceptance can be achieved by no more than internal (including Shell) peer review. In practice,
the majority of materials selection decisions will be driven by reference to the GU-611 PDO codes of
practice, specifications, procedures and guidelines; that is to say, the standard materials selection
option described in this document.
The selection process is structured based on:
a) Standard materials selection
Guidance on the selection of technically proven and economically acceptable materials
selection for most equipment is given in Section 6 of this standard. Selection is based upon
the stated information on the environmental conditions for each system. Standard materials
selection is used to fill in the details for the systems that do not require materials optimisation.
Some optimisation may be required on some process systems, if conditions are encountered
that are not adequately covered in this standard, or if it is required to consider other materials
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choices, in the interest of potential cost savings. This will generally require justification based
on a life cycle cost analysis and a technical integrity verification.
For carbon steel applications, the process of corrosion control option selection, corrosion
control system availability and corrosion allowance selection shall follow the requirements of
DEP 30.10.02.14-Gen.
b) Experimental evaluation (specialist consultation)
Experimental work might be necessary to evaluate materials for specific applications. It shall
be carried out in accordance with the material testing methodology selected for the failure
modes anticipated. Where this is required to assess the suitability of the lowest cost option, it
should be carried out ahead of the Field Development Plan (FDP, in the project select phase).
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The standard materials selection process includes the following steps:a) Define the requirements and the environment
The intended design life of the proposed equipment shall be stated.
The internal and external environments for the equipment shall be defined, including any non routine or non-operational conditions that might be encountered. The variables characterising of
the corrosive environment shall be quantified for normal operating conditions and to some extent,
for unusual or upset conditions.
At this point, the operation has to be characterised, e.g., in terms of manning levels, access by
operators, capabilities of operators, in-house or contract operated, access to supplies, spare
parts availability, etc.
b) Assess the applicability of carbon steel and define possible corrosion control options
As an initial step in the materials selection process, the suitability of the potentially low cost
option involving the use of carbon steel should be thoroughly investigated and evaluated to serve
as a baseline against which to compare more corrosion resistant, and possibly more costly,
alternatives. Part of this process will involve the calculation of the Service Life Corrosion (SLC)
for the proposed operating conditions.
For the carbon steel option, possible corrosion control options to protect the steel from premature
failure should be investigated. These could include chemical corrosion control, coatings, cathodic
protection and control of process fluids, e.g., pH stabilization and dehydration. The results of
these studies could lead to a lower value of SLC being appropriate. This will often result in more
than one corrosion control option being taken forward for further consideration (e.g., carbon steel
with a corrosion allowance and inhibition system versus carbon steel with a (different) corrosion
allowance and a dehydration system). The availability of these solutions should be taken into
account. For example, it is notoriously difficult to achieve a consistently high availability of
corrosion inhibitors, so if this is considered, the training and organizational responsibilities should
be realized.
c) Make materials choices
Typical materials shall be selected with the aid of the guide tables for each type of equipment
(see Section 6 of this standard). While a material included is technically acceptable, it will not
necessarily be the most cost-effective choice. This will often lead to more than one technically
acceptable materials being taken forward for further consideration (e.g., carbon steel with a
corrosion allowance versus one or more alternative corrosion-resistant materials).
d) Develop corrosion management framework
See Section 9 of this standard.
e) Assess economics of choices
In the final analysis, selection of the corrosion control option (which includes materials selection)
is often an economic decision, assessing the total cost of each alternative over the total life of the
system, including quantification of the risks and uncertainties (life cycle cost). These include the
risk of failure of corrosion control, the economic impact of corrosion control, RBI, sand
management, inhibition and the possibility of market changes, whereby certain materials could
become more or less economic. Where the risk of failure of corrosion control is high, the
consequences should be taken into account, e.g., enhanced corrosion control measures, and
enhanced inspection and repair. These will be reflected in the economic consequence of failure,
as assessed in S-RBI. Operations personnel should be involved in the life cycle cost assessment
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to ensure all operating costs are considered. This work shall be completed as part of the
corrosion control options selection report and the materials selection report. It is the responsibility
of the project engineer to complete the life cycle costing. The Life cycle cost shall be completed
as per DEP.82.00.10.12-Gen Life cycle costing.
Activity 1
Activity 2
Activity 3
Activity 4
Activity 5
Activity 6
4.1
SELECT Phase
It is expected that the initial inputs will come from the defined DCAF deliverables of the Assess phase
as per the PDO DCAF Description. The process may be initiated with this information and constantly
revisited as the inputs are further refined and the Select phase deliverables are matured ready for
Define. Materials, corrosion and Inspection (MCI) TA2 will define the required deliverables for each
project.
Activity 1: Define
requirements and environment
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SP-2041
DEP Specification 30.10.02.14-Gen
DEP Specification 30.10.02.31-Gen
If the operating conditions are beyond currently qualified corrosion
inhibitors, the likelihood of successfully qualifying an inhibitor may be
assessed using the NACE paper by A Crossland, et al.
Section 4.5 of this standard
SP-2041
DEP Specification 39.01.10.12-Gen (as amended by this document)
DEP Specification 30.10.02.15-Gen
DEFINE Phase
Activity 1 to 6
EXECUTE Phase
Activity 6
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OPERATE Phase
Assurance
4.2
The following MCI deliverables and requirements shall be implemented for any project regardless of
the scope and value. These are as per PDO version of DCAF.
Table 1: Mandatory deliverables and requirements for Select phase from Materials Corrosion and
Inspection discipline
ORP
Phase
ID
Name
Accountable
Discipline
Description
Select
47
Erosion Management
Philosophy (DG3a)
Materials
Corrosion
Inspection
and
Select
60
Corrosion
Management
Philosophy (DG3a)
Materials
Corrosion
Inspection
and
SP-2161
DEP 39.01.10.11-Gen
DEP 39.01.10.12-Gen (MC CFDH)
Materials and Corrosion Engineer specifies
the acceptable velocity ranges for materials
of construction with respect to corrosion. The
Erosive velocity calculation is done by the
process engineers.
At this stage the overall philosophy should be
defined together with the integrity impact and
need to interface with other disciplines. The
detailed materials selection and details of
inspection techniques will be covered later in
the Preliminary Corrosion and Erosion
Management Manual in the define phase
(ID300).
Provide input on the materials limitation with
respect to erosion velocity. And input into
Preliminary
Corrosion
and
Erosion
Management Manual in the define phase
(ID300).
CP 208 - Corrosion Management Code of
Practice
Mandatory for all projects.
Recommendation
made
in
Corrosion
Management Strategy shall be embedded in
the Corrosion Management Philosophy
including inspection requirements.
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Select
210
Initial
Materials
Selection
Report
(including Corrosion
Management
Strategy) (DG3a)
Materials
Corrosion
Inspection
and
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SP-2161
DEP 39.01.10.11-Gen
DEP 39.01.10.12-Gen (MC CFDH)
DEP 30.10.02.14-Gen
CP 208 - Corrosion Management Code of
Practice
Mandatory for all projects.
The
corrosion
management
strategy
including initial failure mode effect analysis
and the preliminary (high level) materials
selection reports are based on are based
information provided by the project that shall
include
the
required
minimum
information/deliverables as per DCAF for this
phase of the project (e.g. H&MB, etc.).This
should normally consist of referring to the
applicable standards and mention any
important choices that are made, e.g. carbon
steel + corrosion inhibition versus corrosion
resistant alloy. This also includes the
deliverable of materials threats analysis and
the erosion management philosophy.
Materials selection reports shall be prepared
by function (UEOC) for any project. The
report shall be peer reviewed and signed off
by at least two Materials and Corrosion
Engineer TA2s from the Function other than
the author of the report.
External peer review shall be completed for
projects above 1 bln
Table 2: Mandatory deliverables and requirements during the Define phase for Materials Corrosion
and Inspection discipline
ORP
Phase
ID
Name
Accountable
Discipline
Description
Define
64
Materials
Corrosion
Inspection
and
Define
297
Materials Selection
Report - updated
Materials
Corrosion
Inspection
and
SP-2161
DEP 39.01.10.11-Gen
DEP 39.01.10.12-Gen (MC CFDH)
Mandatory for all projects to be made part of
the materials selection report. The report
shall be endorsed and approved by Materials
and Corrosion Engineer TA2 from Function.
This is an FMEA of the corrosion control
systems; for each mode of operation and
corrosion risks, analysis looks at the barriers
and monitoring that need to be in place.
SP-2161
DEP 39.01.10.11-Gen
DEP 39.01.10.12-Gen (MC CFDH)
Mandatory for all projects
Based on the preliminary report (ID 210), this
report shall include detailed assessment to
ensure the agreed materials selection for all
aspects of the projects is properly
documented independently from the Select
phase report based on the updated design
basis.
The updated Materials selection shall be peer
reviewed by PDO Materials and Corrosion
Engineer TA2 other than the author of the
report and Materials and Corrosion Engineer
TA2 from Function. The final endorsement
and approval shall be by Materials and
Corrosion Engineer TA2 from Function.
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Define
298
Corrosion Inhibition
System Design &
Test Proposal
Materials
Corrosion
Inspection
and
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Define
300
Corrosion
Management
Framework
Preliminary
Materials
Corrosion
Inspection
and
Define
302
Materials
Corrosion
Inspection
and
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Table 3: Mandatory Deliverables and requirements during the Execute phase for Materials corrosion
and inspection discipline
ORP
Phase
ID
Name
Accountable
Discipline
Description
Execute
Local
Rule
Updated
Materials
Selection Report
Materials
Corrosion
Inspection
and
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Execute
51
Set-up
and
Optimisation of
Corrosion
Control System
Materials
Corrosion
Inspection
and
Execute
77
Corrosion
Inspection
Management
System Selection
and Population
Materials
Corrosion
Inspection
and
Execute
79
Corrosion
Inhibitor
Selection Report
Materials
Corrosion
Inspection
and
Execute
82
Execute
87
Execute
88
Execute
168
Execute
170
Approval
by
Function
Inspectors
&
Jointers for Non
metallic
for
contractor staff
Approval
by
function:Calculation of PE
Liner thickness
Approval
by
function:- use of
external
MCI
consultancies,
test laboratories
and
test
requirements
Approval
by
Function
operators
for
specialized NDT
processes
Approval
by
Function
Contractors
welding
Engineers & NDT
level III
Materials
Corrosion
Inspection
and
Materials
Corrosion
Inspection
and
Materials
Corrosion
Inspection
and
Materials
Corrosion
Inspection
and
Materials
Corrosion
Inspection
and
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Execute
171
Execute
173
Execute
174
Execute
175
Execute
176
Execute
177
Execute
178
Execute
182
Execute
183
Execute
217
Execute
484
Approval
by
Function:- GRE
1000 hrs test
pressure,
material and type
of joints type
Approval
by
function:New
coating
applicators
or
coating products
Approval
by
function:New
coating
testing
program
Approval
by
function:New
shrink sleeves
All
specialized
material
and
weld qualification
testing
Approval
by
function:CP
design for buried
pipelines, tanks
and submarine
loading liners
Approval
by
function:Approval of Well
casing corrosion
protection
strategy
Review
and
approval of the
corrosion
monitoring plans
for
corrosion
inhibitors,
CP,
DCVG, CIPS
Approval
of
pipeline
and
equipment
integrity
report
including
RBA
and RBI reports
Approve
Assessed
corrosion rate
Field Inspection
Plan / RBI Plan /
Baseline
Inspection
/
CIMS
(for
Operate)
Materials
Corrosion
Inspection
and
Materials
Corrosion
Inspection
and
Materials
Corrosion
Inspection
and
Materials
Corrosion
Inspection
and
Materials
Corrosion
Inspection
and
Materials
Corrosion
Inspection
and
Materials
Corrosion
Inspection
and
Materials
Corrosion
Inspection
and
Materials
Corrosion
Inspection
and
Materials
Corrosion
Inspection
and
Materials
Corrosion
Inspection
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and
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Execute
488
Welding,
Fabrication
Inspection
Procedures
and
Materials
Corrosion
Inspection
and
Execute
1194
Execute
Corrosion
Management
Framework
Materials
Corrosion
Inspection
Final
Material
selection Report
Materials
Corrosion
Inspection
and
and
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Effective: September-2014
Table 4: Mandatory Deliverables and requirements during the operate phase for Materials corrosion
and inspection discipline
ORP
Phase
ID
Name
Accountable
Discipline
Description
Operate
25
Risk
Based
Inspection
Materials
Corrosion
Inspection
and
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Operate
1197
Corrosion
Management
Framework
Materials
Corrosion
Inspection
and
Operate
1206
Materials Failure
Investigation
Report
Materials
Corrosion
Inspection
and
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4.3
4.3.1
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Shall be as per DEP.39.01.10.11-Gen, Section 2.3.3 with the following amendments:a) Section 2.3.3.2. Replace Table 1 with the Table A.1 in Appendix A of this document.
b) Remove reference to EFC 17 as worst case for chloride when not other information is
available.
c) Add the following:
Chlorides carry over evaluation:
For gas production environments (produced gas or without produced water) and downstream
of separator. Salt accumulation scenarios shall be evaluated as part of materials selection
process.. Presence of formation water shall be included in the evaluation. Assumptions of
lower Chloride levels can only be determined with a proper salt materials balance studies
approved by the respective technical discipline authority (process) and supported by
operation and maintenance philosophy.
d) Section 2.3.3.4 and Appendix E Table E.1 for low temperature requirements shall be
replaced by DEP.30.10.02.31-Gen.
4.4
4.5
Degradation mechanisms
Description
CO2 corrosion is one of the most common forms corrosion resulting in wall
thickness loss in carbon steel oil / gas preproduction systems. CO2 corrosion is
caused by electrochemical reactions between the steel and carbonic acid.
CO2 Corrosion
The Hydrocor model has been developed for predicting the likely worst case
corrosion rate of carbon steel. Hydrocor is a model for quantifying the
corrosivity of the operating environments associated with the production and
transportation of water-wet hydrocarbons in carbon steel facilities. The
predicted corrosion rate is used to identify Service Life Cycle (SLC) and to
determine the appropriate corrosion allowance for a carbon steel system or
whether Corrosion Resistant Alloy (CRA), non-metallic materials or other
corrosion mitigation method is required. The HYDROCOR model (Appendix F)
or an alternative model approved by TA1 shall be used for corrosion modelling
in systems containing CO2. The aim of calculating the CO2 corrosion rate is to
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establish the SLC and thereby decide what corrosion allowance might be
needed or whether a CRA is required.
Welds and their surrounding heat-affected zones may have lower resistance to
CO2 corrosion than the parent metal. This phenomenon is known as
Preferential Weld Corrosion (PWC). This may arise for a number of reasons,
partly geometrical, partly chemical and partly metallurgical. Corrosion control by
means of inhibition has been shown to prevent PWC, provided that a suitable
corrosion inhibitor is selected and injected to provide a sufficiently high
concentration. See also DEP.39.01.10.11 (Appendix B). It should be assumed,
for sweet production systems, that the corrosion rate of the weld and heat
affected zone is three times that of the surrounding parent steel.
For more details information, refer to:
DEP 39.01.10.11-Gen Informative, Section 2.4.3
EI Guidance, Annex B1
API RP 571, Section 4.3.6
NORSOK M-601
Compared to CO2 corrosion of steel, H2S may not cause severe metal weight
loss corrosion because the corrosion product, iron sulfide (FeS) usually forms a
protective film on the steel surface. However, whenever the film is imperfect or
damaged, a corrosion cell is set up between FeS covered surface and the bare
metal, resulting in very localised, accelerated corrosion (e.g., pitting corrosion).
Therefore, the corrosion failure mode in sour systems is pinhole leaks, which
are extremely dangerous, considering the health risks associated with H2S.
H2S Corrosion
For carbon steel, the Hydrocor model can be used for corrosion rate prediction
in H2S containing systems. The empirical correlation included in Hydrocor for
o
sour conditions is only verified up to 50 C and 15 bar ppH2S. Above these
values/levels, the corrosion prediction is not considered reliable. Sour corrosion
modelling typically gives over prediction as Hydrocor model provides a worst
case pitting scenario, depending on factors like whether sulphur is present or
not. Testing shall be carried out to optimise the corrosion assessment with
laboratory testing and reviewing operating field analogues.
For more details information, refer to: DEP 39.01.10.11-Gen Informative, Section 2.4.4.2
API RP 571, Section 5.1.1.10
The presence of elemental sulphur increases the corrosivity of the environment
for pitting corrosion, stress corrosion cracking and particularly weight loss
corrosion thus assessment for elemental sulphur deposition shall be carried out
for high H2S content reservoir (>2Mol%). The presence of chloride ions greatly
enhances sulphur corrosion.
Elemental
sulphur
Top-of-Line
Corrosion
Amine Corrosion
ErosionCorrosion
Oxygen
Corrosion
Revision: 0
Effective: September-2014
EFC 46
DEP 39.01.10.11-Gen Informative, Appendix D;
EI Guidance, Annex B12;
API RP 571, 4.2.14
In aqueous corrosion, oxygen is a more corrosive gas than CO2 and H2S. For
bare carbon steel system, pitting corrosion will occur when exposed to
seawater even with only traces amount of oxygen, but the rate of corrosion is
proportional to the mass transfer rate of dissolved oxygen to steel surface. If
oxygen is continually maintained at < 10ppb, a bare carbon steel or lower grade
CRA should be acceptable with minimum expected corrosion downstream of
the oxygen removal point. However, during upset conditions, which are
unavoidable in almost all cases, the dissolved oxygen concentration can reach
fully aerated levels. For carbon steel systems the corrosion rate is proportional
to the rate at which oxygen reached the steel. For hydrocarbon production
systems oxygen is deemed an operationally avoidable corrodent. Where it may
have an impact is in utility water systems for example. Aqueous oxygen
corrosion rates can be predicted with HYDROCOR.
CRA oxygen corrosion is a form of galvanic attack where the normal protective
passive surface oxide film fails at one small point and becomes a small anode
to the surrounding intact surface, resulting in very rapid localised pitting attack.
Oxygen pitting attack on a CRA is often more rapid than on CS, with
penetration rates as much as 6 times higher.
Materials selection for hydrocarbon application does not consider presence of
oxygen in the system. The facilities shall be designed to avoid any potential
ingress of oxygen.
Crevice
Corrosion
Pitting Corrosion
Under Deposit
Corrosion
(UCD)/dead leg
Galvanic
Corrosion
Microbial
Induced
Corrosion (MIC)
Revision: 0
Effective: September-2014
Preferential Weld
Corrosion
Intergranular
Corrosion
Strong Acid (Well
Workover)
Corrosion
Internal Cracking
SP-2041; DEP 39.01.10.11-Gen Specification, 2.4.4.3; EI Guidance, Annex B2;
API RP 571, 5.1.2.3, ISO 15156.
Sulphide Stress
Cracking
SSC is a rapid form of cracking that can cause catastrophic failure. Control of
this form of cracking SHALL [PS] be through selection of materials not
susceptible to cracking under all expected modes of operation (including start
up and shutdown). Materials selection shall be carried out using DEP
30.10.02.15 AND SECTION 5 of this SP.
Many of the requirements of DEP 30.10.02.15-Gen. are related to hardness
restrictions, and it uses both Rockwell C (for non-welded materials) and Vickers
10 kg (22 lb) (for welded materials). Approximate hardness conversion tables
are given in ASTM A370. Note that the conversion factors do not apply to all
types of materials. For hardness conversions of martensitic and
Page 28 of 63
Hydrogen
Induced Cracking
Stress Oriented
Hydrogen
Induced Cracking
Amine Stress
Corrosion
Cracking
Hydrogen
Embrittlement
Chloride Stress
Corrosion
Cracking
Revision: 0
Effective: September-2014
Liquid Metal
API RP 571, 4.5.5
Embrittlement
Corrosion
API RP 571, 4.5.2
Fatigue
External corrosion
Atmospheric
Corrosion
Corrosion Under
Insulation
Crevice and
Pitting Corrosion
Galvanic
Corrosion
High temperature
oxidation
Sulphidation
Soil Corrosion
External Cracking
Chloride Stress
Corrosion
Cracking
Hydrogen
Embrittlement
Liquid Metal
Embrittlement
Corrosion
Fatigue
Mechanical Degradation
Page 29 of 63
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Effective: September-2014
Erosion by Solids
and Liquids
External
Abrasion & Wear
Fatigue Cracking
API RP 571, 4.2.16 and 4.2.17; Energy Institute Process Pipework Fatigue
Guidelines
High Temperature Creep and Stress Rupture
High
Temperature
Creep and Stress
Rupture
Thermal Fatigue
Low Temperature
Embrittlement
Long Running
Ductile Fracture
Galling
Non-Metallic Seal
Degradation
4.6
4.7
Materials selection shall consider all the operating modes including non operational considerations as
per section 3 of DEP 39.01.10.11-Gen.
Page 30 of 63
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Stainless
steel type(1)
Threshold
for pitting
corrosion
316L(2)
6Mo
22Cr
Duplex(3)
25Cr SuperDuplex(4)
Threshold
for crevice
corrosion
Negligible
risk of
CSCC
Significant
risk of
CSCC
5oC
50oC
40oC
<0oC
30oC
15oC
<50oC
<100oC
<80oC
>60oC
>120oC
>100oC
60oC
30oC
<100oC
>110oC
(1) Table gives requirements for generic stainless steel types. Specific materials and conditions may influence
the acceptable temperature
(2) Assumes minimum Molybdenum content of 2%. Higher temperatures may be possible at higher Mo
content.
(3) Assumes PREN > 35
(4) Assumes PREN > 40
Contact of zinc with stainless steel items SHALL[PS] be prevented, including zinc coating
contamination and contamination by zinc in fire scenarios from other equipment.
Page 31 of 63
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Ferritic and Martensitic stainless steels such as those of the 13Cr family are susceptible to both
sulphide stress cracking (SSC) and stress corrosion Cracking (SCC) and therefore their application
shall be in accordance to DEP.30.10.01.15.
Austenitic stainless steels containing less chromium, nickel and molybdenum than AISI 316, such
as AISI 304, shall not be used / applied in PDO production facilities as defined in DEP 39.01.10.12Gen, Appendix A.
All the austenitic stainless steels wrought, forge and cast products shall be subjected to intergranular
corrosion testing in accordance with ASTM A262 Practice E. The materials shall pass required
criteria stated in ASTM A262 specification. The intergranular corrosion test shall be performed for
each heat in the purchase order.
Austenitic/ferritic stainless steels (duplex stainless steels) can suffer both SCC and SSC, hence
hardness requirements from DEP 30.10.01.15 shall apply and strict H2S partial pressure limits shall
be followed as given in Part 6 and DEP 30.10.01.15. Both 22 Cr duplex and 25 Cr super-duplex
stainless steels are susceptible to CSCC at 80 C (176 F) under drop evaporation conditions, and
their use at points of salt accumulation shall be avoided.
Applications of duplex stainless steels at Lower Design Temperatures (LDT), for which the design
code asks for proof of toughness by impact testing, require an additional specification of the steel
being ordered and confirmation of proven toughness on the steel certificate. Welding procedures
shall be qualified or re-qualified with impact testing included, when required by the design code for
the given LDT. The minimum design temperature of duplex stainless steels is -50C (-58F) with
maximum thickness of 40 mm (1.6 in) unless otherwise qualified in accordance with
DEP 30.10.02.31-Gen section 5.4. Duplex stainless steel shall have PREN > 34, with a nitrogen >
0.14%. The super duplex stainless steel shall contain at least 25%Cr and PREN > 40 and nitrogen >
0.2%. Duplex stainless steel and super duplex stainless steel shall comply with DEP 30.10.02.35Gen requirements.
All the DSS and SDSS wrought, forge and cast products shall meet following requirements in
addition to requirements stated in respective MESC SPEs and relevant DEPs.
Transverse tensile test:
Transverse tensile testing is not required for the pipe nominal diameter 6. Diameters 8 and above
shall be subjected to transverse tensile test.
Pitting Corrosion testing:
The materials shall be capable of passing the ferric chloride test in accordance with ASTM G 48,
Method A, with the following amendments. This corrosion test shall be performed for product
qualification only.
The exposure time shall be 24 hours. The test temperature for 22Cr duplex (ferritic-austenitic)
stainless steel shall be 25 C for parent metal and 22 C for welds.
The test temperature for 25Cr superduplex (ferritic-austenitic) stainless steel shall be 40 C for
parent metal and 35 C for welds.
The acceptance criteria shall be a weight loss < 4.0 g/m2 and no initiation of localized corrosion >
0.025 mm (1 mil) at the test face. Note that only corrosion (e.g. pitting) at the test face counts. If the
weight loss is > 4.0 g/m2 and it can be positively identified that this is only due to corrosion at the cut
faces, the test will be invalid. In this case re-testing shall be carried out on replacement specimens.
Frequency of testing shall be each heat in the purchase order.
Page 32 of 63
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Super austenitic stainless steels (>6 % Mo) to ensure corrosion resistance of welds, a nickel alloy
filler with increased Mo, such as alloy 625, shall be used. 6Mo materials shall comply with DEP
30.10.02.35-Gen requirements.
All the UNS S31254 wrought, forge and cast products shall be subjected to ferric chloride test in
accordance with ASTM G48, Method A. The test temperature shall be 50 C and the exposure time
shall be 24 hours. The test specimens shall be in the as-delivered condition. The test shall expose
the external and internal surfaces. No pitting is acceptable at internal or external surfaces at 20 times
magnification. The weight loss shall be < 4.0 g/m.
Frequency of testing shall be each heat in the purchase order.
Precipitation hardening stainless steels in Appendix A of DEP 39.01.10.12 Gen, such as
UNS S17400 (17-4 PH) and UNS S15500 (15-5PH) shall be prohibited for pressure containment
parts in sour environments. Alloy 17-4 shall be limited to a maximum stress of 50% for compressor
internal components.
Nickel alloys such as UNS N07718 (Alloy 718) shall meet the requirements of
DEP 39.01.10.32-Gen. UNS N07725 (Alloy 725) and UNS N07716 (Alloy 625+ ) shall be specified in
accordance with DEP 39.01.10.30-Gen. These materials may suffer from similar issues to those that
have been observed with Alloy 718, and, as such, care shall be taken during manufacturing and heat
treatment, particularly for critical or highly loaded components.
Alloy N08825 (Alloy 825) shall be supplied with Ni content greater than 39% and a PREN greater
than 30. Quality assurance in supply chain should be closely monitored.
Intergranular corrosion test in accordance with A262 Practice C. Acceptance criteria shall be weight
loss < 0.9mm/year and intergranular penetration shall not exceed 30 microns average, with minimum
individual maximum 50 microns into the surface that will be exposed to the corrosive environment in
the specific application when measures by micrography shall be performed at an appropriate
magnification in a minimum of eight separate viewing fields average. The intergranular corrosion test
shall be performed for each heat in the purchase order.
For materials cladded with Alloy 825 exposed to post weld heat treatment or other stress relieve
treatment during fabrication shall be subject to corrosion test at simulated worst case process
conditions to evaluate effect on the materials. Test shall include pitting and crevice assessment.
Alloy UNS N0625
All alloy 625 materials wrought, forge and cast products shall be subjected to integranular corrosion
test in accordance with ASTM G28, Method A. The maximum allowed corrosion rate is
0.075mm/month and intergranular penetration shall not exceed 30 microns average, with minimum
individual maximum 50 microns into the surface that will be exposed to the corrosive environment in
the specific application when measures by micrography at an appropriate magnification in a minimum
of eight separate viewing fields average.
Frequency of testing shall be each heat in the purchase order.
Where galling resistance is required, anti-galling compounds, electroplating, or use of different
materials should be used for the two parts that come into contact, e.g., N06625 and N07725.
Molybdenum Disulfide SHALL [PS] not be used. An alternative anti-galling approach that may be
used is to specify and assure a minimum difference in hardness of 25 HRB of the components.
Glass reinforced plastics. The choice of fibre and resin should be selected after full consideration
of the service requirements in accordance with SP-2092 and DEP 30.10.02.13-Gen. GRP pipelines
and piping shall be in accordance with SP- 2092, SP-2156 and DEP 31.40.10.19-Gen.
Note: Proprietary materials might be considered upon successful qualification and approval from MCI
Corporate Function Discipline Head (CFDH).
All the corrosion tests shall be carried out at PDO and ILAC approved laboratory.
Page 33 of 63
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Specific requirements
5.3
Sudden failure mechanisms such as stress corrosion cracking, Hydrogen embrittement (corrosion)
fatigue, and low temperature embrittlement shall be prevented by means of proper materials
selection and design. Coatings or corrosion inhibition shall not be used as the primary barrier for
environmental assisted cracking or corrosion-fatigue during design.
Performance tested/qualified Coatings or aluminium foils may be considered for mitigation of Cl-SCC
if the risk is assessed as negligible or manageable, approval from MCI TA2 from Function is required.
Page 34 of 63
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Effective: September-2014
Austenitic and duplex stainless steels may suffer from external chloride induced stress corrosion
cracking (CSCC) when exposed to a combination of tensile stresses, chlorides, water, oxygen, and a
temperature threshold. This failure mode, typically caused by exposure to humid marine atmosphere,
may represent a higher risk than the internal service and is generally manifested by a sudden
fracture of pipe or equipment. PDO is operating in desert environment characterised by frequent
sandstorms and deposition of salt laden sand. Therefore the risk of Cl-SCC shall be evaluated and
documented.
Application of stainless steels with significant risk of CSCC above the given temperature shall be
subject to mitigation to an acceptable level (ALARP). Application of stainless steels with risk of CSCC
at high chloride concentration shall be subject to a risk assessment and mitigation if deemed
necessary.
The threshold temperatures which the material has an acceptable risk of external CSCC are shown
in Table 5.1. Above these temperature thresholds (significant risk of CSCC in Table 5.1) austenitic,
duplex stainless steel, super stainless steels and super austenitic stainless steel shall be externally
coated with Thermal Sprayed Aluminium coating (TSA) in accordance to DEP 30.48.40.31-Gen. If
welding is involved, TSA shall be done post welding.
Organic coating qualified for the service life can be applied if ALARP is demonstrated by risk
assessment.
TSA shall not be used for protection of small-bore (<DN 50) (<NPS 2)) components so selecting a
resistant material is the preferred option.
5.4
Stainless steels may be protected against external pitting and crevice corrosion under insulation by
means of coating with Thermally Sprayed Aluminium (TSA). Joints and ends shall be taped with selfadhesive aluminium tape. This aluminium foil acts as both a barrier coat and inhibitor. The applicable
temperature range for the use of aluminium foil under insulation is 50C to 200C (122 F to 392 F)
for continuous service and 50C to 480C (122 F to 896 F) for cyclic conditions.
Only the arc spray application process shall be used for CRA materials and all systems shall be
sealed using a silicone system. TSA shall be applied in accordance with DEP 30.48.40.31-Gen.
5.5
Sealing materials
Where metal-to-metal seals are used, there is a potential risk of galvanic corrosion. To prevent this,
the seal surface materials shall be at least as noble as the surrounding surfaces. Elastomer seals are
addressed in DEP 39.01.10.12, Section 3.2.13.
5.6
DEP. 30.10.02.15-Gen is written as amendments and supplements to the following ISO Standards:
ISO 15156-1:2009
ISO 15156-2:2009
ISO 15156-3:2009
Page 35 of 63
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Effective: September-2014
Wherever reference is made to the above ISO Standards, it shall be understood to mean the
ISO 15156-1:2009, ISO 15156-2:2009 and ISO 15156-3:2009 as amended/ supplemented by DEP.
30.10.02.15-Gen
Materials limits for sour service shall be in accordance with this SP, DEP 30.10.02.15-Gen, and ISO
15156. Remarks made in ISO 15156-3 tables indicating ANY combination of parameters (pH,
ppH2s, temperature and chloride, etc.) shall not be used for materials selections.
Page 36 of 63
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Effective: September-2014
6.1
INTRODUCTION
6.1.1 General
This Section includes materials for process and utility equipment used in onshore operations for
surface facilities.
The materials selected shall meet minimum toughness requirements at the minimum design
temperature during low temperature events such as blowdown. The low temperature requirements of
materials are covered in detail by DEP 30.10.02.31-Gen. and DEP 31.38.01.15-Gen., which refers to
ASME B31.3.
6.2
Shall be in accordance with DEP 39.01.10.12-Gen, Section 3.2.5 with the following amendments.
a) Replace Table 3, with the following Table 6.1 below.
Page 37 of 63
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Effective: September-2014
Materials
selection
for
(10)
piping
Piping
(1)
class
Any*
CS with 1
mm (1/32
in) CA
1410,
1450, or
1470
As for piping
Any*
CS with 3
mm (1/8
in) CA
1430 or
1490
As for piping
Any*
CS with 3
mm (1/8
(2)
in) CA .
CS with
glassflake
lining if
only
limited life
is
(3)
required
1430 or
1490
Any*
SSC and
HICresistant
steel with
1 mm
(1/32 in)
CA
1420 or
1460
As for piping
Any*
SSC and
HICresistant
steel with
3 mm
(1/8 in) CA
1440
As for piping
Any*
SSC and
HICresistant
steel with
3 mm
(1/8 in) CA
(2) 3)
.
1440
3430
SLC
mm
(in)
Temp
C
(F)
pH2S
mbar
(psi)
Cl
ppm
<1
(<1/32)
<200
(<392)
<3.5
(<0.05)
<3
(<1/8)
<200
(<392)
<3.5
(<0.05)
3 to 6
(1/8 to 1/4)
<1
(<1/32)
<3
(<1/8)
<80
(<176)
<200
(<392)
<200
(<392)
<3.5
(<0.05)
<100
(<1.45)
<100
(<1.45)
Vessel material
Comments
SLC
can
be
reviewed
based
on
inspection
frequency.
3 to 6
(1/8 to 1/4)
<80
(<176)
<100
(<1.45)
6
(1/4)
<120
(<248)
<3.5
(0.05)
6
(1/4)
<60
(<140)
<15
(<0.22)
60660
AISI 316L
3430
6
(1/4)
<155
(<311)
<15
(<0.22)
<37000
AIS 316L
3430
6
(1/4
90
<2.0
165000
22Cr
Duplex
3832
120
<2.0
170000
22Cr
Duplex
3832
6
(1/4
120000
AISI 316L
Page 38 of 63
6
(1/4)
<200
(<392)
<10
(<0.15)
160000
6
(1/4
<120
(<248)
<350
(<5.08)
<1 g/l
(1000
ppm)
22Cr
Duplex
22Cr
Duplex
Revision: 0
Effective: September-2014
3832
3832
6
(1/4)
<200
(<392)
<20
(<0.30)
<160000
Super
Duplex
6
(1/4
<200
(<392)
<80
(<1.16)
<30330
Super
Duplex
6
(1/4)
<200
(<392)
<1,000
(<14.5)
<1
(640 ppm)
Super
Duplex
6
(1/4)
6
(1/4)
6
(1/4)
6
(1/4)
<200
(<392)
< 60
<200
(<392)
<200
(<392)
<20
(<0.30)
< 4000
<14,000
(<203)
<36,000
(<522)
<160,000
< 200
(120)
Super
Duplex
6Mo
<160,000
Alloy 825
<160,000
Alloy 28
(pCO2<25
bar (363
psi))
Weld overlay of
alloy 825 shall not
be considered as
material
for
vessels and piping
Weld overlay of
alloy 825 shall not
be considered as
material
for
vessels and piping
Page 39 of 63
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Effective: September-2014
6
(1/4)
<240
(<464)
<30,000
(<435)
<160,000
Alloy
(8)
625
6
(1/4)
<100
(9)
(<212)
Any*
Any*
GRP
GRP
Weld overlay of
alloy 825 shall not
be considered as
material
for
vessels and piping
6.3
Shall be in accordance with DEP 39.01.10.11-Gen, DEP 39.01.10.12-Gen, Section 3.2.6 and DEP
30.01.10.15-Gen. All the applicable MESC SPEs shall be followed for piping, fittings, valves and
other components.
6.4
6.5
Heat exchangers
If carbon steel plus inhibition is used in upstream piping, the vessel exchanger shall be made of a
suitable CRA.
6.5.1 Shell-and-tube heat exchangers
The selection of materials for direct water coolers shall be derived from the materials selected for the
adjacent process piping and the coolant (Table 6.2).
Oxygen contamination of closed circuit cooling systems has been a problem in many cases, and
carbon steel shall only be used if oxygen can be successfully kept out of the system, or where a
sufficient corrosion allowance, based on a good estimate of corrosion rate, can be used. Where Ti is
selected, it SHALL [PS] not be coupled directly to carbon steel.
Glycol reboilers are addressed in DEP 39.01.10.12-Gen, Section 3.2.9, Table 8.
Page 40 of 63
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Effective: September-2014
Incoming pipe
material
(Table 3)
Tubes
Tubesheet and
Channels
Shell, baffles
and
tie-rods
Non-corrosive coolant on
tube side.
On shell side closed circuit
(no 02, inhibited,
(6)
monitored)
Carbon steel
SLC<1
Carbon steel
Carbon steel
Carbon steel
Carbon steel
SLC>1
Upgrade to
appropriate
stainless steel
(not martensitic).
Carbon steel
22Cr Duplex
22Cr Duplex
22Cr Duplex
Carbon steel
Super Duplex
Super Duplex
Super Duplex
Carbon steel
316L
316L
Carbon steel
6Mo
6Mo
Carbon steel
Alloy 625
Alloy 28
Carbon steel
Alloy 825
Alloy 825
Carbon steel
Alloy 625
Alloy 625
Carbon steel
Carbon steel
Super Duplex
Super Duplex
Carbon steel
22Cr Duplex
Super Duplex
Super Duplex
22Cr Duplex
Super Duplex
Super Duplex
Super Duplex
Super Duplex
6Mo
6Mo
6Mo
Alloy 28
Alloy 625
Alloy 825
Alloy 625
825 clad
Alloy 625
Alloy 625
625 clad
Any
C276
Ti
Chlorinated aerated
seawater on tube side.
Max. temperature
<30 C (<86 F)
Chlorinated aerated
seawater on tube side.
Max. temperature
>30 C (>86 F)
NOTES: (1), (2)
(5)
(4)
or C22 or
(3)
(3)
(4)
C276 solid or
(3)
clad or Ti solid
(3)
or clad
As inlet pipe,
solid or clad
(3) Clad tubesheets assume the cladding is on the seawater side and tubes are front welded. The suitability of the
tubesheet carbon steel base metal for exposure to the process fluids shall be considered.
(4) Alloy C276 tubes have been known to fail due to the formation of a crevice under chloride-rich deposits. The
likelihood of the formation of such deposits should be duly considered before selecting a material.
(5) Alloy 28 shall be limited to a pH2S below 36000 mbar (522 psi).
(6) When cooling gas, the definition of non-corrosive service may include an assessment of the gas dew point and
corrosion within the tubes, provided appropriate operating controls are in place. Dew point assessment shall
consider field ramp-up flow rates, duration, and minimum controllable heat transfer capacity.
Page 41 of 63
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Effective: September-2014
Plate coolers
Service
Seawater cooling oil or
produced water
30
(86)
200
(392)
Closed circuit water cooling
crude oil/gas
NOTE:
Incoming
pipe
Plate material
625
6Mo, GRP
6Mo
All others
Super duplex
Any
60
(140)
AISI
316L
subject
to
the
environmental limitations given in
(2.2.1)
200
(392)
Page 42 of 63
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Tube material
Upgrade to appropriate
stainless steel below
depending on maximum
temperature
316L
316L
316L
50 (122)
(1)
22Cr Duplex
22Cr Duplex
22Cr Duplex
80 (176)
(1)
Super Duplex
Super Duplex
Super Duplex
110 (230)
(1)
316L
120 (248)
(2)
22Cr Duplex
190 (374)
(2)
Super Duplex
190 (374)
(2)
6Mo
Alloy 625
NOTES
(3)
6Mo
Alloy 28
(3)(4)
Max. temp.
C (F)
6Mo
200 (392)
Alloy 28
200 (392)
(3)
Alloy 825
200 (392)
(3)
Alloy 625
200 (392)
Alloy 825
Alloy 825
Alloy 625
Alloy 625
(1)
The maximum temperatures are dictated by the risk of external chloride SCC, see (2.2.1).
(2)
These temperatures only apply to heat exchangers with coated tubes that have fully extruded aluminium
fins.
(3)
Likely to have extruded aluminium fins for heat transfer requirements, but not required as part of the
corrosion design as these materials are resistant to Chloride SCC up to at least 200 C (392 F).
(4) Alloy 28 ishall be limited to a pH2S below 36000 mbar (522 psi)
If extruded aluminium fins are used on tubes, no external corrosion allowance is required. There shall
be no exposed steel tube area for both CS and CRA tubes. Achieving no exposed steel at the
tubesheet end is often problematic and requires special attention. For the fins, aluminium Alloy 5083
(UNS A95083) has the best reported performance.
If coating is required on the header boxes, the tubesheet shall be TSA coated prior to inserting the
tubes in the tubesheet, with any repairs to the coating carried out as each row of tubes is inserted.
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Printed circuit heat exchangers have very fine channels, which restricts them to relatively clean
duties (such as gas or NGL cooling). Upstream filters shall be specified and maintained to reduce the
risk of channel plugging.
Materials shall be selected to withstand erosion in the small channels and also crevice corrosion at
the anticipated service condition.
Material choice is limited by the Manufacturers and the manufacturing method to AISI 316L, 22 Cr,
Cu or Ti.
6.6
Shall be in accordance with DEP 39.01.10.12-Gen, Section 3.2.9, Table 8. For severe sour service,
materials selection shall be peer review and approved by TA2 MCI from function.
6.7
6.8
Rotating equipment
c)
6.9
Pumps
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6.10 Bolting
Shall be in accordance with DEP 39.01.10.12-Gen, Section 3.2.12, Table 10 and Table 11.
Add the following notes after second paragraph:
6.12 Pipelines
Pipelines materials selection shall cover the construction materials for below systems:a) Process pipelines
b) Dry hydrocarbon pipelines
c) Water injection pipelines
Carbon steel is widely used for pipelines with or without corrosion inhibition. The corrosion allowance
shall be calculated using DEP 30.10.02.14-Gen. There are two applicable standards for carbon steel
linepipe, according to whether it is critical or non-critical service. Carbon steel line pipe shall conform
to the following standards as appropriate:
Critical Service
DEP 31.40.20.37-Gen.
Non-Critical Service
DEP 31.40.20.35-Gen.
Solid Pipe:
(1)
DEP 31.40.20.34-Gen.
DEP 31.40.20.36-Gen.
production.
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CRA Lined
Pipe:
NOTES
DEP 31.40.20.32.Gen
Suitable materials for process pipelines are given in Table 6.6 and shall be in accordance with DEP
39.01.10.11-Gen, DEP 39.01.10.12 and DEP 30.01.10.15-Gen.
Onshore/subsea
pipelines
Conditions
(1)
SLC
Temp.
pH2S
Cl
mm (in)
C (F)
mbar (psi)
g/l
(2)
Material
<8
(<3/8)
<200
(<392)
<3.5
(<0.05)
Any
CS
with
appropriate
corrosion allowance
<8
(<3/8)
< 200
(<392)
< 100
(<1.45)
Any
N/A
<140
(<284)
0
(0)
<100
Weldable
martensitic
(6)
stainless steel
N/A
<200
(<392)
0
(0)
<12
Weldable
martensitic
(6)
stainless steel
N/A
< 120
(<248)
<3.5
(<0.05)
<120
N/A
<200
(<392)
<10
(<0.15)
<150
22Cr Duplex
N/A
<155
( <311)
15
(<0.22)
<38
N/A
60
(140)
15
(<0.22)
60
N/A
<200
(<392)
<20
(<0.29)
<150
Super duplex
N/A
<200
(<392)
<80
(<1.16)
<30
Super duplex
N/A
<200
(<392)
<350
(<5.08)
<0.6
22Cr Duplex
N/A
<200
(<392)
<1,000
(<14.50)
<0.6
Super duplex
N/A
<200
(<392)
<22,000
(<319)
<120
N/A
<240
(<464)
<30,000
(<435)
<120
N/A
<100
(<212)
N/A
N/A
N/A
<60
(<140)
N/A
N/A
RTP
(Reinforced
thermoplastic pipes) (see
flowline non metallic table
6.7
(3)
(4)
(4)
non
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Conditions
Notes:
(1)
Material
SLC
Temp.
pH2S
Cl
mm (in)
C (F)
mbar (psi)
g/l
N/A
<60
(<140)
N/A
N/A
Thermoplastic
lined
CS
(see flowline non metallic
(5)
table 6.7
N/A
<200
(<392)
<22,000
(<319)
<200
N/A
<200
(<392)
<22,000
(<319)
<200
(1)
For some Corrosion Resistant Alloys, e.g., AISI 316L, more detailed sour service SCC limits can be
found in DEP Part 4.
(2)
If there is any chance of H2S increase during the lifetime (e.g., due to reservoir souring) order SCC
and HIC resistant CS, even if the pH2S is below 3.5 mbar (0.05 psi).
(3)
(4)
The recent CP studies completed revealed that the optimum CP level in DSS lines is recommended to
be adjusted to a potential no less negative than -650 mV. This value is in the range recommended by
ISO 15589 and DEP 30.10.7310 for DSS structures. Previous level ranged from -850 to -1150 mV
increased the risk of internal stray current. This value will reduce significantly the amount of internal
stray current, reducing the risk of failures in the IJ.
(5)
Higher temperature applications are possible refer to DEP 31.40.30.34-Gen. for higher temperature
thermoplastic liners.
(6)
Higher temperature applications are possible refer to DEP 31.40.30.34-Gen. for higher temperature
thermoplastic liners.
6.14 Flowlines
Flowline material selection philosophy shall be as per section 2.1 of SP-2156. For non-metallic flow
line material selection shall be performed in accordance with Table 6.7. For metallic materials
flowlines shall be as pipeline Table 6.6.
Table 6.7: Limitations of non-metallic materials
GRE
HDPE lined CS
(SP-2092)
(SP-2094)
Y
4
Wet Gas
Required Service
FBE coated CS
Flow lines
Reelable Pipes
(SP-2416)
(DEP
31.40.1020-Gen)
Multiphase
Dry gas
Max 7 mol%
Max 3 mol%
Region 1 as per
ISO 15156
No limit
No limit
Corrosivity < 3
1
mm/year.
Water
Oil
H2S
CO2
Max 1 mol%
2 (add
permeation issue)
No limit
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Chlorides
>1% Acide
exposure
pH
No limit
No limit
Corrosivity < 3
1
mm/year.
No limit
Corrosivity < 3
1
mm/year.
3.5 to 12
GOR
Production
Chemical
Wax and Asphalt
Fluid velocity
Design pressure
3.5 to 12
3.5 to 12
No specified limit
300
Up to 10 m/sec
liquid velocity
10 m/s gas
velocity
As per SP2092
300
4 m/sec liquid
velocity
Limited by rapid
decompression
2-4 m/sec
Limited by rapid
decompression
Up to 10 m/sec
liquid velocity
70bar Max
65deg C
(This refers to
Maximum
operating
temperature)
Design
Temperature
Maintenance
pigging
Shall be in Liquid
form
Shall be in Liquid
form
Shall be in Liquid
form
Shall be in Liquid
form
> 20 years
20 years
10 years
Max 2 years
Buried
pipeline/flowlines
Above ground
pipeline/flowlines
Y limited by
corrosion rate
and piping
configuration
Y limited by
corrosion rate and
piping
configuration
Y only water/
burried close drain
Y limited by
corrosion rate
and piping
configuration
Y limited by
corrosion rate and
piping
configuration
Viscosity
Design life
Manifolds
On plot piping
(This refers to
Maximum
operating
temperature)
90 deg C
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X As SP 1246
Internal liner
X As SP 1246
Notes:
1. For service life corrosion requirements refer to section 4.4.
2. Pipe materials can work however, the connections are metallic and the limitations shall
be checked with Materials and corrosion engineer before use.
3. For fluids having PH out of this range shall be referred to Materials and corrosion TA2 for
review and recommendation.
4. Electrical conductivity of the fluid shall not be less tahn 10,000pS/m
5. Flow assurance study shall demonstrate that the produce sand, wax, asphat, etc. will
not have any erosion effect in pipe service and that solid removal will not be required
during the life time of the project. No test data viable. Any sand production areas it is not
recommended to use the non metallic materials without study. Consult MCI Engineer.
6. Paffin wax and Asphalt deposits may have swelling effect on PE materials. Consult
Materials & Corrosion Engineer before selection.
7. Design pressure changes with size & connections. Max Design temperature changes
with type of curing systems used. Refer to SP2092-1 for more details.
8. Compatibility test shall be carried out
Symbols:
Y The material may be considered within the boundaries specified in the above table
- No test data or filed experience available. Consult with the PDO materials function TA2 authority
for more details.
X Shall not be used.
6.16 Flexibles
Shall be in accordance with DEP 39.01.10.12-Gen, Section 3.3.6. Corrosion Prevention and Control
for Water Injection Systems shall be per DEP 31.01.10.11-Gen.
Body
CS
CS
CS
CS+3mm two pass undiluted
316L weld overlay
Internals
CS
316L
825
316L
Skid piping
CS
CS
CS
CS+3mm two pass 316L weld overlay
or
solid SS316L
or
CS+1mmCA+rotolining
or
Page 49 of 63
5
6
7
8
9
DSS
316L
DSS
SDSS
316L
DSS
SDSS
625
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Effective: September-2014
NOTE (1) DSS weld overlay is feasible but the application requires MIC TA approval.
Water systems
Fresh potable water
Brackish/seawater for service water system
Closed circuit cooling water
Fire fighting system
Water injection system
Tubing materials and completion accessories for water injection and disposal wells
Seawater caissons and dip tubes
Inhibitors and other chemicals (shall be in accordance with DEP 39.01.10.12-Gen, Table
22.
Miscellanies Utilities systems (e.g. air system, instrumentation, etc) shall be in accordance
with DEP 39.01.10.12-Gen, Table 23.
Diesel fuel systems (shall be in accordance with DEP 39.01.10.12-Gen, Table 24)
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Materials selection report for all SELECT phase shall be carried by PDO Materials and Corrosion
engineering discipline (Function).
During the DEFINE and EXECUTE phase, materials and corrosion deliverables shall be prepared by
materials, corrosion and welding specialists that have been assessed and approved by PDO
Materials and Corrosion Engineering discipline (UEOC) prior the start of FEED and DD studies.
FEED and DD materials selection report shall be endorsed and approved by PDO Materials and
Corrosion Engineering discipline (UEOC) in peer review session following the requirements indicated
in Section 4.1. Materials selection peer review sessions shall be organized by the Materials and
Corrosion Engineers from the projects or the author of the report and ensuring participation from
Process, Mechanical, Rotating and Pipeline engineering.
SELECT Phase
Materials selection report shall contain the following but not limited to:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
8.2
Executive Summary
Project Introduction and Description
Purpose of the document
Abbreviations and Definitions
Project documents referred to
Standard referred to
Design Basis
Corrosion Predictive Modelling
Erosion Assessment
Materials Selection Discussion
Recommended Materials Selection
Specific Materials Manufacturing / Fabrication Requirements
Specific Corrosion Control Requirements
Threat-Barrier Matrix
Outline of Corrosion Monitoring Methods
Technical References
Attachments / Appendices
DEFINE Phase
During the DEFINE phase Materials selection report shall include detailed assessments and
specifications to develop required materials and corrosion testing program. The detailed assessment
should be carried out as per the sequences of the process flow diagrams. The materials selection
shall discuss the process description for each system and the basis for the materials selection shall
be documented. All the unknowns identified during select phase shall be addressed, documented
and close.
Typical template with the required content for a materials selection in DEFINE phase is shown in
Appendix D.
Materials selection report shall consider and document all the process information and assumptions
for each stream and shall be presented as per the template included in appendix E.
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EXECUTE Phase
Required content shall be as per DEFINE phase and shall be updated to as approved for
construction status for handover.
Elements of corrosion management framework and corrosion management manual (CMM) shall be
in accordance with DEP 39.01.10.11- Gen.
Template for typical CMF is shown in Appendix C.
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Utility Systems
Equipment
carrying sea
water
including
water injection
and fire water
mol%
mol%
Dissolved H2S
ppm
Dissolved Co2
ppm
Elemental sulphur
ppm
Bara
Bara
Ambient Temperature
C
Multiphase/gas/oil
Type of fluid
Flow type
Stratified/ annular/
slug etc
mIn Sm3/d
m3/d
m3/d
Liquid Velocity
m/s
Debris present
yes/No
Inside diameter
Length
Km
Water cut
GOR
Reservoir Date
Reservoir pressure
Page 53 of 63
Mercury
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Water analysis
type of water
Cond/form/iron
saturated
Bicarbonates
ppm
Sulphates
ppm
chlorides
ppm
ppm
g/l
Oxygen in water
ppm
ppm
pH
Sodium
ppm
ORGANIC ACIDS
ppm
Formic acid
ppm
Acetic acid
ppm
Propionic acid
ppm
Mercury
ppm
kg/kmol
Fluid Properties
Gas molecular weight
Gas compressibility factor
API gravity
Oil density
kg/m3
Ns/m2
deg C
N/m
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Reference
Title
API RP 571
2 Edition
February 2012
CP-114
CP-208
Crossland, A., et al
DEP Specification
30.10.02.11-Gen
DEP Specification
30.10.02.14-Gen
DEP Specification
30.10.02.15-Gen
nd
Revision 5.0
1.0
February 2013
February 2013
Page 56 of 63
Smart, J
SP-2041
SP-2062
UK HSE
UK HSE
Revision: 0
Effective: September-2014
February 2013
February 2013
Version 1.0
18a
Revision 1.0
February 2013
February 2013
February 2013
May 2008
January 2008
2007
Revision 0
nd
2 edition with
Technical
Circulars
3.0
1.0
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MSR process
data.xlsx
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Corrosion mitigation measures applicable to a particular item or piping system (e.g. chemical
treatment, cathodic protection) shall be clearly identified.
g) If Contractor MSD does not record the above information for package licensor or Vendor units,
the licensor or Vendor shall supply their own MSD to record such information which shall then be
cross referenced in Contractors materials selection report.
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