PTTEP ARTHIT FIELD DEVELOPMENT

CENTRAL FACILITIES

MATERIAL REQUIREMENTS FOR SOUR SERVICE

A-1-GEN-MC-SP-0001

CONTRACT NO . A-TPD 03-0043

This cover page is a record of all revisions of the standard/specification identified above by number and title.
All previous cover pages are hereby superseded and are to be destroyed.

B1 4-8-04 Issued for Design Siva SNT Siva BMK SW

A1 28-6-04 Issued for Approval Siva SNT Siva BMK
R1 19-5-04 Inter Discipline Check Siva SNT Siva
Rev. Date Purpose of Issue Prepared Checked Discipline Project Client
No. By By Approval Approval Approval
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TABLE OF CONTENTS

1.0 INTRODUCTION 2
2.0 DEFINITION OF WET H2S OR SOUR SERVICE 3
3.0 MATERIALS FOR SOUR SERVICE 3

APPENDIX

Appendix 1—HIC Testing 8

1.0 INTRODUCTION
1.1 This Specification defines the minimum requirements for materials to be used in wet
H2S service or Sour Service. The material damage can be classified in 2 categories
--Sulphide Stress Corrosion Cracking ( SSC )
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--Hydrogen Induced Cracking ( HIC ), Stepwise Hydrogen Cracking ( SWC ), Stress

Oriented Hydrogen Induced Cracking ( SOHIC ) and Hydrogen Blistering

1.2 SSC is a Hydrogen embrittlement phenomenon caused by diffusion of Hydrogen

into the material when subjected to tensile stress. SSC occurs in the presence of
hard material, high stress level and wet H2S solution. Preventive measures are
controlling the material hardness and reducing the stress level by heat treatment ( in
some cases ).
1.3 Blistering, Hydrogen induced Cracking ( HIC ), Stepwise Cracking ( SWC ) and
Stress Oriented Hydrogen Induced Cracking ( SOHIC ) propagate in a stepwise
fashion like lamellar tearing.
1.3.1 Hydrogen Blistering
Atomic Hydrogen produced during reaction with steel diffuses to the
locations of non-metallic inclusions or voids present in the steel and gets
converted to molecular Hydrogen. As molecular Hydrogen cannot diffuse
into metal, this process increase the concentration and pressure of
molecular Hydrogen at the inclusions resulting in localised yielding and
blistering
1.3.2 HIC or SWC
Atomic Hydrogen diffuses to the areas of small and moderate sized laminar
cracks in the metal and gets converted to molecular Hydrogen. As molecular
Hydrogen cannot diffuse into metal, this process increase the concentration
and pressure of molecular Hydrogen resulting in localised yielding and
linking of adjacent planar cracks to form HIC / SWC in the through thickness
direction.
1.3.3 SOHIC
This is a combination of HIC and SSC. This damage occurs in locations
which are susceptible to laminar cracking in the presence of stress. In these
cases, when the metal is subject to stress, small laminar cracks get lined up
in the through thickness direction and step cracks form between them. They
are generally found in weld Heat Affected Zones.

2.0 DEFINITION OF WET H2S OR SOUR SERVICE

2.1 Sour service requirements for SSC will apply when the conditions as defined in
NACE MR0175 are present.
2.2 Requirements for HIC, SWC, SOHIC and Hydrogen blistering will apply when the
partial pressure of H2S in equilibrium with the process media exceeds 0.0035 bar
( abs ) in the presence of an aqueous phase.

3.0 MATERIALS FOR SOUR SERVICE

3.1 General SSC requirements

3.1.1 All materials exposed to sour service media, shall meet the requirements of NACE
MR0175 except as modified in this specification.

3.1.2 Materials shall be selected from those permitted in NACE MR0175.

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3.1.3 All castings shall be suitably heat treated after any welding including repair welding.
Recommended heat treatments are as follows

--Carbon and Carbon Manganese Steels—Thermal Stress Relief

--Austenitic and Duplex Stainless Steels—Solution Anneal

--Martensitic Stainless Steel—Reheat treat or double temper per NACE MR 0175

3.1.4 All carbon steel materials shall be supplied in normalised condition. Hot finished
material is not acceptable.

3.1.5 All internal bolting inside vessels, shall meet NACE MR0175.

3.1.6 For shell & tube heat exchangers, carbon steel tube bundles need to undergo
PWHT if tube ends are welded to the tubesheet.

3.1.7 Nitrile ( NBR ) and Hydrogenated Nitrile ( HNBR ) elastomers are acceptable for
H2S levels of 10 to 100 ppm and 100 to 1000 ppm respectively based on seal
geometry and temperature. For H2S levels upto 5%, FKM “Viton “ type
fluoroelastomers or TFEP “ Aflas “ shall be used. Above 5% H2S level, EFKM
perfluoroelastomers ( Chemrez or Kalrez ) shall be required. PTFE has excellent
H2S resistance.

3.2 General HIC / SWC Requirements

3.2.1 Lower pH and higher CO2 in the presence of H2S, will increase Hydrogen diffusion
rate and hence increase the susceptibility to HIC / SWC.

3.2.2 Material should be supplied in Normalised condition. TMCP and Quenching and
Tempering is acceptable subject to Purchaser’s approval.

3.2.3 Heat Treatment

Vessels shall undergo PWHT irrespective of wall thickness. PWHT requirements
for piping shall be as per ASME B 31.3 and NACE MR0175. For Carbon steel,
minimum PWHT temperature and time should be 610 Deg C and 1 hour.

3.3 Plates

3.3.1 Carbon steel plates shall conform to ASTM A 516 or A 537 specification with
modifications as listed below. Increase of strength increase susceptibility to HIC /
SWC. Maximum tensile strength allowed for process vessel plates is 80 Ksi.

3.3.2 Manufacturing Process

Clean steel with homogenous microstructure provides optimum HI / SWC

resistance. Very low Sulphur and Phosphorous and inclusion shape control using
Calcium decrease the susceptibility to HIC / SWC. The steel shall be vacuum
treated, fully deoxidised, desulphurised and dephosphorised. Calcium treatment
shall be applied for inclusion shape control except that it need not be applied to
plates with very low Sulphur levels ( below 0.001 % ). The Calcium content should
not exceed 3 times Sulphur content. Manufacturing or rolling process shall ensure a
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homogenous microstructure without any ferrite / pearlite banding. One specimen

shall be examined for microstructure for the degree of banding as per ASTM E 1268

3.3.3 Based on product analysis, the steel composition shall be restricted as follows,
except where the standard material specification is more restrictive:

Elemen Max % Element Max %

t
C 0.20 V 0.015
Mn 1.30 Nb 0.015
P 0.01 Ti 0.02
S 0.002 B 0.0005
Si 0.40 Cr + Mo 0.3
Cu 0.40 Ni + Cu + Cr + 0.7
Mo
Ni 0.40 V + Nb 0.02
Cr 0.30 Carbon 0.43
Equivalent ( per
Section
3.1.3.2 )
Mo 0.12
Carbon Equivalent based on the following formula, shall not exceed 0.43

3.3.4 Thru thickness ( Z quality ) steel provides better resistance to HIC / SWC. All plates
shall meet the through thickness testing requirements of ASTM A770 S3, with a
minimum area reduction of 35%. HIC tested plates in accordance with this
specification is acceptable in lieu of through thickness tested material.

3.3.5 Plate material shall be HIC tested in accordance with this specification

3.3.6 Lamination Check

Plates shall be ultrasonic tested for laminations in accordance with EN 10160, grade
S2E2.

3.4 Flanges and Forgings

3.4.1 All carbon steel flanges and forgings shall conform to ASTM A105N or A 350- LF2
with the following composition restrictions

Carbon : 0.25 wt % max

CE : 0.43 max

3.5 Seamless Pipes

Seamless pipe shall be in accordance with ASTM A 106 Grade B or A 333 Grade 6
with the following composition restrictions
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Carbon : 0.23 wt % max

CE : 0.43 max

Sulphur : 0.010% max

3.6 Seamless Fittings

Seamless fittings shall be in accordance with ASTM A 234-WPB or A 420-WPL6.

The requirements on Carbon Content, Sulphur content and CE shall be based on
forging or pipe whichever is used as raw material, to make the finished product.

3.7 Welded Pipe and Fittings

Welded Fittings shall be in accordance with ASTM A 234 WPB or A 420-WPL6.

Plate used for manufacture of these welded fittings shall conform to the
requirements specified for plates in this specification. Welding procedures used
shall also meet this specification.

3.8 Valves

All the wetted parts shall meet the requirements of NACE MR0175. Items which are
not freely vented to atmosphere such as insulated and buried valve and bolts inside
flange protectors etc., where leakage could cause a sour environment, shall meet
NACE MR0175 and this specification. Where plated components are used, the
parent metal on which the plating is deposited, shall conform to this specification.
Any welding or weld repair on a cast component which is exposed to the sour
medium, shall undergo PWHT. All valve springs shall be made of materials meeting
NACE MR0175. In addition, UNS N07090 ( Nimonic 90 ) is also acceptable. Packing
shall be compatible with the stem material. Uninhibited graphite or carbon type
packing is not acceptable

3.9 Bolting

All bolting shall be ASTM A 193-B7 and A 194-2H or A 320-L7 and A 194-7 if the
flanges are not insulated or covered by flange protectors. Otherwise these bolting
shall be ASTM A 193-B7M and A 194-2HM or A 320-L7M and A 194-7M.

3.10 Pipelines

Line pipe specifications for sour service shall be in accordance with the respective
technical specification. Production control tests need to be carried out on all line
pipes used on pipelines to demonstrate their acceptable resistance to HIC using
NACE TM0284 method. HIC testing and other requirements shall be as per this
specification. For welded linepipes, the plates used and welding / fabrication shall
meet the requirements of this specification.

3.11 Welding Requirements

3.11.1 Normally forgings or flanges will have higher carbon content and higher carbon
equivalent compared to plates or pipes. Material used for welding procedure
qualification tests shall have CE equivalent or higher than the material used for
production.

3.11.2 All pipework shall use a minimum of 2 weld passes

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3.11.3 Weld metal deposit shall not contain more than 1% Nickel.

3.10.4 Each Welding Procedure Qualification test shall include a macro and hardness test.
The readings shall extend from unaffected base material on one side, across the
weld to unaffected base metal on the other side. The traverses shall be as specified
below. One 2 mm below the outer surface, one 2 mm below the inner surface and
one across the centre. The distance between measurements across the weld shall
not exceed 2 mm. No part of the weld, HAZ or base metal shall exceed 248 HV 10.
for Carbon Steel. For other materials, the maximum hardness requirements shall be
as per NACE MR0175.

3.10.5 The production welds shall be transverse weld hardness tested using portable
Vickers hardness tester as per ASTM E 110. The hardness tests shall be carried out
on the inside surface for vessels and outside surface for piping. Where PWHT is
mandatory, production hardness tests shall be carried out only after PWHT. One set
of hardness measurement shall be carried out for each welding procedure and for
each 10 m length of finished weld. No part of weld, HAZ or base metal shall exceed
248 HV 10 for Carbon Steel. For other materials, the maximum hardness
requirements shall be as per NACE MR0175.

Appendix-1

HIC Testing

Material inspection certificates shall be as per EN 10204, type 3.1C

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HIC sensitivity tests shall be carried out in the solution prescribed below. The plate
materials shall be tested at a frequency of one test per heat (the thickest & thinnest plates
of the same heat shall be tested).
Testing shall be done as per NACE TM0284 using Solution A.
The acceptance criteria shall be as follows:
CLR% CTR% CSR%
(max) (max) (max)
Average 5 1.5 0.5
Single 7 2 0.7

CLR—Crack Length Ratio

CTR—Crack Thickness Ratio
CSR—Crack Sensitivity Ratio
The maximum individual crack length on any section shall not exceed 5 mm. If any
specimen fails to meet the above acceptance criteria, the heat of steel tested shall
be rejected.
One specimen shall be examined for microstructure for the degree of banding as
per ASTM E 1268. Micro indentation hardness tests are not required.
Following information shall be provided in addition to that required by NACE
TM0284:
Location and dimension of specimens
Full chemical analysis of material tested including analysis for micro alloying
elements
Results of cracking evaluation indicating individual CLR, CTR and CSR for each
section and also averaged over 3 sections, and acceptable / not acceptable.
Photomicrographs of the specimens showing cracking and / or blistering, together
with photomicrographs of adjacent material structures and of bulk material structure
(samples) used to assess microstructure banding: