SP-2041 2014

Petroleum Development Oman L.L.C. Specification for Cracking Resistant Materials in H 2S Containing Environment (SP-2041) Document ID

SP-2041

Document Type

Specification

Security

Unrestricted

Discipline

Owner

Issue Date

Version

Material Selection & Corrosion Engineering

UER- Materials, Corrosion & Inspection Functional Discipline Head

20 February 2014

4.0

Keywords: This Keywords: This document is the property of Petroleum Development 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.

Petroleum Development Oman LLC

Revision: 3.0 Effective: Jul-13

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SP-2041 Specifi cation for Crack ing Resistant Materials in H S Containing 2 Environment

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The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.



iii Related Business Processes Code

Business Process (EPBM 4.0)

CP-117

Project Engineering Code of Practice

iv Related Corporate Management Frame Work (CMF) Documents The related CMF Documents can be retrieved from the Corporate Business Control Documentation Register CMF .

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TABLE OF CONTENTS i

Document Authorisation................................................................................................................... 3

ii

Revision History ............................................................................................................................... 3

iii

Related Business Processes ........................................................................................................... 4

iv

Related Corporate Management Frame Work (CMF) Documents .................................................. 4

1

Introduction ...................................................................................................................................... 7 1.1

2

3

4

Scope ............................................................................................................................................... 7 2.1

Changes to the Specification ..................................................................................................... 7

2.2

Review and Improvement .......................................................................................................... 7

2.3

Specification Owner's Responsibility ......................................................................................... 8

2.4

Effective period .......................................................................................................................... 8

Abbreviated terms and definitions ................................................................................................... 8 3.1

Abbreviated terms ...................................................................................................................... 8

3.2

Definitions .................................................................................................................................. 9

Material requirements ...................................................................................................................... 9 4.1

Raw Material Suppliers .............................................................................................................. 9

4.2

Chemical composition ................................................................................................................ 9

4.3

Line pipe ................................................................................................................................... 10

4.4

Pressure vessels/ heat exchangers/ air coolers ...................................................................... 10

4.4.1

Chemical Composition ........................................................................................... 10

4.4.2

Mechanical Properties ............................................................................................ 11

4.4.3

Examinations .......................................................................................................... 11

4.4.4

Post W eld Heat Treatment ..................................................................................... 12

4.4.5

Manufacturing Process ........................................................................................... 12

4.4.6

Heat Treatment ...................................................................................................... 12

4.5 5

Purpose ...................................................................................................................................... 7

Clad/weld overlay ..................................................................................................................... 12

HIC testing additional requirements ............................................................................................... 12 5.1

Testing Laboratories requirements .......................................................................................... 12

5.2

Retesting .................................................................................................................................. 13

5.3

HIC testing Acceptance criteria ................................................................................................ 13

5.4

Pressure vessels ...................................................................................................................... 13

The following minimum acceptance criteria for HIC for sour service vessels shall apply. ................ 13

6

5.5

Pipeline steel ............................................................................................................................ 13

5.6

On-plot Piping and fittings ........................................................................................................ 14

SSC testing of carbon and low alloy steels ................................................................................... 14 6.1

Acceptance criteria: .................................................................................................................. 14

6.2

SOHIC and SZC testing ........................................................................................................... 14

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7

SSC/SCC testing of CRA materials ............................................................................................... 14

8

Quality Management ...................................................................................................................... 15

9

Appendix 1: Roles and responsibilities .......................................................................................... 16

10

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Appendix 2: References .......................................................................................................... 17


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Petroleum Development Oman LLC 1


Introduction

1.1 Purpose The purpose of this specification is to define additional requirements to other company specifications (SPs), Shell DEPs and MESC SPEs, and International Standards for materials in SOUR service environments. 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 period. 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, some of the equipments are covered below: a) b) c) d) e) f) g) h)

2

Pressure vessels/ Heat exchangers/ Air coolers Pipelines/flowlines/ pig launcher/ receiver and manifolds Compressors Pumps Storage tanks Field instrumentation On plot piping components Well completion

Scope This specification shall be applied in addition to other Company, Shell and international technical specifications for all materials used in sour service environment as defined in DEP 30.10.02.15Gen and ISO 15156. This specification shall be read in conjunction with other Company, Shell and International Technical Specifications such as DEP 39.01.10.11-Gen, 39.01.10.12-Gen, DEP 31.22.00.31Gen, DEP 31.40.20.37-Gen, DEP 30.10.02.15-Gen, DEP 30.10.02.16-Gen, NACE TM0284; NACE TM0177 and ISO 15156-1/2/3. This specification is intended to cover H2S related environmental cracking mechanisms SSC,SOHIC,SWC/HIC, CSCC, and not intended to cover other threats caused by H2S environments such as pitting, crevice or general corrosion. In case of any conflict between this specification and other standards the most stringent requirements shall apply.

2.1 Changes to the Specification This specification shall not be changed without approval from the custodian, the Materials, Corrosion & Inspection Functional Discipline Head (CFDH), UEOC (UER), who owns this specification. Any user of this specification, who encounters an inaccuracy or ambiguity, is requested to notify UEOC, using the User Comment Form provided at the end of this specification and send a copy with comments and personal details to DCS.

2.2

Review and Improvement This specification will be reviewed and updated once every three years. The review authority will be UEOC (UER, CFDH Materials, Corrosion & Inspection). Any revision and updates before three years period, is at the discretion of the reviewing authority, UEOC (UER).

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Petroleum Development Oman LLC 2.3


Specification Owner's Responsibility The owner of this specification UEOC, as CFDH Materials, Corrosion & Inspection is responsible for authorizing 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.

2.4

Effective period The requirements of this specification shall remain in force indefinitely unless superseded by an authorized revision.

3

Abbreviated terms and definitions

3.1

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Abbreviated terms CRA

Corrosion Resistant Alloy

CS

Carbon Steel

CLR

Crack Length Ratio

CSR

Crack Sensitivity Ratio

CTR

Crack Thickness Ratio

DEP

Design and Engineering Practice

EFC

European Federation of Corrosion Publications

ERW

Electric Resistance Welding

GHSC

Galvanically-induced hydrogen stress cracking

HIC

Hydrogen Induced Cracking

H2S

Hydrogen Sulfide

HFI

High Frequency Induction (Welding)

ILAC

International Laboratory Accreditation Cooperation

ISO

International Organization for Standardization

ITP

Inspection and Test Plan

MESC SPE

Material and Equipment Standards and Codes Specification

NACE

National Association of Corrosion Engineers

SSC

Sulfide Stress Cracking

SWC

Stepwise Cracking

SZC

Soft Zone Cracking

SOHIC

Stress Oriented Hydrogen Induced Cracking

SP

Specification

SCC

Stress Corrosion Cracking

TA

Technical Authority

UKAS

United Kingdom Accreditation Services


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4


Definitions Company

: Petroleum Development Oman LLC (PDO).

Shall

: Indicates the requirement

Should

: Indicates the recommendation

SHALL [PS]

: Indicates a process safety requirement

Material requirements The definition of sour service shall be as stated in 3.19 of ISO 15156-1 as indicated by DEP Specification 30.10.02.15-Gen. Therefore the requirements of this specification, and DEP Specification 30.10.02.15-Gen, shall be applied when design estimates, or measured operating conditions, identify any level of H 2S above detectable limits. Unless explicitly specified, the permitted exclusions of Table 1 in ISO 15156-2 and ISO 15156-3 shall not be applied. HIC testing shall apply to all product forms of carbon steel system components when specified in the applicable manufacturing or supply standard. Where HIC testing is left optional (not specified in the product specification), supplementary HIC testing shall be carried out when a risk assessment results in a medium or high risk ranking within the PDO risk assessment matrix as per the following criteria: -

Likelihood rating of B and a consequence rating developed from a loss of containment through a 25 mm hole (a medium hole as described in DNV-RP-G101) in the particular item.

For carbon steel equipment operating continuously above 65ºC HIC testing is not required. Design documents shall identify the service conditions as “Sour” or “Non Sour”. “Sour Service” shall be specified in the Purchase requisition/ ITP, Manufacturing procedure. Carbon steel shall be designed and manufactured from the melting, casting and mechanical working stage to meet the sour service and HIC requirements by controlling the chemistry and microstructure. Original materials (Mill) MTC shall indicate materials compliance with sour service and HIC testing. Clause A.2 of ISO 15156-2 shall apply to all carbon steel items designated as being in “Sour Service.” SSC Regions of ISO 15156-2 shall not be applied.

4.1

Raw Material Suppliers Raw material (plate or coil) manufacturers (steel makers) shall have demonstrated minimum experience of 5 years in supplying materials for sour service applications for use in oil and gas industry. There shall be a minimum of two years statistical information for chemistry, mechanical and cracking resistance properties.

4.2

Chemical composition Carbon steel materials used in sour service shall not have Sulphur content more than 0.002% mass fraction for flat rolled products, 0.01% mass fraction for seamless products, 0.025% mass fraction for forged components and there is no limit on castings. Sulphur content in pipeline flanges shall be in line with ISO 15590-3. Specific equipments shall comply with relevant DEPs or MESC SPEs or International Standards if they are more stringent.

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Line pipe Carbon steel line pipe materials which are not listed in ISO15156-2 Table A.2 shall not be used in sour service. Qualification of un-listed materials by testing is not acceptable. CS - ERW/HFI line pipe For severe sour service (SSC Region 3 as defined in section 7.2.1.2 of ISO15156-2), ERW/HFI line pipe shall be limited to material grades not higher than Gr. L360 (API 5L Gr. X52). ERW/HFI pipe shall not be permitted for use as on plot piping in sour service.

4.4

Pressure vessels/ heat exchangers/ air coolers Components made from flat rolled products and used in fabrication of pressure vessel/air coolers/heat exchangers/nozzles shall comply with sour service requirements of relevant DEPs and guarantee HIC resistance by testing of each heat of material. Other Components procured for fabrication of pressure vessels/heat exchangers/air coolers shall meet respective MESC SPE requirements for sour service.

4.4.1

Chemical Composition Chemical composition (product analysis) of the plates for vessels/ heat exchangers in sour service shall be in accordance with Table 1 below, except where the standard material specification or the appropriate limit specified in Table 1 of ASME SA-20 whichever is more restrictive. Other components such as nozzles, pipes, flanges, fittings etc shall meet applicable MESC SPEs requirements.

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Table 1: Additional chemistry requirements for sour service plates SINGLE ELEMENTS:

MAXIMUM %

Carbon

0.20

Manganese (Mn)

1.30

Phosphorous (P)

0.010

Sulphur (S)

0.0020

Silicon (Si)

0.40

Copper (Cu)

0.40

Nickel (Ni)

0.40

Chromium (Cr)

0.30

Molybdenum (Mo)

0.12

Vanadium (V)

0.020

Niobium (Nb)

0.020

Titanium (Ti)

0.020

Boron (B)

0.0010

MULTIPLE ELEMENTS: Cr + Mo

0.30

Ni + Cu + Cr + Mo

0.80

V+Nb

0.03

CARBON EQUIVALENT (CE): (Notes 1, 2) t  50 mm (2 in)

0.43

50 mm (2 in) < t  200 mm (8 in)

0.45

t > 200 mm (8 in)

0.48

NOTES:

4.4.2

1.

Carbon Equivalent (CE) shall be calculated by the following formula:

2.

The micro-alloying elements boron (B), titanium (Ti), niobium (Nb) and vanadium (V) shall not be intentionally added to the steel, unless the Principal has given prior approval. Chemical analysis results and carbon equivalent shall be reported in a material test report (MTR).

Mechanical Properties All plates shall have a tensile strength of less than 585 MPa (85,000 psi)

4.4.3

Examinations All plate shall be subjected to an ultrasonic lamination check in accordance with EN 10160, quality classes S 2 (plate) E3 (Edge), or ASME SA-578, acceptance Level A, (ASME SA-578 Supplementary requirement S1 shall be applied) or JB 4730, whichever specification is applied.

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Petroleum Development Oman LLC 4.4.4


Post Weld Heat Treatment All CS/Clad CS pressure vessels/air coolers/heat exchanger in sour service shall be subjected to PWHT.

4.4.5

Manufacturing Process The steel shall be vacuum-treated, fully deoxidised, desulphurised and dephosphorised. The manufacturing/rolling process shall be such that a homogeneous microstructure is obtained. Calcium treatment shall be applied for inclusion shape control, except that it need not be applied to plate with very low sulphur levels (below 0.001%). The calcium content should not exceed 3 times the sulphur content. Alternative methods of inclusion shape control shall be subject to the approval of Company .

4.4.6

Heat Treatment Normalised, Normalised & Tempered, NACT (Normalised accelerated cooling and tempered) and Quenched & Tempered shall be the only acceptable heat treatment processes for vessel plates.

4.5

Clad/weld overlay Clad/weld overlay shall not be considered as an SSC barrier. The base carbon steel material shall meet sour service requirements as stated in this specification with the exception of HIC testing.

5

HIC testing additional requirements HIC testing shall be carried out as per DEP 30.10.02.16-Gen with following additional requirements: a.

All HIC tests shall include a control sample. The control sample after testing shall exhibit minimum Average Crack Length Ratio (CLR) of 20%. If the controlled sample fails to meet this requirement the test shall be deemed as failed.

b.

Testing shall be witnessed by Company authorized inspector.

After testing, each specimen section shall be polished metallographically as per ASTM E3 and etched if required as per ASTM E407 for evaluation. Extreme care shall be taken not to contaminate the specimens. They shall be handled using only degreased tongs or clean gloves. Specimens shall not be coated in any way before exposure to environment.

5.1

Testing Laboratories requirements a.

HIC, SSC, SCC, SOHIC/SZC and GHSC testing shall only be carried out at Company approved laboratories. The laboratory approval shall be either by: 1. Formal audit as per Company Quality procedure by Company Function Materials & Corrosion Engineer TA2 or; 2. Approval based on ILAC accreditation (UKAS or equivalent for the applicable testing scope) and credential review by Company Function Materials & Corrosion Engineer TA2 and approved by CFDH. When HIC test is carried out by approved third party laboratory, Steel /item manufacturers (Mill) shall certify and include the results in the MTC.

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5.2

b.

On-plot piping materials/components procured from Traders/Stockist are acceptable if they are originally manufactured for HIC resistance and HIC tested by the Mill. If original HIC testing was not carried out by Company approved lab, HIC testing shall be repeated in a company approved lab.

c.

For each purchase order only one test laboratory shall be used for testing.

Retesting Retesting of the failed heat shall not be permitted. The failed heat shall be rejected. For line pipe manufacturing, when a heat has failed HIC test as part of quality control program, testing of two additional heats (one before and one after the failed heat) shall be carried out. Both of these heats shall pass the HIC test. If one or both of these tests fail the previous ten heats shall be tested and only passed tests shall be accepted.

5.3

HIC testing Acceptance criteria After HIC testing, if any section of the sample reveals vertical cracks (perpendicular to the rolling direction) greater than 0.5 mm the test shall be deemed to have failed.

5.4

Pressure vessels The following minimum acceptance criteria for HIC for sour service vessels shall apply. Table 2: Acceptance criteria sour service shall be as follows: % maximum)

Average per specimen

CLR

CTR

CSR

15

5

2

The maximum individual crack length on any section shall not exceed 5 mm. If any specimen fails to meet any of the above acceptance criteria, the heat of steel represented by the test shall be rejected. For vessels operating with H2S in the gas above 5 %, the following acceptable criteria shall be considered. Table 3: Acc eptance criteria wet con dition s, >5 % of H2S in gas phase.

% maximum) CLR

CTR

CSR

Average per specimen

10

3

1

Single

12

4

1.5

The maximum individual crack length on any section shall not exceed 5 mm. If any specimen fails to meet any of the above acceptance criteria, the heat of steel represented by the test shall be rejected.

5.5

Pipeline steel Acceptance criteria shall be in accordance with DEP 31.40.20.37-Gen.

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On-plot Piping and fittings

Acceptance criteria shall be in accordance with the relevant MESC SPEs and requirements of DEP 30.10.02.16-Gen.

6 SSC testing of carbon and low alloy steels Materials not listed in ISO15156-2 shall be subjected to following tests. Carbon steel testing shall be carried out using following test methods in accordance with NACE TM0177, EFC 16 and ISO 15156. Table 4: SSC test methods for Carbon Steel Qualification validity

Test Method

Applied tensile stress (Constant load)

UT All SSC regions of figure 1 of ISO 15156-2:09

or FPB

Environment

H2S partial pressure

≥90% AYS

or CR

NACE TM0177-05 Environment A (5% mass fraction NaCl + 0.5% mass fraction CH3COOH)

100kPa (15 psi) in accordance with NACE TM0177

Welded sections shall be tested by FPB except longitudinal welds in pipes with ≤6” ND where CR tests are applicable. Test Temperature: The temperature shall be maintained at ambient (24 deg C ± 3 deg C) as this is the “worst case” expected in service for the occurrence of SSC in carbon and low alloy steels. UT : Uniaxial Tensile test in accordance with NACE TM0177-05, Method A FPB: Four Point Bend test is in accordance with EFC Publication 16, Appendix 2 CR : C-ring test in accordance with NACE TM0177-05, Method C AYS : Actual Yield Stress ND: Nominal Diameter

6.1

Acceptance criteria: No cracks are acceptable

6.2

SOHIC and SZC testing Wherever required by the Company SOHIC and SZC testing shall be carried out according to section B.4 of ISO 15156-2.

7 SSC/SCC testing of CRA materials CRA materials designed to operate outside the envelop specified in DEP 39.01.10.12-Gen or DEP 30.10.02.15-Gen shall be subjected to two different SSC/SCC tests including SSRT/RSRT test in accordance with Annex B of DEP 30.10.02.15-gen. and NACE TM0177, EFC 17 and ISO15156-3. Page 14


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Scope of work for SSC/SCC testing shall be reviewed and approved by function Company Materials & Corrosion Engineer CFDH prior to placement of the order.

8

Quality Management All equipment / components intended for sour service shall be manufactured and constructed to meet the requirements of ISO 29001. ITP requirements shall be stated in the purchase specification. For “Sour Service,” ITP shall be in place and the company/ TPI interventions (witness/ review and monitoring stages) as per the equipment criticality rating.

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9


Appendix 1: Roles and responsibilities Company Project Manager/Project Engineer a.

Review of project material specification by Materials and Corrosion Engineer TA 2.

b.

All the first day production test reports for line pipe shall be submitted within the 14 days from the start date of production and shall be approved by a Materials and Corrosion Engineer TA 2.

c.

A purchase order shall not be dispatched unless material testing documentation is approved by Company QA/QC Engineer TA2.

Material Corrosion Engineer (TA 2) 

HIC/SSC/SOHIC/SZC test results shall be reviewed and accepted by Company Material and Corrosion TA2.

Contractor/Manufacturer 

Prepare project specific specification including HIC/SSC/SOHIC/SZC testing requirements, acceptance criteria and as part of purchase requisitions and obtain approval from the Company Function Materials and Corrosion Engineer TA2



Ensure all HIC/SSC/SOHIC/SZC testing is carried out by Company approved laboratories only. Company Materials and Corrosion Function CFDH approval is required before testing for any lab not listed.

Quality Assurance and Quality Control Engineer 

Ensure that the inspector (TPI) deployed is competent to perform the required activities and conversant with testing standards / inspection test procedure.

Third Party Inspector

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

TPI to witness the test including the control coupon.



TPI to review the laboratory certification approval covers the testing scope.



TPI Shall not deviate from the Company approved Inspection & Test Plans (ITP) without formal written approval from Company Function/Quality Assurance CFDH.


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10 Appendix 2: References In this specification, reference is made to the following publications:

PDO Standards Technical Authorities System

SP 2061

Specification for Quality Assurance of Design, Construction and Engineering Works

SP-1171

Shell Group Standards Hydrogen induced cracking sensitivity test (Amendment /supplement to DEP 30.10.02.16-Gen NACE TM0284) Selection of materials for life cycle performance (EP) – Materials DEP 39.01.10.11-Gen selection process Selection of materials for life cycle performance (EP) – Upstream DEP 39.01.10.12-Gen equipment Unfired pressure vessels

DEP 31.22.00.31-Gen

Materials for use in H 2S environments (amendments/supplements to DEP 30.10.02.15-Gen ISO 15156:2009) Vertical Tanks – Erection and Testing (Based on EN 14015)

DEP 64.51.01.31-Gen

Hydrogen Induced Cracking Sensitivity Test

MESC SPE 74/125

International Standards Standard Test Method: Evaluation of Pipeline and Pressure Vessel Steels for Resistance to Hydrogen-Induced Cracking

NACE TM 0284

Laboratory Test Procedures for Evaluation of SOHIC Resistance of Plate Steels Used in Wet H 2S Service

NACE TM0103

Laboratory Testing of Metals for Resistance to Sulfide Stress Cracking and Stress Corrosion Cracking in H 2S Environments

NACE TM0177

Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining Environments

NACE TM0103

Petroleum and natural gas industries – Materials for use in H2S containing environments in oil and gas production

ISO 15156-part 1, 2 and 3

Petroleum and natural gas industries – Steel pipe for pipelines Petroleum and natural gas industries - Induction bends, fittings and flanges for pipeline transportation systems - Part 3: Flanges Steel and Steel Products – Inspection Documents

ISO 3183 ISO 15590-3 ISO 10474

Guidelines on Materials Requirements for Carbon and Low Alloy Steels for H2S- Containing Environments in Oil and Gas Production

EFC16

Corrosion Resistant Alloys for Oil and Gas Production: Guidance on General Requirements and Test Methods for H 2S Service

EFC17

Petroleum, petrochemical and natural gas industries — Sector-specific quality management systems — Requirements for product and service supply organizations

ISO 29001

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Petroleum Development Oman LLC Risk Based Inspection Of Offshore Topsides Static Mechanical Equipment

DNV-RP-G101

User Comment Form If you find something that is incorrect, ambiguous or could be better in this document, write your comments and suggestions on this form. Send the form to the Document Control Section (DCS). They make a record of your comment and send the form to the correct CFDH. The form has spaces for your personal details. This lets DCS or the CFDH ask you about your comments and tell you about the decision. Procedure Details Title: Issue Date: Number: Page Number:

Heading Number:

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Comments:

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User’s personal details Name:

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Signature:

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Ind.: Phone: Document Control Section Actions Comment

Date:

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Ref. Ind.:

Recd.:

To CFDH:

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Recd.

Reject: Accept, revise at next issue:

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Accept, issue temporary amendment

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Ref.

Date:

Ind.:

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Petroleum Development Oman LLC Comments:

Originator

Date:

Advised:

Inits.:

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Inits.:

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SP-2041 2014

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