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EDS-A-9

Page 2 of 30 SELECTION OF METALLIC MATERIALS


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TABLE OF CONTENTS

A SCOPE .................................................................................................................................................44
B ABSTRACT ............................................................................................................................................44
1.0 INTRODUCTION...............................................................................................................................55
2.0 GENERAL...........................................................................................................................................55
2.1 Selection ..........................................................................................................................................55
2.2 Selection Procedure ........................................................................................................................66
2.3 Acceptable Materials ......................................................................................................................66
3.0 RESISTANCE TO ENVIRONMENT...............................................................................................66
4.0 HIGH TEMPERATURE EXPOSURE [ABOVE 232°C (450°F)] ..................................................77
4.1 General Considerations ...................................................................................................................77
4.2 Special Considerations....................................................................................................................77
5.0 EXPOSURE AT INTERMEDIATE AND AMBIENT TEMPERATURES ..................................99
(-10 -230 0C. [15 - 4500F]) .............................................................................................................................99
5.1 General Considerations ...................................................................................................................99
5.2 Special Considerations....................................................................................................................99
5.2.1 Caustic Service........................................................................................................................99
5.2.2 Amine Service.........................................................................................................................99
5.2.3 High pH and Ammonia ......................................................................................................1010
5.2.4 Ammonium Hydrosulphide Environments .......................................................................1010
5.2.5 Velocity Limits and Profiles ..............................................................................................1010
5.3 Special Requirements for Sour Service .....................................................................................1010
6.0 EXPOSURE TO LOW TEMPERATURE ....................................................................................1111
7.0 WEAR PLATES .............................................................................................................................1111
8.0 MATERIALS REQUIREMENTS - GENERAL ..........................................................................1111
8.1 Approval of Vendors ..................................................................................................................1111
8.2 Welding Procedures ....................................................................................................................1111
8.3 Heat Treatment Requirements ....................................................................................................1111
8.4 Material Selection Restrictions ..................................................................................................1212
8.4.1 Carbon Steels ......................................................................................................................1212
8.4.2 Carbon Molybdenum Steels ...............................................................................................1212
8.4.3 Chromium Molybdenum Steels .........................................................................................1212
8.4.4 Nickel Low Alloyed Carbon Steel .....................................................................................1313
8.4.5 Ferritic Chromium Stainless Steel .....................................................................................1313
8.4.6 Austenitic Stainless Steels..................................................................................................1414
8.5 Cast Iron Pressure-Containing Parts ..........................................................................................1616
8.6 Non-Ferrous Metals ....................................................................................................................1616
9.0 MATERIALS REQUIREMENTS - SPECIFIC ............................................................................1616
9.1 Pressure Vessels and Heat Exchangers (except bundles) .........................................................1616
9.1.1 Cladding and Lining ...........................................................................................................1616
9.1.2 Thick Wall Shells ...............................................................................................................1616
9.1.3 Atmospheric Columns in Sour Crude Service ..................................................................1616
9.1.4 Bolting and Gasket Materials .............................................................................................1717
9.2 Heat Exchanger Tubing ..............................................................................................................1717
9.2.1 General ................................................................................................................................1717
9.2.2 Water-Cooled Services .......................................................................................................1717
9.3 Air-Coolers ..................................................................................................................................1818
9.4 Fired Heaters ...............................................................................................................................1919
9.4.1 Acceptable ASTM Material Specifications ......................................................................1919
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9.4.2 Furnace Tubes .................................................................................................................... 1919


9.4.3 Tube Supports and Hangers ............................................................................................... 2020
9.4.4 Flue Gas Sampling ............................................................................................................. 2020
9.5 Centrifugal Pumps ...................................................................................................................... 2020
9.6 Deaerators ................................................................................................................................... 2020
9.7 Tanks ........................................................................................................................................... 2121
9.8 Piping .......................................................................................................................................... 2121
OWNER’S APPROVAL CHECKLIST .................................................................................................... 2121
LIST OF REFERENCES ............................................................................................................................ 2222
APPENDIX I – AVERAGE CORROSION RATES FOR HIGH TEMPERATURES SULPHUR
CORROSION IN A HYDROGEN FREE ENVIRONMENT ................................................................. 2323
APPENDIX II – CORROSION RATES FOR HYDROGEN/HYDROGEN SULFIDE MIXTURES
(Curves have been extracted from API 939-C) ......................................................................................... 2424

LIST OF FIGURES
FIGURE 1 Average Corrosion Rates High Temperature Sulphur Corrosion Hydrogen-free
Environment

LIST OF TABLES
TABLE 1 Heat Treatment Temperatures
TABLE 2 Material Grade Selections for Titanium Tubes
TABLE 3 Maximum Skin Temperatures
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A SCOPE
This specification defines the bases to be used in selecting construction materials for refinery
process equipment, including pressure vessels, tanks, heat exchangers, heaters, piping and
pumps, but excluding instrumentation, electrical equipment and compressors. It also defines
general and specific requirements for materials selected.

B ABSTRACT
Materials selection criteria are described with respect to resistance to deterioration from
exposure to process and non-process environments. Consideration is given to the achievement
of metallurgical stability, and provision against metal wastage (e.g., by corrosion), in order to
attain a specified design life.
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1.0 INTRODUCTION
(i) The Owner’s approach to materials selection is described in the following paragraphs.
In certain instances, materials will have been specifically selected by the Owner.
However, except where a mandatory requirement is noted, nothing in this
specification shall prohibit the Contractor from using more up-to-date corrosion,
metallurgical and mechanical property data than is herein specified, subject to the
Owner’s approval.

(ii) The objective in materials selection is to choose a material that will resist the
corrosion, metal wastage and deterioration by the process environment so that the
equipment will achieve the anticipated design life. The material selected must be
metallurgically stable during normal plant operation, upsets, startups, shutdowns and
in fire situations.

(iii) The required design life of equipment shall be as stated in ‘EDS-A-6 Design
Philosophy’, unless otherwise specified in the Project Specifications.

2.0 GENERAL
2.1 Selection
(i) Stage one in the selection of metallic materials is accomplished by selecting material
types and respective corrosion allowances appropriate to the process conditions under
consideration. This is the information to be provided under 2.2(i) and 2.2(ii) below, as
part of the basic design phase of front-end engineering.

(ii) Stage two is accomplished by proper designation of materials that will be required,
by specification and grade number or by the manufacturer’s proprietary designation:

(a) Where materials specifications are quoted, the full specification description
shall be given, not abbreviated. For example, ‘JIS G3459 SUS 321’, not
merely ‘SUS 321’.

(b) Where a material can be described only by manufacturer’s trade name, the
name of the manufacturer shall be included. For example, ‘Sandvik 3RE60’,
not merely ‘3RE60’.

(iii) Where materials are not specified by the Owner, the Contractor shall select them on
the basis of service conditions, corrosion rates and costs, so as to provide the most
economical equipment to the Owner over the specified design life.

(iv) Once material specifications have been approved by the Owner’s (refer to 2.3), no
substitution is permitted without the Owner’s further approval. It is the
Contractor’s responsibility to ensure that, when substitutions are proposed the
qualifications and limitations on equivalence are fully taken into account.
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2.2 Selection Procedure


(i) The Contractor shall fill in the appropriate columns of form ‘SF-A-612 Material
Selection Basis’ for all pressure vessels, heat exchangers including air-coolers,
heaters, process lines, pump casings and impellers. Equivalent information in an
alternate format may be acceptable, if the details are equally comprehensive. The
details of all corrosive components in process streams must be included.

(ii) For equipment with a minimum design temperature below -10°C (+15°F), the
Contractor shall complete columns one through six and Column 20 of ‘SF-A-612’.

(iii) The information required above shall be submitted by the Contractor for approval
by the Owner before releasing enquiry requisitions for materials and equipment.

2.3 Acceptable Materials


(i) A list of acceptable steels is given in drawing ‘SD-A-23157 Acceptable Steel for
Pressure Vessels’. A list of acceptable non-ferrous metals is given in drawing ‘SD-A-
23191 acceptable Non-ferrous Metals for Heat Exchanger Components’.

(ii) The use of non-listed steels and non-ferrous metals is considered a substitution, and
is subject to the Owner’s prior approval. More detailed requirements for, and
restrictions on, materials substitutions are contained in individual Material and
Equipment Specifications. Complete specifications in English shall be submitted for
substitute material to be approved, where non- English language specifications are
proposed.

3.0 RESISTANCE TO ENVIRONMENT


All environments to which equipment material will be exposed shall be considered when
selecting materials. This includes normal operation, upset conditions, and depressurization,
startup and shutdown and down periods.
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4.0 HIGH TEMPERATURE EXPOSURE [ABOVE 232°C (450°F)]


4.1 General Considerations
(i) Carbon steel is generally the material of choice for most equipment operating up to
approximately 343°C (650°F). Allowable design stresses for carbon steel drop rapidly
over 399°C (750°F), and carbon steel shall not be used above this temperature without
Owner’s approval.

(ii) High temperature hydrogen attack considerations limit the use of carbon steel to
approximately 232°C (450°F) in hydrogen containing environments.

(iii) Carbon steel corrosion rates in environments with hydrogen and hydrogen sulfide
above 232°C (450°F), and hydrogen sulfide without hydrogen above about 260°C
(500°F), require more sulphidation resistant materials to meet required equipment
design life. For most equipment corrosion rate of greater than l0 mpy is considered
high enough to change materials.

(iv) Other considerations when selecting materials for high temperature service include,
but are not necessarily limited to, the following modes of deterioration: stress rupture
and low creep ductility, high creep strain, graphitization, decarburization, oxidation,
carburization, sensitization, embrittlement due to high temperature exposure,
mechanical and thermal fatigue, erosion and corrosion due to naphthenic acid.

4.2 Special Considerations


(i) The maximum operating temperature for materials in oxidizing environments shall
conform to Table 3. For furnace tubes the maximum tube metal temperature shall be
the temperature to consider.

(ii) The maximum design metal temperature for the Cr-Mo steels shall be at least 10°C
(50°F) below the lower critical temperature. The Cr-Mo alloys are air hardening and
they can easily harden when cooled from temperatures above the lower critical.
Hardening may make the material susceptible to brittle failure problems. The lower
critical ranges from 777°C (1430°F) for 1¼ Cr to 824°C (1515°F) for 9Cr.

(iii) For all other modes of corrosion and deterioration, the design pressures and
temperatures shall be used.

(iv) Materials for H2 service shall be selected using API Publication 941 Latest Edition
(currently 7th edition). At the design stage a 20°C (36°F) conservative factor shall be
added to the design temperature used for materials selection. All startup, shutdown,
start of run and end of run temperature and partial pressures shall be considered.
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(v) Corrosion rates in environments containing hydrogen sulfide without hydrogen shall
be estimated using the McConomy curves as shown in Appendix I, Figure 1. These
curves are the original curves generated from an API survey of Naphtha
Desulphurisers and are not strictly applicable to crude unit service. However, ENOC
have had satisfactory experience using these curves in the unmodified form and
using the following materials and temperature breaks:

Carbon steel up to 260°C (500°F)


5%Cr-1/2%Mo from 260°C (500°F) to 343°C (650°F)
9%Cr above 343°C (650°F)

(vi) Hydroprocessing units have environments containing hydrogen sulfide with


hydrogen. Corrosion rates shall be estimated using the Cooper-Gorman curves
contained in Appendix I. these curves were derived from a computer analysis of data
collected by the NACE T-8 Refining Committee. ENOC-EPCL experience is that
these curves are satisfactory for materials selection in hydrogen/hydrogen sulphide
systems, however more recent data may be used with Owner’s Permission. Carbon
steel is generally satisfactory up to about 232°C (450°F), this is also the limit for
hydrogen attack of carbon steel. Because the Cr-Mo steels do not form a protective
sulfide scale in hydrogen/hydrogen sulfide environments and the 11-13Cr stainless
steels suffer unacceptable embrittlement problems, above 232°C (450°F) an
austenitic grade of stainless steel shall be selected (8.4.5).

(vii) Environments with crudes or products containing naphthenic acids generally require
Type 316L austenitic stainless steel between about 232°C (450°F) to 399°C (750°F)
where the acids generally thermally decompose (8.4.5). Crudes with low
neutralization numbers as low as 0.1 may cause naphthenic acid corrosion if the
sulfur level is very low.

SS316L with minimum molybdenum content of 2.0% is required for naphthenic acid
service. Higher alloy materials such as SS317L, 904L, or Inconel 625 may be
required depending upon the expected neutralization number.

(viii) Austenitic stainless steels will sensitize during fabrication by welding or service
above about 399°C (750°F), making them particularly vulnerable to polythionic acid
cracking in wet, sulfur containing atmospheres. Chemically stabilized austenitic
stainless steels types 321 and 347 in a properly stabilized heat-treated condition shall
generally be used to minimize sensitization problems, in areas where polythionic
acid cracking problems are anticipated. An exception is that type 304H may be used
for Fluid Catalytic Cracking Unit regenerator internals because of stress rupture and
creep considerations.
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5.0 EXPOSURE AT INTERMEDIATE AND AMBIENT TEMPERATURES


(-10 -2300C. [15 - 4500F])

This environment includes intermidiate temperatures where coincident pressure can result in
the presence of an aqueous phase.

5.1 General Considerations


Materials selected for these ambient and intermediate temperature environments shall be the
economic choice which will attain the equipment design life and minimize damage from but
not necessarily limited to the following: hydrogen blistering, hydrogen induced cracking
(HIC), stress oriented hydrogen induced cracking (SOHIC), sulfide stress corrosion cracking,
carbonate stress corrosion cracking, caustic cracking, amine cracking, chloride stress corrosion
cracking, ammonia stress corrosion cracking, mechanical and corrosion fatigue, polythionic
acid stress corrosion cracking, general corrosion, erosion, chemical attack, crevice corrosion,
galvanic corrosion, brittle failure and deterioration during shutdowns and startups.

In general, carbon steel is the economic material choice. In some services special requirements
will be needed to minimize damage or deterioration. In some service environments several
different damage or deterioration mechanisms may be active. For example, HIC is not
prevented by postweld heat treatment but SOHIC, sulfide stress corrosion cracking and
carbonate stress corrosion cracking are prevented. Therefore, a reasonable approach would be
to use clean, low sulfur steels with a postweld heat treatment. In addition, these service
environments generally have propane and lighter hydrocarbons which under venting or
depressuring conditions require a fine grained normalized, impact tested steel to minimize
potential brittle failure problems.

5.2 Special Considerations


5.2.1 Caustic Service

Carbon steel is generally satisfactory in caustic service up to about 71°C (160°F ) if stress
relieved. Above this temperature corrosion rates are generally too high and nickel or nickel
based alloys are required. Steam or heat tracing and heat of reaction must be considered when
deciding whether or not to stress relieve carbon steel. Austenitic stainless steels are generally
not considered corrosion resistant in caustic above about 82°C (180°F).

Specific stress relief requirements in caustic service are covered by drawings SD-A-23188
Heat Treatment Requirements and SD-A-23190 Temperature/Concentration Limits for Caustic
Service’.

5.2.2 Amine Service

Heat treatment for steels in amine service shall be in accordance with drawing ‘SD-A-23188’.
(See also 5.2.4(iii)).
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5.2.3 High pH and Ammonia

The use of Copper zinc alloys in environments containing free ammonia requires Owner
approval. Copper nickel alloys are considered satisfactory for service in such environments.

5.2.4 Ammonium Hydrosulphide Environments

Process streams containing between 2% and 10% ammonium hydrosulphide, such as some
Hydroprocessing effluent streams, may require the use of Alloy 825 or Alloy 625 for piping
and aircooler tubes. Alloy 800 shall not be used in these services without Owner approval
due to sensitization concerns. Alloy selection for ammonium hydrosulphide concentrations
greater than 10% shall be subject to Owner approval.

5.2.5 Velocity Limits and Profiles

(i) Stream and velocity limits for heat exchangers and aircooler tubing are given in
‘EDS-E1 Heat Exchange Equipment’ 2.7 and 7.2.

(ii) Velocity of streams high in ammonia and hydrogen sulphide (up to 10% ammonium
Hydrosulphide), such as hydrotreating unit reactor effluent, should be restricted to
6.5m/s (20ft/s) maximum.

(iii) The velocity of amine-containing streams in carbon steel lines shall be restricted to
1.9m/s (6ft/s).

(iv) The velocity of sulfuric acid streams in carbon steel lines should be restricted to
0.7m/s (2ft/s).

5.3 Special Requirements for Sour Service


(i) Sour service, is defined as a wet process stream generally containing greater than
50ppm H2S. Additional Owner’s requirements for equipment in sour service are
contained in ‘EES-C-133 CS Pressure Vessels and Heat Exchangers in Sour
Service’.

(ii) Severe sour service, i.e. wet process streams containing over 1,000ppm H 2S or 500
ppm H2S and 20ppm cyanide, is not covered by this specification. A special Project
Specification shall be developed by the Contractor, in conjunction with the
Owner’s, for material selection under these conditions.

(iii) Owner’s reserves the right to designate equipment and piping as being in ‘severe
sour service’ at H2S/Cyanide levels below those in (ii) above if experience indicates
that the service conditions are particularly conducive to hydrogen attack.
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6.0 EXPOSURE TO LOW TEMPERATURE


Additional Owner’s requirements for material selection for exposure below -10°C (+15°F) are
contained in specification ‘EES-C-132 CS Pressure Vessels and Heat Exchangers for Low
Temperature Operation’.

7.0 WEAR PLATES


Wear plates shall be installed where abnormal erosion/corrosion rates are anticipated, e.g. feed
inlets to distillation columns. In carbon steel equipment suitable alloy steel wear plates shall
be used where anticipated erosion-corrosion rates on carbon steel wear plates exceed 10 mpy.

8.0 MATERIALS REQUIREMENTS - GENERAL


8.1 Approval of Vendors
The Owner’s approval of the Vendor or sub-Vendor will be required in the case of the
following:

(a) Alloy steel equipment (including stainless steel and non-ferrous alloys)

(b) Clad steel vessels - the manufacturing method, the manufacturer of the clad plate and
the vessel fabricator require approval

(c) Alloy deposit lined vessels

(d) Explosion bonded steel plate, pipe, nozzles, etc

(e) Impact tested carbon steel vessels

(f) Cast alloy steel parts for furnace headers and return bends

(g) Any vessel with a wall thickness in excess of 2 inches.

8.2 Welding Procedures


The Owner’s requirements for welding are given in specification ‘EES-B-910 General
Welding Requirements’. [Refer also 4.1 (iii)]

8.3 Heat Treatment Requirements


Heat treatment requirements for various materials and services are given on drawing ‘SD-A-
23188’ and in ‘EES-B-910’. These are mandatory.
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8.4 Material Selection Restrictions


8.4.1 Carbon Steels

(i) Bottom- or side-blown air or air-enriched converter steels shall not be used. Oxygen-
blown converter steels may be used only below the creep range.

(ii) Carbon steels shall not be specified for use above 399°C (750°F) without Owner’s
approval.

(iii) All carbon steels which are to be welded shall have chemistry restrictions as follows:

C = 0.25% max
C + Mn/6 = 0.41% max

Except where tighter restrictions apply, e.g. for equipment in cold services refer to
specification ‘EES-C-132’, for sour services refer to specification ‘EES-C-133’ and for
tubesheets where welded tube joints are required, refer to specification ‘EES-E-120 Shell
and Tube Heat Exchangers’.

8.4.2 Carbon Molybdenum Steels

The use of carbon molybdenum steel is not permitted.

8.4.3 Chromium Molybdenum Steels

(i) The maximum allowable Ultimate Tensile Strength for heavy gauge normalized and
tempered or quenched and tempered plate and forgings is 690 Mpa (100,000 psi).

(ii) Carbon content shall not exceed 0.15%.

(iii) Aluminizing or Alonizing shall not be used for scaling protection on pressure
containing parts without Owner approval. Industry experience is that the protection
afforded is not worth the increased inspection problems caused by the coatings.

(iv) Pressure-containing chromium molybdenum low alloy steels (maximum of 3%


chromium), excluding piping, furnace and heat exchanger tubes, shall have chemistry
restricted to resist temper embrittlement for services at temperatures above 340°C
(644°F). Plate and forgings shall comply with X and J factors given below. The
restrictions on X factors also apply to weld deposits on reactors, pressure vessels and
heat exchangers, but not strength weld tube/tube sheet joints.

X factor = 10P + 5Sb + 4Sn + As = 15 max


100

Where the concentration of each element is given in ppm


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J factor = (Si + Mn) (P + Sn) 10 4 = 100 max

Where the concentration of each element is given as a percentage

Tests for shift of transition temperature after step cooling are required unless
otherwise specified by Owner.

(v) Owner’s approval is required before the T91 or F91 grades of 9Cr-1Mo steels may be
specified. Shop fabrication of T91 and F91 materials by experienced fabricators is
generally acceptable, however field repairs and welding are much more difficult and
can easily result in excessively hard welds due to the high temper resistance of these
materials.

8.4.4 Nickel Low Alloyed Carbon Steel

The use of 3½Ni Low alloyed Steel shall be limited to maximum operating temperature of
340oC (644oF) and to a minimum operating temperature of -73 oC (-150oF). Impact testing at
the Minimum design temperature or -73oC (-150 oF) (whichever is the lowest) is required for
base material, and welding procedure qualifications (including weld metal and heat affected
zone).

The use of 9Ni Low alloyed Steel shall be limited to maximum operating temperature of
340oC (644oF) and to a minimum operating temperature of -196 oC (-320oF). Impact testing at
the Minimum design temperature or -196 oC (-320oF) (whichever is the lowest) is required for
base material, and welding procedure qualifications (including weld metal and heat affected
zone).

For the 9Ni alloyed steel chemistry restriction shall apply: carbon content to 0.10% max,
silicon content to 0.30% max, phosphorus content to 0.002% max and Sulphur content to
0.005% max.

The 3½Ni and 9Ni Low Alloyed Steels shall not be used in Sour Services without
Owner’s Approval.

8.4.5 Ferritic Chromium Stainless Steel

The use of 12Cr or higher ferritic Cr steels for pressure parts is not permitted as they suffer
temper and/or sigma phase embrittlement, and better alternative materials are available.

The above limitation does not apply to the 12Cr 4Ni ½Mo casting alloys, such as ASTM A743
Grade CA-6NM. Unless otherwise specified by the Owner these materials shall be specified
to comply with NACE MR 0175 - Sulphide Stress Cracking Resistant Materials For Oilfield
Service. In order to meet the hardness limits specified in NACE MR0175 the following
chemistry restrictions shall apply: carbon content to 0.03% max and silicon content to 0.5%
max. Unless this chemistry is met even double tempering may fail to produce hardnesses of
HRC 23.
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These chemistry restrictions may only be waived if the service is specified as non-sour and
Owner agrees that hardnesses of up to 300 HB can be tolerated.

8.4.6 Austenitic Stainless Steels

(i) Use of solid austenitic stainless steel shall be kept to a minimum. Because of these
steels susceptibility to attack by minute quantities of aqueous chlorides or sulfur
compounds, particularly during shutdowns and upset conditions, selection of this steel
shall be carefully considered.

(ii) Where the use of austenitic stainless steels is required, clad or weld deposit lined
equipment shall be specified wherever this is possible, rather than using this steel for
pressure containment.

(iii) When austenitic stainless steels are required, the appropriate grades shall be selected
as follows:

(a) Chemically stabilized or low carbon grades of stainless steel shall generally
be specified wherever welding of the stainless steel is required, either during
fabrication or during the life of the equipment. An exception to this
requirement is the use of 304H for FCCU regenerator internals.

(b) Where operating temperatures are sufficiently high to induce risk of in-service
sensitization and the possibility of polythionic acid attack is present during
shut-downs, only the chemically stabilized, titanium or niobium (columbium)
grades shall be used. They shall be supplied in the solution annealed and
stabilization heat-treated condition. The temperatures and times for these heat
treatments are given below in Table 1. The requirement for subsequent
stabilize heat treatment of the welds after fabrication shall be agreed with the
Owner. This applies for both the normal carbon and the high carbon grades.

(c) The low carbon grades of stainless steel shall not be specified for
temperatures above 427°C (800°F) because of sensitization and high
temperature strength limitations.

(iv) Where naphthenic acid corrosion is anticipated, a stabilized or low carbon grade of
molybdenum-bearing austenitic stainless steel shall be used. The steel shall contain a
minimum of 2.2% Mo. (4.2 vii)

(v) All austenitic stainless steel castings and weld metal shall have a delta ferrite content
of 5-14 FN, as determined either by calculation using the modified NACE 1993
DeLong diagram, or measurement using an Owner-approved procedure. Any ferrite
checks should be performed prior to carrying out any heat treatment.
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(vi) Proper consideration and care should be taken when selecting austenitic stainless
steels in environments known to cause either chloride and/or polythionic acid stress
corrosion cracking. Generally, it is advisable to avoid using austenitic stainless steels
where aqueous conditions exist. Special shutdown procedures such as
ammonia/nitrogen blanketing soda ash solution washing help to minimize cracking
problems.

(vii) Care shall be taken to ensure that austenitic stainless steels do not come into contact
with lead, cadmium, zinc, aluminum, copper, tin or other low-melting metals that
promote cracking. Paints containing these metals shall not be used on austenitic
stainless steel. Design shall be such as to avoid contamination of austenitic stainless
steels by such metals during a fire. Note that plated fasteners and gaskets are common
causes of such contamination.

(viii) When austenitic stainless steels are specified, they shall be supplied in the solution
annealed and thermally stabilized condition unless otherwise agreed by the Owner.
Solution annealing temperatures and stabilize heat-treatments where required shall be
per the appropriate materials specification except where shown below in Table 1.

TABLE 1 Heat Treatment Temperatures

Grade Solution Anneal Stabilise Heat-Treatment (*)


SS304H 1065°C+/- 15°C (1950°F +/- 25°F) Not Applicable

SS321 1065°C+/- 15°C (1950°F +/- 25°F) 885°C +/- 15°C (1625°F +/- 25°F)

SS347 1065°C+/- 15°C (1950°F +/- 25°F) 885°C +/- 15°C (1625°F +/- 25°F)

SS321H 1150°C+/- 15°C (1950°F +/- 25°F) 885°C +/- 15°C (1625°F +/- 25°F)

SS347H 1150°C+/- 15°C (1950°F +/- 25°F) 885°C +/- 15°C (1625°F +/- 25°F)

*All stabilization heat-treatments shall be for a minimum of two hours.


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8.5 Cast Iron Pressure-Containing Parts


(i) Cast iron pressure-containing parts shall not be used in process service, but may be
used in fresh cooling water service for heat exchanger equipment channel sections and
covers.

(ii) Ductile or malleable iron shall be used only with the Owner’s written approval.

8.6 Non-Ferrous Metals


Acceptable non-ferrous metals and their specifications are shown on drawing ‘SD-A-23191’.

9.0 MATERIALS REQUIREMENTS - SPECIFIC


9.1 Pressure Vessels and Heat Exchangers (except bundles)
9.1.1 Cladding and Lining

(i) The alloy material of vessel shells and heads required for corrosion resistance shall be
provided as alloy cladding or weld overlay. The backing material of clad plate or the
weld overlay shall be suitably resistant to the other conditions or modes of
deterioration of the intended service such as high temperature hydrogen attack.

(ii) Materials shall be selected in accordance with specification ‘EES-C-134 Clad Carbon
and Low Alloy Steel Pressure Vessels and Heat Exchangers’.

(iii) Heat treatment of austenitic stainless steel clad or deposit-lined equipment shall be
appropriate for the backing steel. However, the heat treatment shall be selected so as
to minimize sensitization effects on the stainless steel.

9.1.2 Thick Wall Shells

(i) Carbon steel equipment with a wall thickness greater than 50 mm (2 in) is covered by
specification ‘EES-C-131 Thick Wall Pressure Vessels and Heat Exchangers’.

(ii) The Contractor shall in conjunction with the Owner develop a special Project
Specification for low alloy equipment with a wall thickness greater than 37 mm
(1½ in).

9.1.3 Atmospheric Columns in Sour Crude Service

Unless otherwise specified by the Owner Monel 400 shall be specified for corrosion
protection for the top head and column shell to below the top two trays. The top two trays and
the tray supports shall also be Monel 400.

Note: the use of Monel 400 is limited to 204 0C (4000F) (max) due to sulphiding.
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Rev-1 Oct-14

9.1.4 Bolting and Gasket Materials

Bolting and gasketing for pressure vessels and for shell and tube heat exchangers shall be in
accordance with drawing ‘SD-E-10286 Flange, Bolting and Gasket Requirements for TEMA
‘R’ Heat Exchangers and Unfired Pressure Vessels’.

9.2 Heat Exchanger Tubing


9.2.1 General

(i) General requirements for materials for heat exchanger tube bundles are included in
‘EES-E-120’. The requirements listed below amplify, or are additional to, the
‘EES-E-120’ requirements.

(ii) Materials for heat exchanger tubes and tubesheets shall be selected for resistance to
both shell and tubeside fluids. Allowances for corrosion shall be made on both sides
of single tubesheets.

(iii) Owner requirements for standard tube gauges are given in ‘EES-E-120’.

9.2.2 Water-Cooled Services

For water-cooled heat exchange equipment, the following considerations apply:

(i) For fresh water service tubes shall normally be Aluminum Brass or Admiralty Brass,
the tubesheets shall be either naval brass or Aluminum Brass. For seawater service
Aluminum Brass tubes with either Aluminum Brass or Aluminum Bronze tubesheets
shall be the minimum requirement. Requirements for Aluminum Bronze castings are
covered by specification ‘EES-E-125 Aluminum Bronze Castings for Water Service’.

(ii) Subject to Owner’s approval, seamless carbon steel tubes may be considered in
freshwater service where the water is not considered corrosive and a water
recirculation system is used. The use of carbon steel tubes in cooling water service
requires specific Owner’s approval.

(iii) Where corrosion of copper base alloys by sulfides in the hydrocarbon stream would
be excessive, consideration shall be given to either providing a greater corrosion
allowance than standard, or to the use of materials such as titanium, super-stainless
steels or nickel-based alloys (e.g., Monel, Incoloy 801).

(iv) Subject to Owner’s approval ASTM B338 titanium tubes may be specified for severe
service conditions in heat exchangers, aircoolers or condensers such as seawater.
Where permitted, the grade of Titanium shall be selected using Table 2.
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TABLE 2 Material Grade Selections for Titanium Tubes

Grade 2 Shall not be specified for process operating streams above 120°C (250°F).
Grade 12 May be used for process operating temperatures between 120°C and 177°C (250°F and 350°F).
Grade 7 Shall be considered for process operating temperatures above 177°C (350°F).
Notes:
1. Welded titanium tubes are acceptable from a materials selection point of view (see Note 3 below), provided that
they are heat-treated. Joints of Grade 2 tubes in solid or clad titanium tubesheets shall be strength welded when
process stream operating temperature is above 93°C (200°F).

2. For titanium tubed bundles, solid titanium tubesheets are preferred. Monel is also acceptable. Copper alloys are not
allowed for tubesheets, except for 70Cu 30Ni and 90Cu-10Ni because potential tube-roll leakage problems due to
the low tensile strength of the copper alloys.

3. Selection of titanium tube bundles shall take account of the special design considerations for baffle spacing to
prevent resonant flow-induced vibrations.

Note: Table 2 is based upon expected resistance to chloride crevice corrosion.

9.3 Air-Coolers

Material selection for air-coolers shall be in accordance with the following considerations and
requirements:

(i) General requirements for materials for air-coolers are included in ‘EES-E-130 Air-
Cooled Heat Exchangers’.

(ii) Owner’s requirements for standard tube gauges are given in ‘EES-E-130’.
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9.4 Fired Heaters


9.4.1 Acceptable ASTM Material Specifications

Owner’s requirements for the materials selection for pressure-containing elements of process
fired heaters (including steam-generating coils) are given in ‘EES-F-210 Material
Specifications for Fired Heaters, Boilers Tubes and Fittings’.

9.4.2 Furnace Tubes

Material for furnace tubes shall be selected in accordance with the following considerations:

(i) Corrosion rates in excess of 0.25mmpy (0.01ipy) are normally not acceptable.

The temperature to be used to determine corrosion rates shall be the calculated inside
tube wall temperature giving the maximum corrosion rate for the design zone under
normal operating conditions. Special consideration may be required to minimize
scaling upstream of fixed bed reactors, so as to minimize pressure drop.

(ii) Owner’s requirements for furnace tube corrosion allowances are given in EDS-F-1
Fired Heaters’.

(iii) Material selected for furnace tubes, and other parts of heater coils exposed to firebox
conditions, shall be such that free scaling temperatures will not be reached in normal
operation. Maximum tube wall temperatures shall be as shown in Table 3.

TABLE 3 Maximum Skin Temperatures

Material Maximum Tubewall Temperature

During Normal Operation During Thermal Decoking


°C °F °C °F
Carbon Steel 538 1000 677 1250
1 ¼ Cr 1/2Mo Steel 593 1100 732 1350
2 ¼ Cr 1Mo Steel 621 1150 732 1350
5 Cr 1/2Mo Steel 649 1200 732 1350
7 Cr 1/2Mo Steel 649 1200 732 1350
9 Cr 1Mo Steel 677 1250 732 1350
18 Cr 8 Ni Steel 816 1500 816 1500
25 Cr 8Ni Steel 1066 1950 - -
Incoloy 801 1066 1950 - -

(iv) The minimum metallurgy for extended surface fins on all furnace tubes shall be 11Cr
steel. The recommended metallurgy for studs is given in ‘EES-F-120 Fired Heaters’.

(v) Only seamless tubes and pipe are acceptable.


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(vi) Where centricast heater tubes are to be used, the tube supplier and material shall be
approved by the Owner. All buttwelds shall use TIG or MIG process.

(vii) Material for headers and return bends, shall be wrought, seamless and be of a
composition and have physical and mechanical properties matching those of the tubes
to which they will be connected, and be of weldable quality.

If cast alloys steel or cast stainless steel parts are required, the Owner shall approve
the Vendor of such parts. If any cast fittings require radiographic inspection, the
Owner shall agree to the extent of radiography.

9.4.3 Tube Supports and Hangers

(i) Tube supports or tube hangers exposed to direct radiation shall normally be of 25Cr
20Ni alloy steel equivalent to ASTM A351 Grade HK40. Cast Iron to A319 Class III
Type C may be used if temperatures are below 538°C (1000°F).

(ii) If the fuel oil to be burned will contain over 50ppm vanadium or 100ppm total
vanadium and sodium, furnace tube supports shall be columbium stabilized 50Cr 50Ni
alloy (INCO IN-657 or equal).

9.4.4 Flue Gas Sampling

Furnace flue gas sampling draught gauge connections and steam sampling lines, valves and
fittings shall as a minimum be stabilized austenitic stainless steel TP 321 or 347. Incoloy 801
shall be used for water sampling lines, valves and fittings.

9.5 Centrifugal Pumps


Materials for centrifugal pump parts shall be in accordance with drawings ‘SD-G-99876
Material Selection for Centrifugal Pumps’ and ‘SD-G-99877 Material Classes for Pump
Service’. Cast iron and ductile iron are not permitted in flammable services.

9.6 Deaerators
(i) Deaerators shall be postweld heat treated to avoid the possibility of corrosion fatigue
in highly stressed areas.

(ii) For the same reason, internal attachments to the shell shall be minimized.

(iii) All internal and external attachment welds, and all seam and nozzle welds shall be
blend ground to a suitable contour. Refer to ‘SD-C-99664 Weld Blending for Sour
Service Pressure Vessels’ for details.
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9.7 Tanks
General requirements for materials for tanks are included in specification ‘EES-D-110
Storage Tanks to API 650’.

9.8 Piping
Material selection for piping and fittings shall take into accounts the following
considerations and requirements.

(i) For brackish water either bronze or SS type 316 trim shall be used, 12 Cr is not an
acceptable trim in this service.

(ii) TP 316 or Stellite No 6 trim valves shall be used in corrosive chloride bearing
process streams.

(iii) The use of electric resistance welded piping is subject to the Owner’s approval. Its
use is not permitted in the following services:

(a) Hydrocarbon or hazardous service under any circumstances

(b) Firewater service, whether fresh water or seawater

(c) Underground piping

OWNER’S APPROVAL CHECKLIST


1.0(i) 8.1 8.5 Table 3 notes
2.1(iv) 8.4.3(iii) 8.6(ii) 9.4.2(vi)
2.2(iii) 8.4.3(v) 9.1.2(ii) 9.4.2(vii)
2.3(ii) 8.4.5(iv) 9.1.3(iii) 9.8(iii)
4.2(v) 8.4.5(v) 9.2.2(ii)
4.2(vi) 8.4.5(viii) 9.2.2.(iv)
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LIST OF REFERENCES
EDS-A-6 Design Philosophy
EDS-E-1 Heat Exchange Equipment
EDS-F-1 Fired Heaters

EES-C-131 Thick Wall Pressure Vessels and Heat Exchangers


EES-C-132 CS Pressure Vessels and Heat Exchangers for Low Temperature
Operation
EES-C-133 CS Pressure Vessels and Heat Exchangers in Sour Services
EES-C-134 Clad Carbon and Low Alloy Steel Pressure Vessels and Heat
Exchangers
EES-B-910 General Welding Requirements
EES-D-110 Storage Tanks to API 650
EES-E-120 Shell and Tube Heat Exchangers
EES-E-125 Aluminum Bronze Castings for Water Service
EES-E-130 Air-cooled Heat Exchangers
EES-F-120 Fired Heaters
EES-F-211 Material Specifications for Fired Heaters, Boiler Tubes and Fittings

SF-A-612 Material Selection Basis

SD-E-10286 Flange, Bolting and Gasket Requirements for TEMA ‘R’ Heat
Exchangers and Unfired Pressure Vessels
SD-A-23157 Acceptable Steels for Pressure Vessels
SD-A-23188 Heat Treatment Requirements
SD-A-23190 Temperature/Concentration Limits for Caustic Service
SD-A-23191 Acceptable Non-ferrous Metals for Heat Exchanger Components
SD-C-99664 Weld Blending for Sour Service Pressure Vessel
SD-G-99876 Material Selection for Centrifugal Pumps
SD-G-99877 Material Classes for Pump Service

API 941 Steels for Hydrogen Service at Elevated Temperatures and Pressures
in Petroleum Refineries and Petrochemical Plants

API 939-C Guidelines for Avoiding Sulfidation (Sulfidic) Corrosion Failures in


Oil Refineries

ASME Boiler and Pressure Vessel Code: Section-1 Power Boilers


Section IIA Ferrous Materials
Section VIII Pressure Vessels
(Division I)

ASTM A578 Specification for Straight-Beam Ultrasonic Examination of plain


and Cla d Steel Plates for Special Applications

NACE MR 0175 Sulphide Stress Cracking Resistant-Metalic Materials for Oilfield


Equipment.
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APPENDIX I – AVERAGE CORROSION RATES FOR HIGH TEMPERATURES SULPHUR


CORROSION IN A HYDROGEN FREE ENVIRONMENT

FIGURE 1 Average Corrosion Rates High Temperature Sulphur Corrosion Hydrogen-free


Environment
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APPENDIX II – CORROSION RATES FOR HYDROGEN/HYDROGEN SULFIDE


MIXTURES (Curves have been extracted from API 939-C)
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