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GP 36-15
Applicability Group
Date 6 December 2007
GP 36-15
Group Practice
BP GROUP
ENGINEERING TECHNICAL PRACTICES
6 December 2007 GP 36-15
Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
Foreword
This is the first issue of Engineering Technical Practice (ETP) BP Group Practice
GP 36-15.
Copyright 2007, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organisation. None of the information
contained in this document shall be disclosed outside the recipient’s own organisation
without the prior written permission of Director of Engineering, BP Group, unless the
terms of such agreement or contract expressly allow.
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6 December 2007 GP 36-15
Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
Table of Contents
Page
1. Scope...................................................................................................................................... 5
2. Normative references.............................................................................................................. 5
3. Terms and definitions............................................................................................................... 7
4. Symbols and abbreviations......................................................................................................8
5. Materials selection philosophy.................................................................................................9
6. Principles of materials selection.............................................................................................12
6.1. Materials selection for process side environment.......................................................12
6.2. Materials selection for external environment..............................................................17
6.3. Materials selection to avoid galvanic corrosion...........................................................18
6.4. Materials selection to avoid fatigue and corrosion fatigue..........................................19
7. Applications of corrosion resistant alloys...............................................................................19
7.1. General...................................................................................................................... 19
7.2. Ferritic stainless steels...............................................................................................19
7.3. Austenitic stainless steel............................................................................................19
7.4. Precipitation hardening stainless steel.......................................................................20
7.5. Duplex stainless steel.................................................................................................20
7.6. Nickel-copper alloys...................................................................................................21
7.7. Copper based alloys...................................................................................................21
7.8. Aluminium based alloys..............................................................................................21
7.9. Titanium based alloys.................................................................................................21
7.10. Cladding..................................................................................................................... 22
8. Pressure vessels................................................................................................................... 23
8.1. General...................................................................................................................... 23
8.2. Materials options........................................................................................................23
9. Piping systems...................................................................................................................... 26
9.1. General...................................................................................................................... 26
9.2. Production flowlines and manifolds............................................................................26
9.3. Wet gas piping............................................................................................................ 27
9.4. Flare tips.................................................................................................................... 27
9.5. Glycol unit piping........................................................................................................27
9.6. Amine unit piping........................................................................................................28
9.7. Raw seawater piping..................................................................................................28
9.8. Treated water piping...................................................................................................29
10. Heat exchangers................................................................................................................... 29
10.1. General...................................................................................................................... 29
10.2. Materials options........................................................................................................29
11. Valves.................................................................................................................................... 31
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
11.1. General...................................................................................................................... 31
11.2. Materials options........................................................................................................31
12. Instrument impulse and chemical injection tubing..................................................................33
12.1. General...................................................................................................................... 33
12.2. Materials options........................................................................................................33
13. Rotating machinery................................................................................................................34
13.1. General...................................................................................................................... 34
13.2. Materials options........................................................................................................34
14. Fired heaters......................................................................................................................... 34
14.1. General...................................................................................................................... 34
14.2. Materials options........................................................................................................35
Bibliography................................................................................................................................... 36
List of Tables
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6 December 2007 GP 36-15
Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
1. Scope
2. Normative references
The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. For dated references, subsequent
amendments to, or revisions of, any of these publications do not apply. However, parties to
agreements based on this technical practice are encouraged to investigate the possibility of
applying the most recent editions of the normative documents indicated below. For undated
references, the latest edition of the normative document referred to applies.
BP
BPOUS RP 13-1-1 Crude Units
GIS 18-011 Welded Fabrication and Construction
GIS 18-013 Integral Cladding, Weld Overlay, and Limited Loose Lining of
Pressure Vessels and Components
GIS 22-101 Group PracticeMaterials Selection for Surface (Topsides)
Equipment in Oil and Gas Production Facilities
GIS 22-201 API 537 Flare Details
GIS 26-101 ISO 16812 Shell and Tube Exchangers (API 660)
GIS 26-103 ISO 13706 Air Cooled Heat Exchangers (API 661)
GIS 36-107 Materials Selection for Surface (Topsides) Equipment in Oil and
Gas Production Facilities
GIS 43-316 Manufacture of CRA Clad or Lined Steel Pipe.
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
ASTM A182 Standard Specification for Forged or Rolled Alloy and Stainless
Steel Pipe Flanges, Forged Fittings, and Valves and Parts for
High-Temperature Service.
ASTM A216 Steel Castings, Carbon, Suitable for Fusion Welding, for High
Temperature Service
ASTM A 217 Steel Castings, Martensitic Stainless and Alloy, for Pressure-
Containing Parts, Suitable for High Temperature Service
ASTM A265 Standard Specification for Nickel and Nickel-Base Alloy-Clad Steel
Plate.
ASTM A350 Standard Specification for Carbon and Low-Alloy Steel Forgings,
Requiring Notch Toughness Testing for Piping Components.
ASTM A 351 Castings, Austenitic, Austenitic-Ferritic (Duplex), for Pressure-
Containing Parts
ASTM A352 Standard Specification for Steel Castings, Ferritic and Martensitic
for Pressure-Containing Parts Suitable for Low Temperature
Service
ASTM A 395 Ferritic Ductile Iron Pressure-Retaining Castings for Use at
Elevated Temperatures
ASTM A 494 Castings, Nickel and Nickel Alloy
ASTM A 744 Castings, Iron-Chromium-Nickel, Corrosion Resistant, for Severe
Service
ASTM A 890 Castings, Iron-Chromium-Nickel-Molybdenum, Corrosion
Resistant, Duplex (Austenitic/Ferritic) for General Application
ASTM B 164 Nickel-Copper Alloy Rod, Bar, and Wire
ASTM B 348 Titanium and Titanium Alloy Bars and Billets
NACE International
NACE MR0175 Petroleum and natural gas industries - Materials for use in H2S-
containing environments in oil and gas production.
Norsk Sokkels Konkuranseposisjon (NORSOK) Norwegian standards
association
NORSOK M-630 Materials Data Sheets for Piping
NORSOK M-001 Materials Selection
For the purposes of this GP, the following terms and definitions apply:
BP approval
Approval by the relevant BP Engineering or Technical Authority
Carbon steel
Weldable grades of carbon manganese steels suitable for pressure systems equipment.
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
Cladding
Metallurgically bonded corrosion resistant layer (e.g. as applied by roll bonding or fusion
welding).
Coating
A material applied as a layer onto a substrate to provide corrosion protection.
Lining
Non-metallurgically bonded corrosion resistant layer.
Obturator
Part of the valve positioned in the flow stream to permit or block flow i.e. gate or ball.
Equipment that comprises the main pressure-containing envelope, i.e. where failure would
result in an uncontrolled loss of containment to the atmosphere.
PREw
Pitting resistance equivalent number (PREw = %Cr + 3.3 (%Mo + 0.5 %W) + 16 x %N).
For the purpose of this GP, the following symbols and abbreviations apply:
CE Carbon equivalent
CA Corrosion allowance
CP Cathodic protection
EA Engineering authority
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
GP Group practice
SS Stainless steel
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
CO2 -content
H2S-content
Hg-content
Content of oxygen and other oxidising agents
Design and operating temperature and pressure
pH including effects of organic acids
Chloride/halide ion concentration
Velocity, flow regime
Sand or other solids production
Micro-biological activity
Condensing conditions
Transient conditions e.g. shut-down and start-up
A gas is normally considered ‘dry’ (i.e. no risk of free water) when the water
dew point at the actual pressure is at least 10 °C lower than the actual
operation temperature for the system. Materials for stagnant gas
containment need particular attention.
2. Approach to materials selection.
3. Application of national and international materials specifications.
4. Compliance with regulations.
5. Requirements for materials and welding qualification testing.
6. Application of relevant GIS documents.
Project materials selection philosophy is normally developed during select
and/or define stages.
b. Construction materials for surface equipment shall be selected and specified to
provide required levels of operational integrity, taking account of the following:
1. Material availability in appropriate product forms
2. Operations and maintenance strategy.
3. Weldability
4. Inspectability
5. Project cost and schedule requirements.
6. Complexity and novelty of equipment manufacture and fabrication.
7. Internal and external in-service damage mechanisms for normal and transient
conditions, including:
a) Corrosion (general and localised).
b) Environmentally assisted cracking.
c) Brittle fracture.
d) Erosion.
e) Fatigue and corrosion fatigue.
f) Hydrogen embrittlement.
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
Due to the large number of variables, only general guidance can be provided
and specialist advice should be sought.
b. Where sufficient data on the resistance of candidate materials to these forms of
attack is not available, laboratory-based qualification corrosion testing shall be
undertaken.
c. If doubts exist about suitability of highly-alloyed austenitic or duplex stainless steel,
consideration shall be given to more chloride SCC resistant materials, such as
Alloy 825 or carbon steel internally clad with Alloy 825 / 625.
Nickel based alloys may be considered highly resistant to chloride ion SCC
in surface facility (topsides) equipment. The advice of materials/corrosion
specialists should be sought for the most appropriate materials selection.
6.1.4. Erosion
a. Internal erosion rates in surface equipment and implications for materials selection
shall be evaluated in accordance with GP 06-14 and GN 06-001.
6.1.5. Chemicals
a. Surface system materials selection shall consider the range of expected chemical
treatments, including understanding of how required chemicals will interact with all
materials they contact (metals and elastomers) and how they will behave with one
another if mixed.
Carbon steel can typically be specified for non-corrosive chemicals such as
methanol. Potentially corrosive chemicals such as concentrated solutions of
corrosion and scale inhibitors normally require suitable CRAs as specified by
the vendors.
For non-metallic materials, requirements for testing of compatibility of
elastomers and plastics with production chemicals are described in GN 36-
007.
b. Titanium alloys shall not be specified where contact with methanol (<5% water)
could occur.
c. For amine duties refer GP 36-12.
d. Glycol systems using ethylene glycol (EG), monoethylene glycol (MEG) or
triethylene glycol (TEG) to remove water vapour from hydrocarbon gas streams
should be specified in carbon steels except for the hot sections of glycol
regeneration which may be CRAs.
Rich solutions contain absorbed water while lean solutions contain
essentially no water. Acid gas components present in the hydrocarbon
vapour are absorbed by the dehydration glycol along with water vapour.
Carbon steel is the common material used for equipment handling both lean
and rich glycol with the possible exception of the hot sections of the glycol
regeneration equipment. If CRA materials are required upstream of the
glycol contactor, then use CRA materials for the vapour wetted sections of
the glycol regeneration equipment (for example the vapour space of the
reboiler, the still column and the overhead piping). Assess the need for the
rich glycol piping and glycol regeneration equipment to be suitable for sour
service.
e. Hypochlorite systems shall be specified in titanium or GRP.
f. Compatibility of non-metallic materials with particular chemicals shall be
demonstrated as required and in accordance with GN 36-007.
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
dissolved CO2 and possibly H2S) either alone or co-mingled with treated
seawater, with the consequent requirement for corrosion management.
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
7.1. General
a. Typical examples of corrosion resistant alloys for pressure boundary equipment
are included in Table 1. The selection of CRAs for fasteners, valve stems and
instrument tubing are not included in Table 1.
There is often a requirement for fasteners, valve stems and instrument tubing
to be made from different, usually more corrosion resistant materials than the
parent equipment.
b. Copper alloys shall not be used in flammable or otherwise hazardous service.
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
The limits for duplex stainless steel were largely developed for downhole
tubing grades. For applications involving welding, further qualification for the
field-specific conditions is recommended.
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
7.10. Cladding
a. CRA clad plate shall comply with GIS 18-013.
Clad plate should also be purchased to meet a suitable ASTM specification
such as ASTM A264 (austenitic and duplex stainless steel clad plate), ASTM
A265 (nickel alloy clad plate) or ASTM B898 (titanium alloy clad plate).
b. CRA clad pipe shall comply with GIS 43-316. Supplementary requirements for
induction bending shall be subject to BP approval.
c. Options for clad pipe produced by internal weld overlay techniques may be
proposed for acceptance by BP (see GN 18-003).
d. Mechanically lined pipe shall not be specified.
e. Internal CRA linings and claddings for pressure vessels shall comply with GIS 36-
107.
Table 1 – Typical corrosion resistant alloys for pressure boundary applications
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
8. Pressure vessels
8.1. General
a. Materials for pressure vessels, heat exchanger shells designed to pressure vessel
codes (including external bolting) shall be selected and specified in accordance
with GIS 46-010.
b. Materials for internal bolting shall be selected to be compatible with the corrosivity
of the process fluids.
Internal fasteners are often manufactured from a more corrosion resistant
material than parent equipment to reduce the possibility of their failure in
service.
c. Acceptable materials for corrosive oil and gas production duties are detailed in 8.2.
Alternatives to these materials may be proposed for review by BP.
d. Materials selection for topping unit vessels shall follow the guidance for refinery
crude units in BPOUS RP 13-1-1.
Topping units are small distillation units installed on remote sites or pipeline
locations taking a diesel cut to provide fuel.
http://technical_practices.bpweb.bp.com/ousrp/rps/rp13/1311.pdf
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
(demister, trays, fastening, and internal piping etc.) Alloy 400 and type 304L
stainless steel should not be specified. The structured packing should be non-
metallic, e.g. polypropylene.
b. Identical considerations apply to vacuum deaeration towers.
9. Piping systems
9.1. General
a. Materials, including external bolting, shall be selected and specified in accordance
with GP 42-10.
Guidance on welding components and pipework is detailed in GIS 42-101
and GIS 42-102.
b. A range of approved piping and piping component specification sheets are
included in GN 36-016. Alternatively, relevant NORSOK M-630 piping materials
data sheets may be proposed for acceptance by BP.
c. Acceptable materials for corrosive oil and gas production duties are detailed in 9.2.
Alternatives to these materials may be proposed for review by BP.
d. GN 42-002 provides guidance on gasket selection.
e. Coating of piping shall be carried out in accordance with GP 06-60 and GIS 06-
601.
f. Materials selection for topping unit piping shall follow the guidance for refinery
crude units in BPOUS RP 13-1-1.
http://technical_practices.bpweb.bp.com/ousrp/rps/rp13/1311.pdf
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6 December 2007 GP 36-15
Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
9.2.1. Flowlines
a. Production flowlines may be in potentially corrosive and erosive duty due to
handling raw well fluids. They may be in HP/HT duty and may experience
vibration, highly turbulent flow conditions, low temperatures downstream of the
choke and contact with well treatment fluids. Their relatively small diameter usually
precludes use of internal clad or coated / lined constructions. Options which may
be proposed for acceptance by BP are listed below. Other options, including
martensitic stainless steels for non-sour duties, may also be proposed, though
their limited availability in all required product forms and their fabrication
complexity does not often make them first choice. Specific design features for
erosion control may be required, e.g. long radius bends, target tees.
1. Impact tested carbon and low alloy steels.
This option may be considered for relatively benign fluid conditions that are
inhibited at the wellhead or downhole, and where routine inspection and
monitoring is feasible and cost effective. Adequate corrosion allowance
should be specified for the inhibited predicted corrosion and erosion rates.
Impact tested carbon and low alloy steel grades, suitable for design
temperatures down to -46°C, are specified to cater for possible auto-
refrigeration conditions.
2. Austenitic stainless steels.
316L type stainless steel may be considered for pipework from the wellhead
to the separator when no H2S is present.
3. Duplex and super duplex stainless steels.
These options will generally be preferred for moderately corrosive
applications, typically with CO2 and chlorides, but only mildly sour. Super
duplex grades should only be specified when 22%Cr grades cannot be
used, e.g. due to lower H2S limits for 22%Cr grades.
4. Alloy 825.
This option should be considered for highly corrosive and sour well streams.
In some cases highly-alloyed austenitic stainless steels may be appropriate
lower cost alternatives but may require qualification, and the availability of all
required product forms may be problematic. The advice of
materials/corrosion specialists should be sought.
9.2.2. Manifolds
a. Similar considerations and options to 9.2.1 apply to production manifolds except
that their greater size may additionally allow internally CRA-clad options for the
most severe duties, e.g. carbon steel internally clad with Alloy 825.
Effective corrosion inhibition of carbon steel manifolds may be difficult to
achieve and should be avoided.
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6 December 2007 GP 36-15
Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
1. 316L stainless steel for lower pressure gas streams and where chloride
carryover should not occur (maximum 50ppm chlorides).
2. Duplex and super duplex stainless steel for mildly sour duties with chlorides,
and for higher pressures.
3. Highly-alloyed austenitics or Alloy 825 for more severe sour service with CO2
and chlorides.
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
that internal corrosion products will not compromise safety critical protective
systems.
c. 90-10 cupro-nickel is suitable provided its susceptibility to internal erosion at
stream velocities exceeding about 3.5m/s is accounted for in design.
The alloy has excellent resistance to bio-fouling and crevice corrosion, but
suffers corrosion in sulphide-polluted waters. Excessive chlorination will
adversely affect performance.
d. Alloy 400 is suitable for many seawater components but its high cost usually limits
its applications to small diameters / components, and equipment internals, e.g.
valve trim.
e. Super duplex and 6Mo stainless steels (PREw >40), have good resistance to
localised corrosion up to maximum design temperatures of about 30°C in
seawater. Susceptibility to crevice corrosion is usually the limiting factor hence
threaded fittings shall not be used.
Strict welding controls are required for super duplex to minimise loss of
corrosion resistance at the weld zones.
f. For raw seawater with residual chlorine, 25%Cr super duplex (PREw >40) can be
used up to a maximum design temperature of 20°C with 1.0ppm maximum
residual chlorine.
This allows the use of 25%Cr super duplex upstream of the deaerator, if
conditions are within the specified limits. For higher temperatures, resistor
controlled cathodic protection (RCP) of super duplex could be proposed or
more resistant materials, such as titanium, considered.
g. Internal cathodic protection systems for super duplex and 6Mo stainless steels
may be proposed for acceptance by BP.
h. Nickel-chromium-molybdenum alloys may be proposed for higher temperature
applications for acceptance by BP.
10.1. General
a. Selection, design and construction of heat exchangers shall be in accordance with
GP 26-10.
b. Acceptable materials for corrosive oil and gas production duties are detailed in
10.2. Alternatives to these materials may be proposed for review by BP.
c. Similar principles of materials selection shall be applied to other heat exchanger
design types.
d. Materials selection for topping unit exchangers shall follow the guidance for
refinery crude units in BPOUS RP 13-1-1.
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
http://technical_practices.bpweb.bp.com/ousrp/rps/rp13/1311.pdf
Table 2 Typical materials for shell and tube heat exchangers in corrosive duties
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
Table 3 Typical materials for air cooled heat exchangers in corrosive duties
Duty Plates
Table 4 Typical materials for plate and frame exchangers on corrosive duties
11. Valves
11.1. General
a. Metallic and non-metallic materials selection and specification for valves shall
conform with GP 62-01.
b. Acceptable materials options are in 11.2.
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Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities
Material Notes
13% Chromium stainless steel* General non-corrosive and non-erosive service, gases, oil
13% Chromium stainless steel, hard General services, gas, oil and oil vapour.
faced with Stellite, Colmonoy, etc.
Abrasion resistant trim (e.g. tungsten Dirty/abrasive service, including untreated oil and gas production,
carbide, carbide + stellite,) or critical valves where commissioning/ line clearing conditions
are onerous.
316L stainless steel Corrosive service, deaerated water, cryogenic service. Unsuitable
for seawater.
17/4 PH stainless steel* Corrosive service where high strength required. Not to be used
for stems in sour service.
Bronze Cold / hot water, marine applications and low temp. service.
Nickel aluminium bronze Seawater, brine, firewater. Unsuitable for sulphide polluted water.
Duplex stainless steel* Corrosive service.
Super Duplex stainless steel* Seawater, corrosive service.
Nickel alloys Highly corrosive and sour services.
Titanium Sodium hypochlorite, seawater.
Electroless Nickel Plating Used for ball valves on clean service.
* If used for obturator or seats, needs hard facing for dirty/abrasive service.
12.1. General
a. Tubing shall be designed and installed in accordance with GP 30-25.
There is often a requirement for instrument tubing to be made from more
corrosion resistant materials than parent equipment and acceptable
materials options are listed in 12.2.
b. Unless specified otherwise by BP, material selection for valves and fittings shall
follow that for associated tubing.
c. All grades of tubing shall be seamless unless otherwise accepted by BP.
Welded and drawn tube may be subject to derating factors for weld integrity.
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13.1. General
a. Materials requirements for rotating machinery shall comply with the relevant 34-
series ETPs.
b. Casing materials should generally be of equivalent type to the corresponding
piping.
c. Internal components should match casing material class for corrosive duties as far
as practicable, e.g. pump impeller, shaft.
d. Materials for typical corrosive duties are in 13.2.
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14.1. General
a. Materials requirements for fired heaters designed to ISO Materials Selection for
Surface (Topsides) Equipment in Oil and Gas Production Facilities shall comply
with GIS 22-101.
b. Materials requirements for directly fired heaters and incinerators to designs other
than ISO 13705 shall be agreed with BP.
c. Materials for refractory linings shall be selected and specified in accordance with
GP 72-00.
d. Materials selection for topping unit heaters shall follow the guidance for refinery
crude units in BPOUS RP 13-1-1 to take account of potential internal corrosion by
sulphidation and naphthenic acid corrosion.
http://technical_practices.bpweb.bp.com/ousrp/rps/rp13/1311.pdf
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Bibliography
BP
[1] GIS 42-101, Fabrication, Assembly, Erection, and Inspection of Carbon, Carbon Manganese, and
Low Alloy Steel Pipework (ASME B31.3).
[2] GIS 42-102, Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3).
[3] GN 06-009, Dead Leg Internal Corrosion Management Guidelines. Previously GN 32-019.
[6] GP 32-49, In Service Inspection and Testing of Special and Other Equipment.
NACE International
[9] NACE TM0177, Laboratory Testing of Metals for Resistance to Specific Forms of Environmental
Cracking in H2S Environments.
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