GP 36-20 - Materials Selection For Subsea Equipment

Group Practice
GP 36-20
Materials Selection for Subsea Equipment
8 February 2012
Engineering Technical Practice
Engineering
Table of Contents
Page
Foreword ........................................................................................................................................ 5
1 Scope .................................................................................................................................... 6
2 Normative references............................................................................................................. 7
3 Terms and definitions........................................................................................................... 10
4 Symbols and abbreviations .................................................................................................. 11
5 Materials selection philosophy ............................................................................................. 12
6 Principles of materials selection ........................................................................................... 15
6.1 Materials selection for process side environment ...................................................... 15
6.2 Materials selection for external seawater environment.............................................. 19
7 Applications of corrosion resistant alloys and nonmetallic materials..................................... 20
7.1 General..................................................................................................................... 20
7.2 Austenitic stainless steel and nickel alloys ................................................................ 21
7.3 Precipitation hardening stainless steel and nickel alloys ........................................... 23
7.4 Duplex stainless steel ............................................................................................... 23
7.5 Nickel-copper alloys.................................................................................................. 23
7.6 Cladding and linings.................................................................................................. 23
7.7 Nonmetallic materials................................................................................................ 24
8 Wellheads and christmas trees ............................................................................................ 24
8.1 General..................................................................................................................... 24
8.2 Materials options....................................................................................................... 25
9 Piping, fittings, and connectors ............................................................................................ 27
9.1 General requirements ............................................................................................... 27
9.2 Additional requirements for piping............................................................................. 32
9.3 Additional requirements for fittings ............................................................................ 32
9.4 Additional requirements for connectors ..................................................................... 32
9.5 Additional requirements for internal CRA clad constructions ..................................... 32
10 Flowlines, pipelines, and risers ............................................................................................ 33
10.1 Flowlines and pipelines carrying production fluids..................................................... 33
10.2 Flowlines and pipelines carrying other products........................................................ 36
Copyright © 2012 BP International Ltd. All rights reserved.

This document and any data or information generated from its use are classified, as a
minimum, BP Internal. Distribution is intended for BP authorised recipients only. The
information contained in this document is subject to the terms and conditions of the
agreement or contract under which this 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, unless the terms of such agreement or contract
expressly allow, or unless disclosure is required by law.
In the event of a conflict between this document and a relevant law or regulation, the
relevant law or regulation shall be followed. If the document creates a higher obligation, it
shall be followed as long as this also achieves full compliance with the law or regulation.
Page 2 of 58 GP 36-20
8 February 2012
10.3 Production and injection risers .................................................................................. 37

10.4 Carbon steel pipeline flanges.................................................................................... 38
10.5 Polyethylene liners for carbon steel risers and flowlines............................................ 39
10.6 Flowline and riser insulation...................................................................................... 39
11 Manifold and flowline/pipeline valves ................................................................................... 40
11.1 General..................................................................................................................... 40
11.2 Impact properties ...................................................................................................... 41
11.3 Castings.................................................................................................................... 41
11.4 Use of bar stock........................................................................................................ 41
11.5 Erosion and wear resistant materials ........................................................................ 42
11.6 Weld overlaying of duplex stainless steels ................................................................ 43
11.7 Valve internals - metallic ........................................................................................... 43
11.8 Valve internals - nonmetallic ..................................................................................... 44
12 Fasteners............................................................................................................................. 45
12.1 Scope ....................................................................................................................... 45
12.2 Low alloy steels ........................................................................................................ 45
12.3 Corrosion resistant alloys (CRAs) ............................................................................. 46
13 Gaskets ............................................................................................................................... 47
13.1 General..................................................................................................................... 47
13.2 Gaskets for wellheads............................................................................................... 47
13.3 Gaskets for christmas tree assemblies...................................................................... 47
13.4 Ring type joint (RTJ) gaskets and other metallic sealing rings................................... 48
13.5 Nonmetallic seals...................................................................................................... 49
14 Hydraulic control and chemical injection systems ................................................................ 49
14.1 General..................................................................................................................... 49
14.2 Hydraulic control systems ......................................................................................... 49
14.3 Chemical injection systems....................................................................................... 49
14.4 Hydraulic and chemical injection valves .................................................................... 50
15 Umbilicals ............................................................................................................................ 50
15.1 Nonmetallic hose conduits ........................................................................................ 50
15.2 Metallic tube conduits ............................................................................................... 52
Annex A (Normative) Fabrication sequences ................................................................................ 53
Annex B (Normative) BP approval ................................................................................................ 55
Bibliography .................................................................................................................................. 56
List of Tables
Table 1 - Acceptable candidate corrosion resistant alloys for subsea applications ........................ 22
Table 2 - Maximum allowable hardness for stainless steels .......................................................... 22
Table 3 - Charpy V-notch impact energy requirements for high strength precipitation hardening
nickel alloy piping, fittings, and connectors .......................................................................... 23
Table 4 - Design temperature limits for hydraulic control and chemical injection tubing................. 27
Table 5 - Standards for seamless and welded pipe and fittings in carbon and low alloy steel ....... 29
Page 3 of 58 GP 36-20
8 February 2012
Table 6 - Standards for seamless and welded pipe and fittings in stainless steel and nickel alloys30
Table 7 - Standards for forged pressure retaining pipe components ............................................. 30
Table 8 - Charpy V-notch impact energy requirements for carbon and low alloy steel piping, fittings,
and connectors (1) ............................................................................................................... 30
Table 9 - Materials requirements for low alloy steel internally clad components for piping, fittings,
and connectors .................................................................................................................... 34
Table 10 - Typical acceptable materials for manifold and flowline/pipeline valves ......................... 42
List of Figures
Figure A.1 - Option 1: Fabrication of low alloy steel components and valve bodies with C-Mn
buttering layer, welded to C-Mn steel pup piece, with C-Mn butt weld.................................. 53
buttering layer, welded to C-Mn steel pup piece, with alloy 625 butt weld ............................ 54
Page 4 of 58 GP 36-20
8 February 2012
Foreword
This is a revised issue of Engineering Technical Practice (ETP) GP 36-20. This Group Practice (GP)
incorporates the following changes:
• Shared learnings and comments received from the Subsea Community of Practice,
including equipment vendors and contractors.
• References to relevant ETPs published since the first issue.
Changes to this document are indicated by a bar in the left margin.
Page 5 of 58 GP 36-20
8 February 2012
1 Scope
a. This GP provides requirements, recommendations, and possibilities for selection of

materials for construction of oil and gas production equipment that is fully immersed in
seawater and installed at or above seabed, including water, gas, and chemical injection
systems and their associated controls within Upstream entities.
b. The following items are outside the scope of this GP:
1. Drilling equipment, casing hangers, tubing hangers, well tubulars, and downhole
completion equipment installed below the hangers (refer to GP 10-50 and
GN 36-004).
2. Items used only for deployment, retrieval, or maintenance of permanently installed
facilities.
3. Structural items and structural steel fabrications.
Although this GP does not deal with detailed requirements for components and
structures identified in 1, 2, and 3 above it is nevertheless important to ensure
adequate integrity of even temporary equipment that is immersed subsea. In this
respect it is important to ensure fundamental rules concerning materials of
construction for subsea as outlined in this GP and also ISO 21457 are applied.
Particular attention is drawn to the following points:
 Actual yield strength of any steel grade should not exceed 950 MPa (138 ksi)
and the hardness should not exceed 34 HRC or 325 Hv10.
 SMYS for carbon and low alloy steels intended for welded fabrications should
not exceed 560 MPa (81 ksi) unless documentation showing acceptable
properties with respect to weldability, the base material, HAZ, and weld metal is
presented.
 Maximum HAZ hardness for welded steel structures should be 325 Hv10.
4. Surface (topsides) equipment (refer to GP 36-15).
5. Unbonded flexible pipe risers and flowlines (refer to GP 65-75).
6. Flexible pipe.
This GP is not an alternative to involvement of suitably qualified metallurgical,
materials, welding, and corrosion specialists in subsea projects. The complexity of
some issues involved is such that this GP cannot always provide definitive
recommendations. The requirement for expert advice on materials issues will
remain while deriving project specifications and Site Technical Practices (STPs)
from this GP.
Many associated topics that could affect materials performance and equipment
integrity are not addressed in any detail in this document but are covered in other
GPs, including:
 Welding and cladding procedures (refer to category 18 and 42 documents).
 Nondestructive examination requirements.
 Quality assurance/quality control (QA/QC) procedures during component
manufacture (refer to GP 32-17).
 Quality assurance for welded fabrication of process vessels and piping (refer to
GP 18-01 and GIS 18-011).
 Verification and validation testing of assembled equipment (refer to GP 32-17).
 Chemical treatment of hydrotest fluids (refer to GP 06-29).
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8 February 2012
 External coating and cathodic protection designs (refer to category 06

documents).
 Thermal insulation (refer to GN 36-009 and GN 36-010).
 Methods of equipment deployment to avoid seawater ingress.
 Subsea connection procedures to avoid or minimise seawater ingress.
2 Normative references
The following normative documents may, to the extent specified in subsequent clauses and normative
annexes, be required for full compliance with this GP:
• For dated references, only the edition cited applies.

• For undated references, the latest edition of the referenced document (including any
amendments) applies.
BP
GIS 18-011 Welded Fabrication and Construction.
GIS 18-013 Integral Cladding, Weld Overlay, and Limited Loose Lining of Pressure
Vessels and Components.
GIS 18-015 Weld Deposited Overlay of Linepipe, Fittings, and Other Components.
GIS 18-041 Manufacture of Duplex Stainless Steel Fittings and Components.
GIS 42-103 Fabrication, Assembly, Erection, and Inspection of Pipework
(ASME B31.3).
GIS 43-311 Longitudinal or Helical Seam Submerged Arc Welded Linepipe in
Grades up to X80 (API 5L or ISO 3183).
GIS 43-312 High Frequency Induction (HFI) or Electric Resistance Welded (ERW)
Linepipe in Grades up to X70 (API 5L).
GIS 43-313 Seamless Linepipe in Grades up to X80 (API 5L or ISO 3183).
GIS 43-314 13% Chromium Seamless Linepipe (API 5LC).
GIS 43-315 22% and 25% Chromium Duplex Stainless Steel Seamless Linepipe
(API 5LC).
GIS 43-316 Manufacture of CRA Clad or Lined Steel Pipe.
GIS 43-317 Carbon Steel Induction Bends for Pipelines in Grades up to X80
(ISO 15590-1).
GIS 43-318 Carbon Steel Fittings for Pipelines in Grades up to X80 (ISO 15590-2).
GIS 43-319 Carbon Steel Flanges for Pipelines in Grades up to X80 (ISO 15590-3).
GIS 43-352 Subsea Pipeline Valves (EN ISO 14723).
GN 06-001 Erosion Guidelines.
GN 06-010 CO2 Corrosion Prediction Guidelines.
GN 36-001 Requirements for Alloy 718 Equipment.
GN 36-003 Nonmetallic Materials Selection.
GN 36-005 Guideline for avoiding gas decompression damage of elastomer seals.
GN 36-007 Guideline for compatibility testing of non-metallic materials within
subsea chemical delivery systems.
GN 36-009 Specification for Subsea Insulation and Buoyancy Materials.
GN 36-012 Specification for Titanium Risers and Forged Components for Use with
Workover, Top Tensioned, and Catenary Riser Systems: 110 and 135 ksi
SMYS Titanium Forgings.
Page 7 of 58 GP 36-20
8 February 2012
GN 36-016 Piping Materials Data Sheets.

GN 36-020 Guidelines on Avoidance of Hydrogen Embrittlement in Dissimilar Metal
Welds in Subsea Applications.
GN 36-025 Design of Duplex and Superduplex Stainless Steel Subsea Equipment
Exposed to CP: Guidance on the Application of DNV RP F112.
GN 65-706 Dynamic Riser Materials.
GP 06-10 Corrosion Management Systems.
GP 06-14 Erosion Control.
GP 06-29 Corrosion Protection During Hydrotesting.
GP 18-01 Welded Fabrication and Construction.
GP 18-04 Manufacture of Duplex Stainless Steel Fittings and Components
(EEMUA 218).
GP 36-25 Materials for Sour Service in Exploration and Production Operations.
GP 43-31 Linepipe Material Selection and Procurement.
GP 46-01 New Pressure Vessels.
GP 65-73 Design of Steel Catenary Risers (SCRs).
GP 78-19 Design and Operation of Subsea Production Control Umbilicals
(ISO 13628-5).
SRP 5.0-0001 Engineering Management.
American Petroleum Institute (API)

API RP 15S Qualification of Spoolable Reinforced Plastic Line Pipe.
API Spec 5L Line Pipe.
API Spec 6A Wellhead and Christmas Tree Equipment.
API Spec 6A718 Nickel Base Alloy 718 (UNS N07718) for Oil and Gas Drilling and
Production Equipment.
API Spec 17D Subsea Wellhead and Christmas Tree Equipment.
API Spec 17E Subsea Umbilicals.
American Society of Mechanical Engineers (ASME)

ASME B16.34 Valves Flanged, Threaded and Welding End.
American Society for Testing and Materials (ASTM)

ASTM A182 Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings,
and Valves and Parts for High Temperature Service.
ASTM A194 Carbon and Alloy Steel Nuts for Bolts for High Pressure or High
Temperature Service, or Both.
ASTM A265 Nickel and Nickel-Base Alloy-Clad Steel Plate.
ASTM A269 Standard Specification for Seamless and Welded Austenitic Stainless
Steel Tubing for General Service.
ASTM A312 Standard Specification for Seamless and Welded Austenitic Stainless
Steel Pipe.
ASTM A320 Alloy-Steel and Stainless Steel Bolting Materials for Low-Temperature
Service.
ASTM A333 Standard Specification for Seamless and Welded Steel Pipe for Low
Temperature Service.
ASTM A350 Carbon and Low-Alloy Steel Forgings, Requiring Notch Toughness
Testing for Piping Components.
Page 8 of 58 GP 36-20
8 February 2012
ASTM A352 Steel Castings, Ferritic and Martensitic, for Pressure-Containing Parts,
Suitable for Low-Temperature Service.
ASTM A358 Standard Specification for Electric-Fusion-Welded Austenitic Chromium
Nickel Stainless Steel Pipe for High-Temperature Service.
ASTM A403 Standard Specification for Wrought Austenitic Stainless Steel Piping
Fittings.
ASTM A420 Standard Specification for Piping Fittings of Wrought Carbon Steel and
Alloy Steel for Low-Temperature Service.
ASTM A453 Standard Specification for High-Temperature Bolting Materials, with
Expansion Coefficients Comparable to Austenitic Stainless Steels.
ASTM A694 Standard Specification for Carbon and Alloy Steel Forgings for Pipe
Flanges, Fittings, Valves, and Parts for High-Pressure Transmission
Service.
ASTM A707 Standard Specification for Forged Carbon and Alloy Steel Flanges for
Low-Temperature Service.
ASTM A789 Seamless and Welded Ferritic/Austenitic Stainless Steel Tubing for
General Service.
ASTM A790 Standard Specification for Seamless and Welded Ferritic/Austenitic
Stainless Steel Pipe.
ASTM A815 Standard Specification for Wrought Ferritic, Ferritic/Austenitic, and
Martensitic Stainless Steel Piping Fittings.
ASTM A860 Standard Specification for Wrought High-Strength Low-Alloy Steel Butt-
Welding Fittings.
ASTM A928 Standard Specification for Ferritic/Austenitic (Duplex) Stainless Steel
Pipe Electric Fusion Welded with Addition of Filler Metal.
ASTM A988 Standard Specification for Hot Isostatically-Pressed Stainless Steel
Flanges, Fittings, Valves, and Parts for High-Temperature Service.
ASTM A989 Hot Isostatically-Pressed Alloy Steel Flanges, Fittings, Valves, and Parts
for High Temperature Service.
ASTM B366 Factory-Made Wrought Nickel and Nickel Alloy Fittings.
ASTM B423 Standard Specification for Nickel-Iron-Chromium-Molybdenum-Copper
Alloy (UNS N08825 and N08221) Seamless Pipe and Tube.
ASTM B444 Standard Specification for Nickel-Chromium-Molybdenum-Columbium
Alloys (UNS N06625) Pipe and Tube.
ASTM B564 Nickel Alloy Forgings.
ASTM B705 Standard Specification for Nickel Alloy (UNS N06625, N06219 and
N08825) Welded Pipe.
British Standards Institute (BSI)

BS EN 12201-1 Plastic piping systems for water supply. Polyethylene (PE) - Part 1:
General.
Det Norske Veritas (DNV)

DNV-RP-F112 Design of Duplex Stainless Steel Subsea Equipment Exposed to Cathodic
Protection.
International Organisation for Standardisation (ISO)

ISO 3183 Petroleum and natural gas industries - Steel pipe for pipeline
transportation systems.
Page 9 of 58 GP 36-20
8 February 2012
ISO 10423 Petroleum and natural gas industries - Drilling and production
equipment - Wellhead and Christmas tree equipment.
ISO 13628-1 Petroleum and natural gas industries - Design and operation of subsea
production systems - Part 1: General requirements and recommendations.
ISO 13628-4 Petroleum and natural gas industries - Design and operation of subsea
production systems - Part 4: Subsea wellhead and tree equipment.
ISO 14723 Petroleum and natural gas industries - Pipeline transportation systems -
Subsea pipeline valves.
ISO 15156-2 Petroleum and natural gas industries - Materials for use in H2S-containing
environments in oil and gas production - Part 2: Cracking-resistant
carbon and low alloy steels, and the use of cast irons.
ISO 21457 Petroleum, petrochemical and natural gas industries - Materials selection
and corrosion control for oil and gas production systems.
NACE International (NACE)

NACE MR0175 Petroleum and natural gas industries - Materials for use in H2S -
containing environments in oil and gas production.
3 Terms and definitions
For the purpose of this GP, the following terms and definitions apply:
BP approval
Approval by the relevant BP materials/corrosion/welding engineer defined in Annex B.
Carbon Equivalent International Institute of Welding (CEIIW)

Mn Cr  Mo  V Ni  Cu
CE  C   
6 5 15
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.
High pressure/high temperature (HP/HT)

Equipment rated at or above 1 034 bar (15 ksig) and 121°C (250°F) in accordance with API RP 6HP.
Historically, BP considered pressures and temperatures above 690 barg (10 ksig)
and 82°C (180°F) to be HP/HT, but this has evolved to the above referenced
industry recommended practice definition.
Lining
Nonmetallurgically bonded corrosion resistant layer (e.g., as applied by cold hydraulic expansion).
PREw
Pitting resistance equivalent number (PREw = %Cr + 3,3 (%Mo + 0,5 %W) + 16 x %N).
Quality heat treatment

Collective sequence of heat treatments applied to forgings and forging qualification test coupons to
achieve final properties.
Page 10 of 58 GP 36-20
8 February 2012
Includes final austenitisation, quench from final austenitisation, tempering or

ageing, and quenching (if applicable) from tempering or ageing.
4 Symbols and abbreviations
For the purpose of this GP, the following symbols and abbreviations apply:
CE Carbon equivalent.
CP Cathodic protection.
CRA Corrosion resistant alloy.
ELI Extra low interstitial.
ENP Electroless nickel plating.
ERW/HFI Electric resistance welded/high frequency induction.
FEA Finite element analysis.
FFKM ASTM designation for perfluoroelastomers.
FKM Viton type fluoroelastomers.
HAZ Heat affected zone.
HBN Brinell hardness number.
HDT Heat distortion temperature.
HIC Hydrogen induced cracking.
HIP Hot isostatic pressed.
HNBR Hydrogenated NBR (nitrile butadiene rubber).
HP/HT High pressure/high temperature.
HRC Rockwell hardness “C”.
Hv Vickers hardness number.
LME Liquid metal embrittlement.
MDT Minimum design temperature.
NBR Nitrile butadiene rubber.
NDE Nondestructive examination.
PEEK Polyether ether ketone.
PLET Pipeline end termination.
PREw Pitting resistance equivalent (w).
Page 11 of 58 GP 36-20
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PSL Product specification level.
PTFE Polytetrafluoroethylene.
PWC Preferential weld corrosion.
PWHT Postweld heat treatment.
QA/QC Quality assurance/quality control.
RTJ Ring type joint.
SCC Stress corrosion cracking.
SCR Steel catenary riser.
SMYS Specified minimum yield strength.
SOHIC Stress oriented HIC (hydrogen induced cracking).
SSC Sulphide stress cracking.
Tg Glass transition temperature.
TFEP Tetrafluoroethylene/propylene.
UNS Unified numbering system.
UV Ultraviolet.
XLPE Cross linked polyethylene.
5 Materials selection philosophy
a. Projects shall produce a single materials selection philosophy document, from which the
conclusions and recommendations shall be integrated into the project specific basis of
design.
b. Materials selection philosophy shall include:
1. Design and operating conditions.
2. An evaluation of corrosivity, which shall include:
a) CO2 content.
b) H2S content.
c) Hg content.
d) Content of oxygen and other oxidising species.
e) Design and operating temperature and pressure.
f) pH, including effects of organic acids.
g) Chloride (or other halide) ion concentration.
h) Velocity and flow regime.
i) Sand and other solids production.
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8 February 2012
j) Microbiological activity.
k) Transient conditions (e.g., shutdown and startup).
l) Condensing conditions.
A gas is normally considered “dry” (i.e., no risk of free water) if the water dewpoint
at the operating pressure is always at least 10°C (18°F) lower than the operating
temperature for the system.
3. Approach to materials selection.
4. Application of national and international materials standards and specifications.
5. Compliance with regulations.
6. Requirements for materials and welding qualification testing.
7. Application of relevant GIS documents.
Project materials selection philosophy normally is developed during select and/or
define stage.
c. Materials for subsea equipment shall be selected to provide required levels of operational
integrity, taking into account:
1. Material availability in appropriate product forms.
2. Operations and maintenance strategy.
3. Weldability.
4. Project cost and schedule requirements.
5. Complexity and novelty of equipment manufacture and fabrication.
6. Internal and external damage mechanisms during:
a) Storage and transport.
b) Deployment.
c) Wet parking.
d) Hydrotesting.
e) Commissioning.
f) Operations (including shutdown and startup).
g) Decommissioning.
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) Plastic collapse, overload, or buckling.
e) Erosion and erosion-corrosion.
f) Fatigue and corrosion fatigue.
g) Hydrogen embrittlement.
8. Predicted changes in reservoir conditions over design life (e.g., souring).
9. Effect of contact with well treating and completion chemicals.
Page 13 of 58 GP 36-20
8 February 2012
10. Operational criticality.

11. Required life.
High reliability is required in subsea systems due to difficulties and high cost
associated with inspection and maintenance.
d. Suitably qualified metallurgical, materials, welding, and corrosion specialists shall be
involved in materials selection in projects.
Complexity of some issues involved is such that this GP or derived project
specifications and STPs cannot always provide definitive recommendations.
e. Nonmetallic materials selection should follow the guidance provided in GN 36-003.
f. Materials for subsea application shall be:
1. Covered by a recognised standard or written material specification, subject to BP
approval.
In most cases, ASTM standards will form the basis of detailed specification, but
equivalent national standards may be appropriate.
2. Manufactured in accordance with qualified manufacturing procedures, subject to BP
approval. For major pressure containing components, the manufacturing procedure
qualification shall be derived from sacrificial components of similar dimensions and
include the specified range of mechanical tests. The use of a prolongation may be
acceptable to BP, provided that section thickness, degree of mechanical work, and
thermal history are the same as the critical regions in the actual component.
g. Standards and specifications for metallic materials shall include requirements for the
following, as appropriate:
1. Melting, secondary refining, and casting practice.
2. Chemical composition (heat and product).
3. Forging practice to produce fully wrought microstructure.
4. Quality heat treatment as related to forgings.
5. Sampling for mechanical testing.
6. Mechanical property requirements, including fracture toughness.
7. Requirements for special testing (e.g., chemical resistance, metallography, and
corrosion testing).
8. Welding and PWHT.
9. Nondestructive evaluation and defect acceptance criteria.
Equipment for HP/HT designs may be beyond normal limits of typical API/ISO
standards. Supplementary materials characterisation and NDE requirement are
likely to be needed. Reference should be made to API RP 6HP.
Relevant ETPs for welding and fabrication include GP 18-01, GIS 18-011,
GIS 18-012, and GIS 42-103.
h. If design temperature for material is above the range for which allowable stresses are listed
in the applicable reference code, elevated temperature tensile testing (including welds)
shall be performed and an allowable stress determined.
i. Components for subsea application shall be specified with high levels of traceability.
Refer to RD 78-002 for recommended approach for traceability methods and
GP 32-17 for quality management, inspection, and test requirements for subsea
equipment.
Page 14 of 58 GP 36-20
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6 Principles of materials selection
6.1 Materials selection for process side environment

Principles of materials selection and specification for process side subsea
environments are similar to those for surface (topsides) facilities, except that a more
conservative approach normally is required to achieve higher reliability.
6.1.1 General
The potential for exposure to raw or treated seawater (e.g., during installation, hydrotesting, and
commissioning) shall be assessed and materials with adequate corrosion resistance specified.
Unintended exposure to raw seawater can occur by leakage through mechanical
joints and seals during deployment and commissioning.
6.1.2 H2S containing environments
a. Materials for H2S containing environments shall conform to GP 36-25.

b. UNS S42400 (F6NM) shall be qualified for use in all levels of H2S.
BP has no specific domain diagrams for the application of this alloy in sour service.
However, some limited tests have shown SSC failures at conditions less onerous
than permitted by ISO 15156.
c. ISO 15156-2 compliant grades of carbon and low alloy steels should be specified for
environments containing even low H2S levels (i.e., within Region 0 of ISO 15156-2).
Cost of using “H2S resistant” grades of carbon or low alloy steels is usually
minimal, and they are recommended for environments containing even low H2S
levels.
d. Materials selection process should consider any predicted souring over the design life of
the reservoir.
Potential increases in H2S levels during life of field (e.g., if additional tie-ins from
other sources or unexpected souring behaviour occur) should be considered in the
risk and business case.
e. For solids (sand) erosion, GP 06-14 shall be used to demonstrate that adequate CRA
internal cladding or lining will remain for the design life of the component. The predicted
remaining thickness at the end of design life shall be at least 1,0 mm (0,04 in).
f. H2S partial pressure limits for avoidance of SSC in welded CRAs are not well defined.
Application specific corrosion testing shall be specified, including the effects of welding,
unless approved otherwise by BP.
Susceptibility to SSC is a function of temperature, H2S level, pH, and chloride
content of the transported water. Current guidance should be sought from BP
materials specialists and by reference to GP 36-25.
g. Effects of operations on SSC resistance, such as welding and plastic straining (e.g., during
pipe reeling), shall be assessed and a conservative approach to materials selection adopted.
h. If conditions are marginal between different classes or grades of steels and alloys:
1. Conservative approach to materials selection shall be adopted.
2. Alternates (e.g., carbon steel clad or lined with CRA such as alloy 625) should be
specified.
i. Resistance to H2S shall be assessed in the selection of nonmetallic materials.
Refer to GN 36-003.
Page 15 of 58 GP 36-20
8 February 2012
j. BP materials specialists should be consulted for guidance on elemental sulphur.

Elemental sulphur deposits increase the susceptibility of carbon and low alloy steels
to environmental cracking, pitting corrosion, and general corrosion. However,
corrosion can be controlled by using solvents to prevent sulphur deposition or
selecting sulphur resistant CRAs. NACE MR0175/ISO 15156 provides requirements
on environmental limits and selection of alloys resistant to elemental sulphur.
6.1.3 CO2 containing environments

a. CO2 corrosion rates on carbon and low alloy steel shall be predicted in accordance with
GP 06-10 following guidance provided in GN 06-010. Predictions shall be developed using
the latest BP CO2 corrosion model for assessment of viability of use for subsea equipment.
b. Effects of organic acids shall be considered in corrosion prediction modelling and in
testing for corrosion inhibitor selection.
Refer to GN 06-006.
c. Performance of CRAs in CO2 containing environments shall be adequate in terms of both
general corrosion and localised corrosion, especially in high temperatures and/or high
salinity waters.
Most CRAs have good resistance to CO2 corrosion. Nevertheless, attack in the form
of pitting corrosion, crevice corrosion, or environmentally induced cracking may
occur if one or more of the following conditions are present:
 High temperature.
 Chlorides.
 Low pH.
 Oxygen.
 H2S.
d. Nonmetallic materials shall have adequate resistance to CO2.
Refer to GN 36-003.
6.1.4 Chloride/halide ion containing internal production environments

a. Materials selected shall have adequate and proven resistance to localised corrosion and
SCC caused by chloride ions in produced or injected fluids. Due to the large number of
variables, only general advice can be provided in this GP, and BP specialist advice should
be sought.
b. If sufficient data on the resistance of candidate materials to these forms of attack is not
available, laboratory based qualification testing shall be performed.
c. If doubts exist about the suitability of a material (e.g., weldable 13%Cr [UNS S41426],
316L clad carbon steel, or duplex stainless steel), more chloride SCC resistant materials
(e.g., nickel based alloys or carbon steel internally clad with alloy 625) shall be specified.
Weldable 13% Cr and 316L are susceptible to chloride SCC under some conditions.
Duplex stainless steels have superior resistance to chloride SCC, but high
concentrations of chloride ions in combination with high temperatures can lead to
failures, and conditions under which cracking can occur are not well understood.
Nickel based alloys are highly resistant to chloride ion SCC in subsea equipment.
The advice of a materials and corrosion specialist is recommended for the most
appropriate materials selection.
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8 February 2012
6.1.5 Erosion
Erosion rates in subsea equipment and implications for materials selection shall be evaluated in
accordance with GP 06-14 and should follow the guidance provided in GN 06-001.
6.1.6 Chemicals
a. Materials selected for subsea systems shall have adequate resistance to the range of
expected chemical treatments.
It is important to understand how chemicals interact with materials they contact
(metals and elastomers) and how they behave with each other if mixed.
b. Compatibility between treatment chemicals shall be established before final selection and
use.
Potential incompatibility may result in neutralisation of one or more of product
active ingredients or in precipitation and blockage (i.e., “gunking”).
Refer to GP 78-11 for design guidelines for subsea chemical injection.
Chemical treatments are frequently adopted for flow assurance and/or control of
corrosion or scaling in subsea producing systems, such as:
 Corrosion inhibition/pH modifier.
 Scale inhibition.
 Hydrate inhibition.
 Wax control.
 Asphaltene control.
 Flow improvers.
c. Compatibility of nonmetallic materials with specific chemicals shall be demonstrated
following the guidance provided in GN 36-007.
6.1.7 Mercury and LME

a. Materials of construction shall have adequate resistance to the effects of mercury in
produced fluids.
b. Copper and aluminium based alloys or alloy 400/K500 shall not be specified for any
components in mercury bearing streams.
c. Titanium alloys containing aluminium and/or copper for duty in systems that may contain
mercury shall be qualified by testing.
Mercury and associated mercury compounds can be detrimental to certain
materials. Mercury can occur naturally as a contaminant in well production fluids,
especially gas. Potential presence of mercury should be recognised at the earliest
possible stage of design to avoid potentially susceptible materials being specified.
It is generally accepted that mercury needs to be present as free liquid for damage
to occur. Attack can be by amalgamation or by LME.
6.1.8 Preferential weld corrosion (PWC)

a. Propensity for PWC shall be assessed.
b. PWC shall not be mitigated by additional design corrosion allowances.
c. Seawater injection systems in carbon steel shall use welding consumables containing at
least 0,7% Ni to 1,0% Ni for the root and second (hot) pass (refer to GIS 42-103).
Page 17 of 58 GP 36-20
8 February 2012
d. Produced hydrocarbon systems in carbon and low alloy steels should use welding
consumables that match parent steel.
PWC is a particular concern with carbon and low alloy steels and has been
experienced in systems handling produced hydrocarbons and seawater for injection.
In seawater injection systems, welding with consumables that nominally deposit 1%
Ni weld metal has been used extensively to avoid PWC. Several cases of PWC
subsequently have been reported, but, overall, it appears to have significantly
reduced the PWC risk.
In systems handling produced hydrocarbons, the current industry accepted
approach to avoid PWC is:
 Use of weld consumables matching the composition of the parent steel.
 Treatment with an appropriately selected corrosion inhibitor.
Care is needed to select the correct inhibitor and dosage to provide adequate
protection, or it can make the likelihood and rate of PWC more acute (refer to
EFC 39 for more detail).
PWC can be exacerbated by the presence of acetic acid/acetate and is particularly
critical in wet gas systems. For produced hydrocarbon systems, if the acetate to
bicarbonate ratio is favoured towards acetate, the greater the effect of acetate on
system corrosivity and, by implication, PWC.
6.1.9 Water injection

a. Materials for treated water injection equipment shall be selected in accordance with
predicted water corrosivity, based on dissolved oxygen and chlorine levels, and
specification and reliability of water treatment facilities.
Although treated injection seawater is typically deaerated to a design limit of 10 ppb
oxygen or less, excursions to higher oxygen contents can often occur, causing
considerable corrosion in unlined carbon steel equipment.
In addition, there is increasingly a move to reinject produced water (containing
dissolved CO2 and possibly H2S), either alone or comingled with treated seawater
with the consequent requirement for corrosion management.
b. Materials for raw seawater injection processes shall be designed using seawater resistant
materials and/or using carbon steel with robust internal protective coatings or linings.
For raw seawater handling equipment, super duplex stainless steels (PREw greater
than 40), some highly alloyed austenitic stainless steels, and some copper base
alloys have good resistance to corrosion for restricted (i.e., lower) operating
temperatures. Care is required with chlorine or hypochlorite injection into raw
seawater injection processes, as this can greatly increase water corrosivity, further
restricting operating temperatures for these materials.
For higher service temperatures, alloys with a higher PREw may be required.
Plastic lined carbon steel is a robust option for seawater and comingled seawater
and produced water flowlines and pipelines, as described in 10.2.1 and GN 36-006.
6.1.10 Hydrotest water

Chemical treatment of hydrotest water by using biocides and oxygen scavengers shall conform
to GP 06-29.
Care is required in the specification and control of hydrotesting media (and any
other transient environments) to avoid internal corrosion and fouling. Many grades
Page 18 of 58 GP 36-20
8 February 2012
of stainless steel used for internal components are not resistant to localised pitting
and crevice corrosion in raw seawater (i.e., grades with PREw less than 40).
Generally, fresh hydrotest water (in accordance with GP 06-29) should be specified
in all cases other than systems designed for raw seawater duty. Prolonged durations
of hydrostatic test water remaining in equipment and pipework should be avoided.
Some assemblies, such as manifolds, can be deployed after filling with treated and
noncorrosive fluids. Venting should be adequate to minimise the volume of trapped
air, which promotes corrosion. Duration of exposure to these “transient” fluids
prior to commissioning should be minimised.
6.1.11 Additional internal environment considerations

Additional considerations for the materials selection philosophy shall include:
a. Internal corrosion at locations of no flow (dead legs) and low flow.
Sludge, scale, deposits, sediments, and/or biofilms may accumulate over time,
particularly at low flow locations, and result in internal corrosion.
b. Internal corrosion due to water dropout at low points.
Internal corrosion mechanisms include bacteria, which proliferate in stagnant
conditions, and under deposit corrosion caused by sand or corrosion products.
Areas where water could collect, drop out, and remain stagnant or become acidic
are also prone to internal corrosion. Corrosion inhibitors and biocides are unlikely
to be effective at locations of no flow and water dropout.
c. Localised pitting or general corrosion in CRAs at elevated temperatures, especially for
13% Cr and duplex or super duplex stainless steels.
d. Effect of gas lift operations on corrosion.
Consider the nature of the gas and whether it is wet, contains CO2, and potential to
introduce corrosive species into the production stream.
e. Specification and reliability of facilities for treatment of reservoir injection fluids.
f. Corrosivity of internal fluids encountered during installation and operational transients
(e.g., well workovers, and spent acids), including chemical treatments and seawater entry.
6.2 Materials selection for external seawater environment

a. Metallic materials for subsea application that are not inherently resistant to seawater
corrosion shall be protected by a combination of external coatings and CP.
Materials that can be considered for design purposes to be inherently resistant to
corrosion in seawater (even though this resistance is retained only up to certain
temperature limits) are 25% Cr super duplex SS PREw greater than or equal to 40,
alloy 625, other nickel base alloys of equal or higher PREw, and titanium.
Potentials that are more negative than optimal (-850 mV to -950 mV versus
Ag/AgCl/seawater) can lead to hydrogen embrittlement of martensitic, ferritic, and
duplex stainless steels.
A well designed and installed CP system normally will protect against the following
forms of external attack:
 General corrosion of carbon and low alloy steel.
 Crevice corrosion (e.g., at screwed and flanged connections). Flange protectors
are not necessary and are not recommended.
 Galvanic corrosion at junctions of dissimilar metals.
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8 February 2012
 Chloride ion SCC of austenitic stainless steels.

 Pitting corrosion of stainless steel.
 Bacterial corrosion.
External chloride SCC of duplex stainless steels due to concentration of chlorides on
unprotected high temperature surfaces is generally unlikely to be a problem on
painted or insulated subsea components additionally protected by CP. A theoretical
risk will exist for HP/HT installations (e.g., at crevices).
b. Materials requiring inherent resistance to marine fouling (e.g., exposed valve stems that
could damage stem seals or packing during operation) shall be specified accordingly.
Copper base alloys are particularly suitable. Various high strength versions are
available, including precipitation hardening cupro-nickel alloys. Nonmetallic
materials requiring resistance to marine growth (e.g., riser strakes and splash zone
coatings) typically are impregnated with copper based additives during
manufacture.
c. Avoidance of external hydrogen embrittlement of carbon or low alloy steels and CRAs
induced by CP systems shall be addressed in the materials selection philosophy, taking into
account the equipment specific requirements of this GP.
d. Maximum allowable individual hardness of all grades of carbon and low alloy steels that
will be exposed to CP for any amount of time shall be 34 HRC or 325 Hv10.
These hardness values are not a direct conversion and the maximum value applied
should correspond with the hardness measurement technique used.
e. The individual maximum weld zone hardness of fabricated equipment items in carbon and
low alloy steels shall be 325 Hv10.
The hardness limits in d and e should render carbon and low alloy steels highly
resistant to hydrogen embrittlement.
f. External coatings shall not be used to provide primary protection against hydrogen
embrittlement (i.e., as a substitute for highly resistant materials).
7 Applications of corrosion resistant alloys and nonmetallic materials
7.1 General
a. Acceptable candidate corrosion resistant alloys for pressure boundary equipment should be
selected from Table 1. CRAs for valve stems, fasteners, and hydraulic control and
chemical injection systems should be selected by reference to 11, 1, and 14.
There is often a requirement for fasteners, valve stems, and tubing to be made from
different, usually more corrosion resistant materials than the parent equipment.
b. Use of CRAs for pressure boundary equipment other than those listed in Table 1 shall be
subject to BP approval.
c. Free machining grades shall not be used.
Free machining grades have relatively poor corrosion resistance, especially in
seawater.
d. Copper based alloys shall not be specified for pressure boundary equipment in hazardous
duty.
e. CRA forgings made to 0,2% proof strengths that exceed 827 MPa (120 ksi) shall be
qualified to mechanical, corrosion, and environmental cracking performance requirements,
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8 February 2012
7.2 Austenitic stainless steel and nickel alloys

a. Low carbon grades of austenitic stainless steels shall be specified for welded applications.
Dual grade alloys, such as 316 and 316L, shall be acceptable.
b. Austenitic and highly alloyed austenitic materials used for pressure boundary equipment
shall be:
1. Specified in solution treated and water quenched conditions.
2. Free from any cold work intended to enhance their mechanical properties, unless
approved otherwise by BP.
High strength versions of austenitic stainless steels, such as Nitronic 60HS (90 ksi),
are susceptible to stress corrosion cracking in an oxygenated seawater environment
and pitting in a warm, humid marine environment.
c. Forced air or gas quenching may be specified for thin walled components, provided that
quenching results in a homogenous single phase austenitic microstructure with no
deleterious secondary precipitation.
d. Cast 6Mo highly alloyed austenitic stainless steel shall not be specified for components to
be welded.
e. Maximum hardness of austenitic stainless steels and weldments (including effects of cold
working) shall be specified in accordance with Table 2.
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8 February 2012
Table 1 - Acceptable candidate corrosion resistant alloys for subsea applications
Generic type Common name UNS

Austenitic stainless steels 316 SS S31600
316L SS S31603
Nitronic 50 S20910
Highly alloyed austenitic stainless 254SMO or 6Mo S31254
steels 904L N08904
Alloy 28 N08028
Precipitation hardened austenitic Grade 660 S66286
stainless steels
Duplex stainless steels Nitronic 19D S32001
22% Cr duplex S31803
25% Cr super duplex S32750
Martensitic stainless steels F6NM S42400
Super 13% Cr (weldable) S41426
Nickel based alloys Alloy 825 N08825
Alloy 925 N09925
Alloy 625 N06625
Alloy 718 N07718
Alloy 725 N07725
Alloy C-4 N06455
Alloy C-22 N06022
Alloy C-276 N10276
Alloy 400 N04400
Cobalt based alloys Elgiloy R30003
MP35N R30035
Copper based alloys Nickel aluminium bronze C95800
High strength cupro-nickel
Titanium based alloys Grade 5 R56400
Grade 12 R53400
Grade 19 R58640
Grade 23 R56407
Grade 29 R56404
Table 2 - Maximum allowable hardness for stainless steels
Generic type Maximum allowable hardness

Non welded components Weld metal
and parent metal of and HAZ
welded components
Austenitic and highly alloyed stainless steels 345 Hv or 35 HRC 345 Hv 10
22% Cr duplex SS 334 Hv or 28 HRC (1) 334 Hv 10
25% Cr duplex SS 378 Hv or 32 HRC (1) 378 Hv 10
Notes:
1. HRC to Hv conversion using TWI correlation for duplex stainless steels.
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8 February 2012
7.3 Precipitation hardening stainless steel and nickel alloys

a. If specified, martensitic precipitation hardened alloy 17-4PH (UNS S17400) shall conform
to GP 36-25.
In general, 17-4PH is not suitable for H2S containing duties (refer to GP 36-25 for
additional information). In addition, 17-4PH is not suitable for seawater exposure
and is prone to hydrogen assisted cracking if used subsea with cathodic protection.
b. High strength precipitation hardening nickel alloys, other than alloy 718, shall be:
1. Impact tested to meet the requirements of Table 3.
2. Examined for deleterious phases using microstructural analysis at 100 times
magnification and 500 times magnification to confirm the microstructure is free from
continuous networks of secondary phases along the grain boundaries.
c. Alloy 718 forgings shall conform to API Spec 6A718 following the guidance provided in
GN 36-001.
Table 3 - Charpy V-notch impact energy requirements for high strength

precipitation hardening nickel alloy piping, fittings, and connectors
Test Transverse (1)

temperature
°C °F Minimum average Minimum single Minimum lateral
value (J) value (J) expansion
mm in
-60 -76 47 43 0,38 0,15
Notes:
1. Indicates test specimen orientation.
7.4 Duplex stainless steel

a. Duplex and super duplex stainless steel components shall conform to GP 18-04. Fasteners
shall conform to 12.3c.
Definitions for duplex stainless steels are provided in GP 18-04. 25% Cr super
duplex SS with a PREw greater than 40 has a limited application regime in raw
seawater. A BP materials specialist should be consulted.
b. Maximum hardness of duplex stainless steels and weldments (including effects of cold
working) shall be specified in accordance with Table 2.
7.5 Nickel-copper alloys

a. Nickel-copper alloys (e.g., alloy 400 [UNS N04400]), if used in wet sulphide
environments, such as wet H2S, shall be limited to an in service temperature not exceeding
150°C (302°F).
Sulphides, especially H2S, can reduce the corrosion resistance of these alloys in
environments that normally would be considered acceptable.
b. UNS N04400 may be used in H2S containing service at a H2S partial pressure greater than
0,34 kPa abs (0,05 psia), but N05500 shall not be used (refer to GP 36-25 for
requirements).
7.6 Cladding and linings

a. CRA clad plate shall conform to GIS 18-013.
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8 February 2012
b. CRA clad pipe shall conform to 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,
subject to BP approval (refer to GIS 18-015).
d. Mechanically lined pipe shall conform to GIS 43-316 but shall not be used for reeled
flowlines or pipelines.
e. Alloy 625 weld overlays shall have:
1. At least two passes.
2. Thickness of at least 3 mm (0,12 in) at the final finished surfaces, including machined
locations.
3. Iron content at the finished surfaces, including machined locations not exceeding
10%.
4. Iron content not exceeding 10% at the end of design life thickness, if erosion is
predicted, unless it can be demonstrated and documented by application specific
corrosion testing that higher iron content is adequate.
Greater finished clad thickness may be required to meet the maximum iron
requirement at the end of design life thickness (refer to 6.1.2e).
7.7 Nonmetallic materials

a. Nonmetallic materials shall be selected through evaluation of the temperature, pressure,
fluid exposure, and mechanical loading to which they will be exposed.
b. Verification of materials performance over the design life of any component or system
shall be through testing, analysis, or documented field experience, subject to BP approval.
Verification shall include the time and temperature dependent properties of the materials
involved, as required.
Selection of elastomer and plastic materials has to take account of the impact of
operating conditions over field life. That impact may be in the form of physical or
chemical aging of the materials or simply as a result of the time and temperature
dependence of the mechanical properties of polymers.
In some instances (e.g., pipe applications), these issues are well understood and
quantified but less so in other instances (e.g., long term seal life prediction). FEA
modelling has limited capability, primarily as a result of the complex, nonlinear,
and time dependent properties of the materials.
c. Materials shall be purchased and processed in accordance with either written specifications
or industry standards, which shall include measurable physical, mechanical, and chemical
characteristics and tolerances.
8 Wellheads and christmas trees
8.1 General
a. Materials shall be specified and selected to provide required levels of operational integrity,
taking into account predicted changes in duty of a subsea tree during its lifetime (e.g., from
production to injection).
Wellhead and christmas tree equipment can be used for hydrocarbon production
and seawater injection (raw and treated).
b. Materials for major components that are wetted by process fluids shall conform to
GP 36-25.
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8 February 2012
c. Unless specified otherwise by BP, major components shall be forged products.

Major components in wellhead equipment, excluding bolting, are:
 Christmas tree connector.
 Christmas tree body.
 High pressure wellhead housing.
 Seal assemblies.
 Valve and choke bodies.
 Flow spools.
Although valves and bolting form part of this equipment, they are considered in
separate sections of this GP.
d. Wellhead equipment shall be resistant to corrosive production and injection fluids in all
internally process wetted areas.
Due to the complex geometry and turbulent flow, corrosion inhibition cannot be
relied on to protect carbon and low alloy steels. It is also unlikely that protective
scales will form at high velocities experienced in christmas trees, especially with
chemicals being injected downhole.
e. Materials in direct contact with corrosive production fluids may be either:
1. Inherently corrosion resistant.
2. Weld overlaid with suitable CRA.
f. Impact testing
1. Impact testing requirements of ISO 13628-4 (API Spec 17D) product specification
level (PSL) 3 shall be specified for pressure boundary materials, including fasteners.
Test temperatures are specified in ISO 13628-4 and ISO 10423, Table 6
(API Spec 6A).
2. Acceptance criteria for equipment of all pressure ratings shall average at least 40J and
at least 30J for individual test specimens oriented in transverse direction.
g. Forged components designed to fracture mechanics methods (e.g., ASME Boiler and
Pressure Vessel Code Section VIII Division 3) shall be subject to inspection and testing
specifically agreed with BP.
h. Fasteners shall conform to 1.
i. Gasket materials for christmas tree assemblies shall conform to 13.
8.2 Materials options
8.2.1 Christmas tree and connector bodies

a. Forged tree master valve blocks, wing valve blocks, and wellhead and tree connector
bodies up to and including 689 bar (10 000 psi) rating shall be specified in one or more of
the following materials:
1. AISI 4130 and AISI 8630, internally clad with alloy 625.
2. ASTM A182 F22 (2,25% Cr 1% Mo steel), internally clad with alloy 625.
3. ASTM A182 F6NM (13% Cr 4% Ni 0,75% Mo martensitic SS).
It is unlikely that low alloy steel would be acceptable without weld overlay cladding,
except in the most benign and short service conditions or for treated seawater
Page 25 of 58 GP 36-20
8 February 2012
injection. Even in those conditions, seat pockets and seal areas should be clad with
alloy 625, and trim should be a suitable grade of stainless steel.
Of materials listed in a., low alloy steel weld overlaid with alloy 625 represents the
lowest risk option for subsea. The preferred low alloy steel is ASTM A182 F22, since
this provides better through thickness hardenability in thick section forgings and is
considered the preferred material for critical equipment, such as block master
bodies, other than in exceptional circumstances.
b. Equipment rated above 689 bar (10 000 psi) shall be ASTM A182 F22 internally clad with
alloy 625.
8.2.2 Wellhead housing and seal assemblies

a. Wellhead housing and seal assemblies shall be manufactured in AISI 4130 or AISI 8630
steels or F22 low alloy steel, subject to BP approval.
b. Process wetted areas and/or seal areas shall be clad with alloy 625 for corrosion resistance,
as applicable for the service conditions.
8.2.3 Christmas tree valves and chokes

a. Body and bonnets of valves and chokes shall be manufactured from either:
1. Carbon or low alloy steels for all equipment ratings. As a minimum, seal areas shall
be weld overlaid with alloy 625.
2. ASTM A182 F6NM for equipment ratings up to and including 689 bar (10 000 psi).
b. Process wetted materials for valve bodies shall match or exceed the corrosion resistance of
the associated well production and injection tubing.
c. Stems
1. Stems shall be specified in high strength CRAs.
2. Alloy 718 may be specified up to SMYS of 827 MPa (120 ksi).
3. Alloy 725 may be specified up to SMYS of 896 MPa (130 ksi).
4. Stems shall be hard faced with tungsten carbide to prevent rubbing between stems and
housings. Alternatives to hard facing, if rubbing is prevented by suitable mechanical
design (e.g., bearings located above and below seal areas), may be proposed, subject
to BP approval.
d. Faces of gates, balls, and seats shall be hard faced using tungsten carbide or, subject to BP
approval, other materials of comparable or superior wear resistance.
e. If erosion is a factor (erosion rate greater than 0,1 mm/yr [0,004 in/yr]) (e.g., in sand
service or if proppant flowback occurs), material selection for internal surfaces of pressure
boundary parts shall conform to the practice adopted for flowlines (refer to GN 06-001).
f. If unusually high local fluid velocities are expected, special materials for erosion or
erosion-corrosion resistance shall be specified (e.g., outlet ports of choke valves shall have
erosion resistant inserts).
g. Choke valve trim
1. Choke valve trim shall be specified in highly erosion resistant material, such as
sintered tungsten carbide with Ni/Co matrix.
2. If choke valve trim components might be exposed to impact from upstream debris,
the valve shall have an appropriate screen in ductile material, or the carbide valve
cage shall be encapsulated in ductile material.
Page 26 of 58 GP 36-20
8 February 2012
8.2.4 Hydraulic tubing

a. Hydraulic tubing shall be selected in accordance with the design pressure and temperature
limits in Table 4.
The limits in Table 4 are somewhat arbitrary and based on a combination of
satisfactory service experience and resistance to internal and external corrosion.
b. Electrical continuity of tubing with cathodic protection system shall be verified (e.g., in
accordance with RD 78-001).
Table 4 - Design temperature limits for hydraulic control and chemical injection tubing
Material Maximum design temperature Max pressure rating
°C °F Bar psi
ASTM A269, TP 316L 60 140 689 10 000
ASTM B423, UNS N08825 80 176 No limit No limit
ASTM A269, UNS S31254 100 212 No limit No limit
ASTM B444, UNS N06625 180 356 No limit No limit
8.2.5 Flow loops (spools)

a. Tree mounted/guidebase mounted flow loops shall be one of the following:
1. 22% Cr duplex SS or 25% Cr duplex SS with induction bends in the solution
annealed condition (full component solution heat treatment and water quench).
2. Higher grade austenitic alloys for sour conditions beyond safe limits for 25% Cr
duplex SS (e.g., alloy 825).
3. Carbon steel internally weld overlaid with alloy 625.
b. Materials specifications and fabrication shall conform to 9.
These spools will incorporate butt welds, possibly with buttered joint faces.
c. Flow loops shall be externally painted.
9 Piping, fittings, and connectors
9.1 General requirements

a. This clause provides requirements for the components that make up the piping used in
fabrication of subsea manifolds, PLETs, sleds, jumpers, and christmas tree flow loops. The
components are pipes, fittings, and connectors. Manifold valves are specified in 11.
Manifold piping is commonly sized in 50 mm to 400 mm (2 in to 16 in) diameter
range, with wall thicknesses up to approximately 40 mm (1,6 in) for pipe and 80 mm
(3,2 in) for fittings.
Design and construction codes for manifolds specify allowable stresses for piping
components manufactured from seamless pipe, plate, castings, and forgings and by
HIP (refer to GP 78-10 [draft]).
Manifold piping often requires compact designs with numerous components.
Components in the selected materials need to be commercially available in all
required product forms and capable of being fabricated by conventional processes.
b. Materials shall be wrought/forged or HIP in accordance with ASTM A988 or
ASTM A989.
c. Use of castings shall be subject to BP approval.
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8 February 2012
d. Yield strength requirements for carbon and low alloy steels

1. Specified minimum yield strength of carbon and low alloy steels intended for welding
shall not exceed 560 MPa (81 ksi) in accordance with ISO 21457.
2. Maximum yield strength of low alloy steels not intended for welding shall not exceed
950 MPa (138 ksi) in accordance with ISO 21547 and the maximum hardness shall
not exceed 325 Hv10 or 34 HRC.
3. The impact test requirements for low alloy steels with specified minimum yield
strengths exceeding 560 MPa (81 ksi) will be specified by BP based on application
and design requirements.
Low alloy steels with specified minimum yield strengths exceeding 560 MPa (81 ksi)
are used in collet type connectors.
The hardness values are not a direct conversion and the maximum value applied
should correspond with the hardness measurement technique used.
e. Piping and fittings for hydrocarbon duties shall be specified in materials of appropriate
strength, fracture toughness, and corrosion resistance to have a reliable, minimum weight
facility.
In most cases, especially for deep water applications, corrosion resistant
constructions will be required. For short field life (typically 2 yr to 5 yr) or if
hydrocarbon fluids are relatively benign, carbon steel construction can be
considered.
In service inspection and corrosion monitoring of manifold piping usually is not
possible.
f. Unless approved by BP, carbon steels shall have CEIIW of 0,43, maximum.
For forgings, CE values up to 0,46 have been used by projects for shop fabrications
in which adequate welding controls have been demonstrated and qualified.
g. Acceptable CRA options include:
1. Duplex and super duplex stainless steel.
2. 6Mo super austenitic SS.
3. Alloy 825 or alloy 625.
4. Carbon steel internally clad with alloy 625.
h. If duplex and super duplex stainless steels are specified:
1. Design stress guidelines in DNV-RP-F112 shall be followed to reduce the probability
of external hydrogen embrittlement.
2. The application of DNV-RP-F112 should follow the guidance provided in
GN 36-025.
DNV-RP-F112 was developed from industry experience and research relating to
hydrogen embrittlement failures in duplex stainless steel manifolds in the North Sea.
It represents current best practice to avoid repetition of these failures.
Practical experience in the application of DNV-RP-F112 indicates that:
 Early application in the design cycle is necessary, because it can take a long
time to analyse complex piping systems.
 There is a potential for a large amount of finite element analysis.
i. Subject to BP approval, treated water injection piping shall be specified in corrosion
resistant materials, such as:
Page 28 of 58 GP 36-20
8 February 2012
1. Carbon steel with internal alloy 625 cladding.

2. Duplex and super duplex stainless steel.
If the oxygen content of injection water is less than 10 ppb to 20 ppb and if flowlines
to manifold are not plastic lined, consumption of residual oxygen by corrosion
should occur upstream of the manifold. If this is the case, the use of carbon steel for
manifold piping may be considered, subject to BP approval.
If injection water is not treated, super duplex stainless steel and titanium are
optimum selections for high pressure ambient temperature raw seawater.
j. Dry injection gas lift piping shall be specified in carbon steel with a nominal corrosion
allowance (e.g., 1,5 mm [0,06 in]).
For wet injection gas, carbon steel or CRA should be selected according to the
corrosivity of the gas.
k. Acceptable materials
1. Acceptable materials standards and grades are listed in Table 5, Table 6, and Table 7,
with “supplementary requirements” that should be applied.
2. Alternative standards and/or grades may be proposed, subject to BP approval.
3. Projects shall develop detailed material data sheets for all materials and grades.
A range of approved piping and piping component specification sheets for duplex
stainless steels is included in GN 36-016. NORSOK M-630 piping materials
datasheets may be proposed for BP approval for materials or component forms not
included in GN 36-016.
Table 5 - Standards for seamless and welded pipe and fittings in carbon and low alloy steel
Standard Description Applicable grades “Supplementary requirements”

API 5L PSL2 Seamless and welded As defined in As defined in GIS 43-311,
line pipe GIS 43-311, GIS 43-313
GIS 43-313
ASTM A420 Seamless and welded WPL6, WPL9 ASTM A960: S53, S66
fittings
ASTM A860 Seamless and welded All ASTM A960: S53, S56, S57,
fittings S62, S66
ASTM A333 Seamless pipe 1, 6 None
Page 29 of 58 GP 36-20
8 February 2012
Table 6 - Standards for seamless and welded pipe and fittings in stainless steel and nickel alloys

ASTM A312 Seamless and welded UNS S31254 S1, S5
stainless steel pipe
ASTM A358 Welded stainless steel pipe UNS S31254 S1, S3
ASTM A403 Seamless and welded UNS S31254 ASTM A960: S50, S52, S62
stainless steel piping fittings
ASTM A790 Seamless and welded UNS S31803, S32750, Refer to GP 18-04, GIS 18-041,
duplex stainless steel pipe S32760, S39274 GN 36-016
ASTM A928 Duplex stainless steel UNS S31803, S32750, Refer to GP 18-04, GIS 18-041,
welded pipe S32760 GN 36-016
ASTM A815 Seamless and welded UNS S31803, S32750, Refer to GP 18-04, GIS 18-041,
stainless steel fittings S32760, S39274 GN 36-016
ASTM A988 HIPped stainless steel UNS S31803, S32750, Refer to GP 18-04, GIS 18-041,
flanges, fittings and valves S32760, S39274 GN 36-016
ASTM B366 Seamless and welded UNS N06625, N08825 S3, S5
nickel alloy fittings
ASTM B705 Nickel alloy welded pipe UNS N06625, N08825 None
(Class 2)
Table 7 - Standards for forged pressure retaining pipe components

ASTM A350 Carbon and low alloy LF2 Class 1LF6 ASTM A350: S5
steel forgings Classes 1 and 2 ASTM A961: S55, S58
ASTM A694 Carbon and low alloy F60, F65, F70 Impact testing in accordance with
steel forgings this GP
ASTM A707 Carbon and alloy steel L2 Class 2 and 3L3 S5
flanges Class 2 and 3
ASTM B564 Nickel alloy forgings UNS N06625, N08825 None
Table 8 - Charpy V-notch impact energy requirements for carbon

and low alloy steel piping, fittings, and connectors (1)
SMYS (MPa) Transverse (2,3)

Minimum average value (J) Minimum single value (J)
≤ 360 30 25
> 360 and ≤ 450 40 30
> 450 and ≤ 560 60 45
Notes:
1. Required for thicknesses ≥ 6 mm (0,24 in).
2. Indicates test specimen orientation.
3. Impact values of weld metal and HAZ shall be same as for transverse direction.
l. Impact test requirements

1. Piping, fittings, and forged components in carbon and low alloy steels shall be impact
tested at -46°C (-50°F). Minimum single and average absorbed energy from three
specimens, including weld metal and HAZ of welded products shall conform to
Table 8, unless the design code specifies more onerous requirements.
2. Impact test requirements for piping, fittings, and forged components in 22% Cr
duplex SS and 25% Cr duplex SS shall conform to GP 18-04 following the guidance
provided in GN 36-016.
Page 30 of 58 GP 36-20
8 February 2012
3. If the MDT is lower than -46°C (-50°F), impact testing shall be performed at the
MDT.
Manifolds designed to ASME Code Section VIII Division 3 for high pressure
applications may require more onerous fracture toughness properties and testing.
API RP 6HP may impose similar requirements in the future.
4. Components in high strength, precipitation hardening nickel alloys shall conform to
7.3b.
5. Impact testing is not required for austenitic stainless steels or nickel base alloy piping,
components, or fittings. Weldments in austenitic stainless steels and nickel base
materials shall include impact testing as part of the welding procedure qualification in
accordance with GIS 42-103.
m. Individual components and valve bodies shall be designed in accordance with the
following:
1. Maximum wall thickness shall be minimised and shall not be substantially more than
necessary to conform to structural and pressure containment requirements.
2. Elbows shall not be manufactured from tee forgings, unless acting as target tees for
erosion control.
Target elbows are less flexible than radiused elbows, therefore adding to the
stiffness of the assembly.
3. Design of components and geometry of welding ends shall be such that ultrasonic
and/or radiographic examination may be performed on 100% of the component
during both manufacture and fabrication into the assembly.
4. Welding ends shall contain sufficient parallel length to ensure that the fabrication
weld can be subjected to ultrasonic scanning from both sides of the weld.
5. Thickness transitioning across welds shall not be used without BP approval.
This type of weld is difficult to NDE by ultrasonic testing. Thickness transitions
should be at least 100 mm (4 in) away from the edge of the weld preparation and
located in the parent material of the thicker component. Transitions should be
smooth with no sharp notches or contours, with length to depth ratio of at least 4:1.
6. Dissimilar welds using alloy 625 filler metal shall be inspected by both radiography
and ultrasonic testing or other qualified NDE methods approved by BP.
7. NDE regime shall maximise detection of both planar and volumetric defects,
especially in HP/HT designs, which may have smaller allowable defect sizes.
n. Qualification test
1. Individual component and valve body designs and vendors shall be qualified on the
basis of a manufacturing procedure qualification test.
2. Testing shall involve mechanical testing on a sacrificial component or forging
prolongation, as approved by BP.
3. The applicable size range for each manufacturing procedure qualification test shall be
o. Coating and insulation systems shall not be used to prevent hydrogen assisted cracking.
Refer to GN 36-020.
p. Coating and insulation materials should follow the guidance provided in GN 36-020 and
GN 36-009.
Page 31 of 58 GP 36-20
8 February 2012
9.2 Additional requirements for piping

a. Piping shall be seamless or longitudinally welded by arc welding, unless approved
otherwise by BP.
Volumes of pipe materials used for subsea manifolds, PLETs, etc., are relatively
small, and the cost benefit of welded versus seamless pipe is likely to be minimal in
most cases. If delivery timing of the two types is equivalent, seamless grade is
preferred.
b. ERW/HFI grades shall not be used, unless approved otherwise by BP.
The thickness limitations and risks with product quality make these grades
unsuitable for subsea piping.
9.3 Additional requirements for fittings

a. Pipe fittings shall be seamless, extruded, forged, or HIPped.
The piping design should maximise the use of HIPped components and pulled tees.
HIPped tees may contain multiple branches.
b. Proprietary branched connections, such as Sweepolets® and Weldolets®, shall not be used
for the connections between individual production or injection flowlines and headers.
Weldolets® may be used for branched connections up to DN 50 (NPS 2) on nonclad carbon
steel and solid CRA constructions (e.g., for chemical injection and instrumentation).
Pulled tees can be 100% volumetrically inspected during fabrication and are
preferred to Weldolets®. Welding of proprietary branched connections should follow
manufacturer guidelines with weld profiles of reasonably smooth finish to avoid
crevices (potential sites of corrosion and stress concentrations) and facilitate
inspection and painting.
9.4 Additional requirements for connectors

If carbon or low alloy steel hubs or flanges are mated to CRA hubs/flanges, the mating face of
the carbon or low alloy steel shall be fully weld overlaid with alloy 625.
9.5 Additional requirements for internal CRA clad constructions

a. Internally clad piping and fittings shall be manufactured as follows:
1. In carbon manganese (C Mn) steel grades X60/F60, X65/F65, or X70/F70.
API 5L PSL 2 with supplementary requirements SR5, SR11, and others, as
applicable, should be specified for small procurement lots that are not associated
with flowline and riser orders. Pipe bends may require special chemistries. For
thick wall high strength pipe, materials specialists should be consulted.
2. Internally weld overlaid with alloy 625. Alternative weld overlay compositions may
be proposed, subject to BP approval.
b. Fabrication welds
1. Internally clad C Mn steel components and valve bodies shall be welded into the
assembly using alloy 625 or other nickel based consumables, subject to BP approval.
PWHT generally will not be applied to fabrication welds, subject to code
requirements.
c. Fully internally clad piping components (e.g., flanges, tees, elbows, reducers, and valve
bodies) shall be manufactured as follows:
1. C-Mn steel unless supported by a technical justification to use low alloy steel, subject
to BP approval.
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8 February 2012
2. Low alloy steel piping components and connectors shall conform to Table 9.
Technical justifications should identify why C-Mn steels cannot be used. In most
situations, it should be possible to procure Grade X65/F65 C-Mn components at
thicknesses up to approximately 35 mm (1,4 in). Section size and strength
requirements may justify the use of more hardenable low alloy steel.
d. Maximum HAZ hardness of internally clad components and valve bodies shall be
325 Hv10.
e. Welding (including overlay cladding) and NDE procedures shall be qualified, either
specifically for the fabrication contract or by application of existing procedures, in
accordance with GP 18-01, GIS 18-011, and GIS 18-015.
Requirements for welding components and pipework are provided in GIS 42-103.
f. Heat treatment procedures for clad low alloy steels should include the maximum time at
temperature in addition to the specified minimum time.
10 Flowlines, pipelines, and risers
Subsea flowlines, pipelines, and risers may be used to transport the following fluids:
 Production fluids.
 Injection or wash water.
 Injection gas.
 Chemicals.
 Heating medium.
 Service or displacement fluids (e.g., dead crude or diesel).
Material options in relation to fluid transported are discussed in 10.1.
10.1 Flowlines and pipelines carrying production fluids
10.1.1 General
a. Materials of construction for subsea production flowlines and pipelines shall be assessed
on a case by case basis using principles described in 5 and 6.
Production fluids in flowlines and pipelines may be gas, oil, or multiphase. Since
these fluids are untreated, they might contain condensed or formation water and
CO2. As such, they are likely to be corrosive to carbon steel. H2S and sand also may
be present.
b. Christmas tree to manifold flowlines
1. Christmas tree to manifold flowlines shall be of corrosion resistant construction.
2. Carbon steel may be specified for short service lives or for particularly benign
conditions, especially if the flowlines are relatively long.
Risk and economic factors will favour the use of CRAs for christmas tree to manifold
product flowlines. Flexible pipe also may be specified for these duties, especially for
short lengths. Refer to GP 65-75. Reservoir souring may preclude the selection of
martensitic, duplex, or super duplex stainless steels.
Page 33 of 58 GP 36-20
8 February 2012
Table 9 - Materials requirements for low alloy steel internally clad components
for piping, fittings, and connectors
Forgings Materials
Low alloy steel components - preferred ASTM A182 F22
option
Low alloy steel components - non AISI 8630, 4140, 4130,
preferred grades and other low alloy high carbon steel forgings
Butt welds Fabrication sequence
Option 1 - Low alloy steel components  Apply C-Mn (or low alloy steel) weld buttering to weld
and valve bodies with C-Mn buttering preparation on F22 forging.
layer, welded to X65/F65 C-Mn steel pup  Apply alloy 625 cladding to F22 forging and stop
piece with C-Mn butt weld, subject to BP cladding on C-Mn butter weld.
approval.
 PWHT F22 forging and buttered layer.
 Weld F22 forging to X65/F65 pup piece using C-Mn
welding consumable.
 Apply alloy 625 cladding to C-Mn buttering and
X65/F65 pup piece (no additional PWHT).
 Refer to Figure A.1.
Option 2 - Low alloy steel components  Apply C-Mn (or low alloy steel) weld buttering to weld
and valve bodies with C-Mn buttering preparation on F22 forging.
layer, welded to pre-clad X65/F65 C-Mn  Apply alloy 625 cladding to F22 forging and C-Mn
steel pup piece with alloy 625 butt weld, butter weld.
 PWHT F22 forging and butter weld.
 Weld F22 forging to clad X65/F65 pup piece using
alloy 625 weld consumable (no additional PWHT).
 Refer to Figure A.2.
Option 3 - Low alloy steel components  Shall not be used, except if Options 1 and 2 are
and valve bodies with alloy 625 buttering demonstrated as impractical.
layer, welded to pre-clad X65/F65 C-Mn  Apply alloy 625 weld buttering to weld preparation on
steel pup piece with alloy 625 butt weld, F22 forging.
 Apply alloy 625 cladding to F22 forging and alloy 625
butter weld.
 PWHT F22 forging and buttered layer.
 Weld F22 forging to clad X65/F65 pup piece using
alloy 625 weld consumable (no additional PWHT).
 Qualification of welding procedures should follow the
guidance provided in GN 36-020 (see Note).
Note:
A brittle fusion line can develop in CRA/low alloy steel substrate combinations. PWHT has been found to
exacerbate this problem. Several brittle failures at butt welds incorporating CRA buttering on low alloy steel
have been experienced in the subsea industry due to hydrogen embrittlement and cracking in the fusion zone.
c. CRAs should be specified for pipelines downstream of production manifolds if:

1. Carbon steel predicted corrosion rates are too high.
2. Operational cost of corrosion control, monitoring, and inspection exceeds higher
capital costs involved.
3. Corrosion control, monitoring, and inspection activities are impractical.
Although pipelines in CRA, CRA clad, or CRA lined pipe will give lowest
operational cost and risk, the high capital cost may be prohibitive for longer
pipelines. Therefore, it is normal practice to assess feasibility and cost of pipelines
in carbon steel if internal corrosion can be reliably controlled.
d. Linepipe shall be selected and procured in accordance with GP 43-31.
Page 34 of 58 GP 36-20
8 February 2012
10.1.2 Carbon steel flowlines and pipelines

a. Carbon steel linepipe shall conform to one of the following, as applicable:
1. GIS 43-311.
2. GIS 43-312.
3. GIS 43-313.
b. Corrosion allowances
1. Suitable corrosion allowance shall be specified.
Considerations for corrosion allowance should include:
 Corrosivity of the process fluids.
 Design codes and design factors.
 Pressure decay over field life.
 Actual pipe wall thickness.
Typical minimum corrosion allowances are:
 1 mm (0,04 in) for noncorrosive nonhydrocarbon service.
 1,5 mm (0,06 in).for dry gas service to allow for process upsets.
 3 mm (0,12 in) for other hydrocarbon service, including service and
displacement fluids.
2. Maximum corrosion allowance for any duty shall be 8 mm (0,315 in).
3. Corrosion allowance assessment shall be performed using the latest BP corrosion rate
prediction models.
Specification of corrosion allowances for service and displacement fluid lines
should consider potentially long periods of stagnant conditions and long term
effectiveness of chemical treatments.
c. Carbon steel linepipe fittings shall conform to GIS 43-317, GIS 43-318, and GIS 43-319.
Pipeline ETPs require that carbon steel pipelines in hydrocarbon duty are capable
of being pigged.
10.1.3 Corrosion resistant flowlines and pipelines

a. Acceptable corrosion resistant materials include:
1. Duplex and super duplex stainless steels.
2. Weldable 13% Cr SS (UNS S41426).
3. Carbon steel internally clad with CRA, typically type 316L SS, alloy 825, or
alloy 625.
4. Carbon steels lined with CRA, usually type 316L SS, 904L SS, or alloy 825.
b. Specification of other weldable 13% Cr SS shall be subject to BP approval.
c. CRA linepipe shall conform to one of the following, as appropriate:
1. GIS 43-314.
2. GIS 43-315.
3. GIS 43-316.
Page 35 of 58 GP 36-20
8 February 2012
d. 13% Cr martensitic SS shall not be specified for flowlines or pipelines requiring cathodic
protection by directly fitted aluminium sacrificial anodes. Other options may be proposed
as alternatives, subject to BP approval.
Options include:
 Internally clad spool pieces to attach the sacrificial anodes.
 Diode controlled sacrificial anodes.
 Soft iron anodes.
e. Designs that provide cathodic protection for martensitic stainless steel lines from remote
anodes may be proposed, subject to BP approval.
Additional guidance on application of weldable 13% Cr for subsea pipelines is
provided in GN 36-002.
f. Lined pipe shall not be specified for installation by reel barge or for induction bending.
g. Clad pipe may be proposed for reeling and induction bending, subject to qualification
testing, and BP approval.
10.2 Flowlines and pipelines carrying other products
10.2.1 Water injection

a. Carbon steel with plastic (polyethylene) liner should be specified as the preferred option
for treated and untreated water injection duties, as described in 10.5.
Although they have higher capital cost, such lines are immune to internal corrosion
arising from excursions in oxygen content or microbial activity and can be used to
carry raw seawater, treated seawater, and commingled seawater or produced water.
Marginal reservoir injectivity may dictate CRA or plastic lined carbon steel flowline
to prevent the inevitable corrosion products from plugging the formation.
b. Unlined carbon steel flowlines for treated water injection duty shall be subject to BP
approval and have corrosion allowance of at least 3 mm (1/8 in). If consistent achievement
of a 20 ppb dissolved oxygen limit cannot be guaranteed, plastic lined carbon steel or
corrosion resistant material should be specified.
Unlined carbon steel may be acceptable for produced water flowlines, subject to:
 Exclusion of oxygen.
 Stringent chemical treatment (e.g., biocide, oxygen scavenger, corrosion
inhibitor, and scale inhibitor).
 Maintenance pigging.
 Monitoring and intelligent pigging.
 Removal of internal mill scale by grit or shot blasting to improve corrosion
performance.
c. Welding consumables containing 0,7 Ni to 1,0% Ni shall be specified for the root and
second (hot) pass, as a minimum, to avoid preferential weld corrosion for unlined pipe.
d. 22% Cr duplex SS is suitable for treated injection water up to 30°C (86°F) and may be
specified within qualified limits of oxygen and residual chlorine levels. Proposals for use
at higher design temperatures shall be subject to BP approval.
Additional guidance on injection water quality is provided in GN 36-019.
e. Nonplastic lined pipe for raw seawater injection shall be:
1. Stainless steel or nickel based alloy with PREw greater than 40.
Page 36 of 58 GP 36-20
8 February 2012
2. Carbon steel pipe clad or lined with stainless steel or nickel based alloy with PREw
greater than 40.
3. Titanium.
f. Spoolable, fibre reinforced, plastic composite flowlines that conform to API RP 15S may
be proposed, subject to BP approval.
10.2.2 Gas injection

a. Dry gas injection lines shall be specified in carbon steel.
b. Materials for wet gas injection shall be selected on the same basis as that for production
fluids.
10.2.3 Chemicals (service lines)

Lines for bulk noncorrosive chemicals, such as glycol or methanol, shall be carbon steel.
Injection chemicals required in smaller quantities (e.g., corrosion or scale
inhibitors) are usually transported in small diameter tubing within umbilicals. Such
tubing is normally austenitic (316L) or duplex stainless steel depending on design
temperature.
10.2.4 Heating medium

Lines for heating media (usually potable water or water glycol mixtures) shall be carbon steel.
10.3 Production and injection risers

Materials selection and corrosion control principles for rigid metallic risers,
especially vertical designs, are essentially the same as those for flowlines and
pipelines, and, in many cases, the same materials will be used. Many different
designs of risers have evolved, falling into the following broad categories:
 Vertical (or near vertical) rigid risers for platform based designs, clamped to the
platform structure.
 Vertical rigid risers or bundles for floating production systems that can be either
top tensioned or bottom weighted.
 Hybrid risers or bundles, typically a vertical rigid section from seabed to subsea
buoyancy chamber, then connected to floating production unit via flexibles.
 Steel catenary risers.
 Flexibles from seabed to surface.
Additional guidance on materials for dynamic risers is provided in GN 65-706.
10.3.1 SCRs
a. Project specifications for SCRs shall conform to GP 65-73 and GIS 43-313 and should
follow the guidance provided in GN 65-706.
SCRs are dynamic items with a design likely to be dominated by fatigue damage
considerations, especially if connected to floating production systems. Fatigue
damage mainly originates from vessel motions and vortex induced vibration and
may be exacerbated by internal slugging, pressure cycling, and installation.
Steel grade selection and specification is determined by strength requirements,
fracture toughness, fatigue performance, and sour service resistance, as applicable.
Most installed SCRs are API 5L X65 type steel.
Of particular relevance to achievement of adequate fatigue performance are:
Page 37 of 58 GP 36-20
8 February 2012
 Girth weld quality.

 Fracture toughness exceeding normal levels required for static piping
applications.
 Pipe end alignments.
 Out of roundness.
NDE requirements are likely to be specified on the basis of fatigue life and fracture
mechanics assessments. The following, in particular, should be specified:
 Stress concentration factors from weld fit up (high/low) limits due to nonuniform
wall thickness of seamless pipe.
 Stress concentrations and residual ovality induced by plastic deformation during
installation.
 Weld fatigue class and defect tolerances, especially in the root, as determined by
required fatigue resistance.
 Basis of fatigue or corrosion fatigue data (i.e., steel in air, freely corroding steel
in seawater, cathodically protected steel in seawater, or project specific data for
the expected internal environment).
SCRs from solid CRA materials require an extensive development programme to
address materials selection and fabrication. Materials specialists should be
consulted.
b. Fatigue data for cathodically protected steel shall be used for the fatigue assessment of the
weld cap on the outside of risers, even for coated risers.
c. If the riser internal fluids are corrosive, either a suitably conservative allowance shall be
made to the fatigue design code data or project specific corrosion fatigue data shall be
developed.
d. If steel risers require very reliable inhibition for severely corrosive applications,
consideration shall be given to internally CRA cladding regions of maximum fatigue stress
(e.g., at riser top and at seabed touchdown zone).
10.3.2 Titanium risers and stress joints

a. ELI titanium grade 23 and ELI titanium grade 29 shall be specified.
b. Alternate grades may be proposed for qualification, subject to BP approval.
DNV-RP-F201 specifies seamless and welded pipe in most commercially available
ASTM grades, including 2, 9, 12, 19, 23, 28, 29, and 32. A strong preference for ELI
grades is expressed in DNV-RP-F201. Guidance is provided on mechanical, fatigue,
and fracture toughness properties and corrosion resistance, including
environmental cracking and LME behaviour, wear, weldability, manufacturing
procedure specifications, qualification, and NDE.
c. Specifications for titanium components for workover, top tensioned, and catenary risers
should follow the guidance provided in GN 36-012 and shall be subject to BP approval.
10.3.3 Flexible joints

Additional materials requirements for flexible joints are specified in GP 65-73.
10.4 Carbon steel pipeline flanges

Flange faces shall be weld overlaid with alloy 625 in accordance with ISO 13628-1.
Page 38 of 58 GP 36-20
8 February 2012
10.5 Polyethylene liners for carbon steel risers and flowlines

a. Plastic liners for water injection service shall be manufactured from established pipeline
grades (e.g., PE80 or PE100, as defined by BS EN 12201-1).
b. Plastic liners shall have sufficient thickness, with appropriate safety factors, to resist loads
induced during insertion, installation, and operation, including collapse by the action of
applied vacuum and permeated residual gas.
c. Materials shall be purchased and processed in accordance with written specifications or
industry standards, which shall include measurable physical, mechanical, and chemical
characteristics and tolerances.
d. Plastic liners shall be inserted into riser and flowline sections using proven lining
techniques to provide a tight fit within the carbon steel host.
e. Joints and tie-in connections used between adjacent sections of lined pipe shall be:
1. Proven for the pipe installation method employed.
2. Demonstrated by calculation and/or testing to be effective for the design life of the
riser or flowline.
f. If required, joints and tie-in connections shall have a demonstrated capability to perform in
dynamic service or be subject to project specific testing to prove this ability.
g. Stages of fabrication shall be governed by specifications approved by BP.
10.6 Flowline and riser insulation

a. Material properties of wet insulation shall be documented under relevant combinations of
temperature and pressure to include:
1. Thermal conductivity.
2. Specific heat.
3. Hydrostatic strength.
4. Thermal aging resistance.
5. Water absorption.
b. Acceptance criteria generally shall be based on retention of acceptable insulation
properties at end of field life. Vendor should demonstrate heat transfer characteristics at
end of field life (e.g., by demonstrating constant properties or slow and predictable
decline).
c. Water absorption shall be characterised for all layers exposed to external water
environment and should be presented as justification that “dry” layers stay dry over field
life to avoid “hot/wet” conditions.
d. Other properties should be documented to include the following (minimum acceptable
properties should be stated if possible):
1. Abrasion.
2. Adhesion.
3. Bending resistance.
4. Bulk modulus.
5. Cathodic disbondment.
6. Compressive creep.
7. Impact.
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8 February 2012
8. Density.
9. Fatigue resistance.
10. Friction.
11. Shear, tensile, and compressive properties.
12. Thermal expansion.
13. Thermal shock resistance.
14. Tg or HDT of resins.
15. Resistance to biological effects and UV.
e. Qualification of insulation systems shall be performed on factory coating and field joint,
and shall, as a minimum, include:
1. Simulated service test to confirm the heat transfer characteristics of the system.
2. Simulated installation tests (e.g., static bend test for reeling or tensioner simulation).
3. Cyclic bend tests for dynamic applications.
11 Manifold and flowline/pipeline valves
11.1 General
a. Considerations for materials selection for subsea valves shall include the following, as
applicable:
1. Service temperature and pressure ranges.
2. Corrosivity and erosivity of fluids contacting valve body and parts.
3. Abrasion potential of solids (wear on rubbing or sliding surfaces).
4. Impact potential of solids, such as frac’ing proppants (e.g., on brittle choke
components).
5. Likelihood of seawater ingress during deployment or operation.
6. Galvanic effects due to proximity of different materials.
7. Crevice corrosion resistance (e.g., at seal and flange faces).
8. Galling resistance for moving parts in contact.
9. Rapid gas (explosive) decompression, temperature, and chemical resistance for
nonmetallic materials.
Applicable standards include ISO 10423 (API Spec 6A), ISO 10433, ISO 13628-4
(API Spec 17D), ISO 13628-6 (API Spec 17F), ISO 14313, ISO 14723, and
GIS 43-352.
b. If materials not listed in reference standards are specified, there shall be a clearly defined
and recorded justification for pressure and temperature ratings being claimed.
Metallic materials for pressure boundary parts may be limited by the chosen design
or product standard, since pressure and temperature ratings are applicable only for
listed materials. For this reason, materials for christmas tree valves and manifold or
pipeline valves frequently differ.
c. Internally clad valve bodies shall conform to 9.5.
d. Typical generic and acceptable materials are shown in Table 10.
Page 40 of 58 GP 36-20
8 February 2012
e. Subsea manifold and flowline valve materials shall conform to ISO 14723, ASME B16.34,
and GIS 43-352. Other materials, such as nickel base alloys, are not precluded from use
and may be proposed, subject to BP approval.
f. Carbon and low alloy steel valves shall be specified, as a minimum, with alloy 625 weld
overlaid seat pockets and seal contact areas regardless of service.
g. Material requirements of ISO 10423 and ISO 13628-4 shall be complied with if:
1. Design is required to conform to ISO 10423 and ISO 13628-4.
2. Design pressure exceeds limits of ASME Class 2500.
h. If duplex or super duplex stainless steels are specified for pressure retaining parts and
design is in accordance with ISO 10423, allowable stresses shall be limited as specified by
GIS 43-352.
This is to avoid the phenomenon of “cold creep” that can occur at high stress levels.
i. Metal seals and seats shall be more noble than surrounding surfaces.
j. Base material specifications shall be controlled to give good weldability, as applicable. If
necessary, base material weldability trials shall be performed.
k. For carbon steel materials for welding, the following product limitations shall be specified:
1. Carbon - 0,23%, maximum.
2. CEIIW - 0,45, maximum.
11.2 Impact properties

a. Impact testing shall be specified for all manifold and flowline valves in accordance with
ISO 14723 and GIS 43-352.
b. Components in carbon and low alloy steels shall be impact tested at -46°C (-50°F).
c. Impact test requirements for components in 22% Cr duplex SS and 25% Cr duplex SS shall
conform to GP 18-04 following the guidance provided in GN 36-016.
d. If the MDT is lower than -46°C (-50°F), impact testing shall be performed at the MDT.
e. Impact testing is not required for HIPped, wrought or forged austenitic, super austenitic, or
nickel base alloy components.
11.3 Castings
For castings, assurance of adequate soundness and required mechanical properties shall be
achieved by incorporation of appropriate NDE and destructive testing and control of defect
repairs in material specification.
Cast construction for manifold and pipeline valves can offer advantages of weight
and cost savings, especially if operating pressures are high.
Cast valves for subsea applications are likely to have a high criticality rating and
high quality level in accordance with GP 32-15 and GP 32-17. This will mandate
additional NDE requirements for castings.
11.4 Use of bar stock

Duplex and super duplex stainless steel bar stock used to manufacture valve bodies shall
conform to GP 18-04 following the guidance provided in GN 36-016.
The maximum finished diameter of duplex and superduplex stainless steel forged
barstock that may be used to produce valve bodies as well as testing requirements
are provided in GN 36-016 data sheets.
Page 41 of 58 GP 36-20
8 February 2012
Table 10 - Typical acceptable materials for manifold and flowline/pipeline valves
Component/duty Typical acceptable materials

Valve bodies
Hydrocarbon production Carbon steels (e.g., ASTM A350, ASTM A352, ASTM A694)
(1)
Low alloy steels: AISI 4130/8630, ASTM A182 F22
(2,25 CrMo) (1)
Austenitic stainless steels (e.g., type 316L)
Highly alloyed austenitic stainless steels (e.g., 6Mo)
22% Cr duplex SS and 25% Cr super duplex SS (2)
13% Cr martensitic SS F6NM (3)
Deaerated seawater injection Low alloy steels or carbon steel as above (4)
Duplex stainless steel as above
Aerated seawater injection Low alloy steels or carbon steel as above (5)
25% Cr super duplex SS for operating temperatures below
45ºC (113ºF)
Valve internals
Stems Alloy 718, alloy 925, 22% Cr duplex SS, and 25% Cr super
duplex stainless steels, UNS S20910
Seats, gates, balls Alloy 718, alloy 625, alloy 925, 22% Cr duplex SS, and
25% Cr super duplex SS, UNS R30035/R30003/NI0276
Springs Alloy 718, UNS R30035/R30003
Gaskets 6Mo, alloy 825, alloy 625 (6)
Actuators and gearboxes
Actuator cylinder and spring housings Same as for valve bodies (7)
Torque converter and gearbox housings Carbon/low alloy steel or ductile iron (spheroidal graphite) (8)
Actuator springs Low alloy steel, alloy 718, X-750
Notes:
1. Alloy 625 overlay on sealing surfaces or over all process wetted surfaces, depending on service life and
corrosivity of product or chemicals. Note requirements of 9.5 for internally weld overlaid designs.
2. Weld overlaid carbon and low alloy steels generally are preferred to duplex and super duplex castings and
forgings.
3. Martensitic stainless steels are rarely used for subsea valves, as they are not listed by reference standard, and
they have no P-T ratings.
4. Alloy 625 weld overlay on sealing surfaces.
5. Alloy 625 internal weld overlay throughout.
6. 316 SS may be acceptable for internal gaskets not contacted by seawater.
7. Appropriate corrosion protection shall be applied to carbon steel cylinder bores.
8. Impact tested at or below MDT in accordance with material specification.
11.5 Erosion and wear resistant materials
11.5.1 General
A conservative approach towards the use of erosion resistant materials shall be adopted.
Presence of sand rarely can be predicted accurately, and all valves are required to
tolerate pipe scale. For most valves in these applications, wear resistance will be
more important than erosion resistance. Erosion resistance of materials will vary
widely due to local conditions (angle of impingement), but, as a rule of thumb, the
following materials have increasing erosion resistance in the order listed:
 Cobalt alloy 6.
 Cobalt alloy 1.
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8 February 2012
 Partially stabilised zirconia.

 Tungsten carbide with Co binder.
 Sintered silicon carbide.
 Diamond-like carbon.
Other materials that have exhibited good resistance to erosion and corrosion
conditions in testing (warm seawater or sand) but for which there is limited reported
service experience include:
 Diffusion coatings of chromium and boron chromium.
 Thermally sprayed sintered coatings of nickel 17% Cr 3,5% B Si Fe C and
nickel 16% Cr 4% B 4% Si 3% Mo Fe Cu C.
11.5.2 Carbide coatings

a. Tungsten carbide shall be specified at critical locations for optimum erosion and wear
resistance.
b. Unless specified otherwise by BP, binders for tungsten carbide coatings shall nominally
contain 10% cobalt and 4% chromium by total weight (binder composition is 28% Cr).
c. Pure chromium and nickel binders for tungsten carbide coatings shall not be used without
specific BP approval.
11.5.3 ENP and hard chromium plating

a. ENP and hard chromium coatings shall not be specified for preventing long term corrosion
or erosion in process environments.
ENP may be applied to CRA balls of soft seated ball valves for wear resistance, but
thinness of plating means that it is ineffective as an erosion resistant coating.
Plating procedure and testing should be agreed with the valve vendor. For most
applications, a coating containing approximately 11% phosphorous (grade Ni-11P)
is used.
b. The following shall be subject to risk assessment and BP approval:
1. Proposals to use ENP over carbon and low alloy steel components in deepwater valve
applications.
2. If service life is likely to be more than approximately 5 yr.
This is because of the galvanic corrosion susceptibility of carbon steel and low alloy
steel valve parts if the coating is microcracked or porous.
11.6 Weld overlaying of duplex stainless steels

If duplex or super duplex stainless steels are to be weld overlaid with cobalt based hard facing
material or alloy 625, weld procedure qualification shall demonstrate that:
a. Substrate under or adjacent to the overlay is free from sigma or other embrittling phases.
b. Corrosion resistance is not impaired.
Weld overlay of duplex stainless steel may lead to nitrogen depletion and impair
corrosion resistance at overlay/substrate interface.
11.7 Valve internals - metallic

a. Metal to metal seals or seats exposed to raw seawater without CP shall be CRAs, such as
alloys 625, C276, UNS R30003 (AMS 5833), and R30035 (AMS 5834).
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8 February 2012
b. Adequate hardness differential between contacting metallic faces shall be specified to

avoid galling.
A hardness differential of 30 HBN to 40 HBN is recommended. If extensive use is
made of duplex or other stainless steels of the same grade, surface coatings or
plating may be necessary to achieve this differential.
11.8 Valve internals - nonmetallic

a. Selection of nonmetallic materials should follow the guidance provided in GN 36-003.
b. Graphite packing and seat and seal materials (irrespective of whether they are “inhibited”)
shall not be used.
c. Valves containing elastomer or polymer seats or seals shall be fully rated in accordance
with rating tables of ASME B16.34 up to the maximum service temperature, which shall
be clearly indicated on the valve nameplate.
All elastomers have limitations in terms of maximum and minimum operating
temperatures, as described in GN 36-003. For O-ring type seals, nitriles should not
be specified for use above 120°C (248°F). Fluoroelastomers, such as Viton and
Aflas, can function up to 200°C (392°F).
The low temperature limit is often more restrictive, particularly if combined with a
requirement for resistance to rapid gas decompression. Elastomers withstand
exposure to low temperature transients without suffering permanent damage, but
high thermal contraction can lead to transient leaks. Low temperature requirements
need to be considered in detail and defined as accurately as possible. For example,
simply specifying an MDT at standard impact test temperature of valve body or pipe
material should be avoided. A more realistic assessment of minimum temperatures
should be performed and applied.
Elastomers also have limitations in terms of chemical compatibility, and all
materials need to be assessed and assured versus design requirements.
d. Suitability of specific elastomers for use in H2S service shall be established by testing or
service experience.
e. If the potential of extrusion cannot be excluded by control of housing dimensions and
tolerances, seals for high pressure applications shall include filled PTFE up to 345 bar
(5 000 psi) or PEEK (up to 1 034 bar [15 000 psi]) antiextrusion backup rings. HP/HT
design conditions (at or above 1 034 bar and 120°C [15 000 psi and 248°F) shall require
specific testing to assure this aspect of seal performance.
f. Selection of elastomers for dry gas service should consider expected decompression rates
as described in GN 36-005.
If decompression rates differ from “very slow” (e.g., blowing down a long pipeline),
the possibility of gas decompression damage exists in dry gas service. Specific
decompression resistant grades of FKM and HNBR are available. Experience shows
there are very few elastomers that have acceptable resistance, and all of these have
restricted low temperature capability. Testing on actual seals in realistic housings
after prolonged exposure (e.g., 48 hr or more) to high pressure at operating
temperature is the only way to gain confidence in material resistance to rapid gas
decompression.
g. Suitability of elastomers for pressure, temperature, and the fluids for any given service
shall be confirmed or qualified as appropriate.
Product verification testing of subsea valves, generally in accordance with
ISO 10423 (API Spec 6A Appendix F) to performance requirement level 2 (PR2), is
recommended to establish general suitability, leak tightness, and compatibility of
Page 44 of 58 GP 36-20
8 February 2012
materials through the temperature range. Depending on operating requirements,

additional testing (e.g., endurance cycles and/or individual seal performance tests)
may be advisable. Due to the consequences of failure, such testing should be
specified, unless there is a proven track record in the application and the technology
is mature. Paragraph F1.14 of API 6A applies to nonmetallic seals. Guidelines in
NORSOK M-710 also may be useful for confirming nonmetallic material suitability.
12 Fasteners
12.1 Scope
Fasteners shall include:
a. Bolts and nuts for flanged connections (e.g., ASME, API, and compact).
b. Bolts threaded directly into components (e.g., for valve bonnets and instrument
connections).
c. Bolts for tightening clamps (e.g., hub connector clamps and pipe support clamps).
d. Cap screws, circlips, and similar items.
e. Bolts and nuts in lifting equipment or frames used in subsea deployment of permanently
installed items.
12.2 Low alloy steels

a. Low alloy steel bolting shall be specified for flanged connections between carbon and low
alloy steels and for flanged connections between CRAs.
It generally is accepted that, if low alloy steel bolting is used for conventional
flanged connections, CP from sacrificial anodes is effective over the full length of
the bolt, even if the flanges are in CRA materials.
b. Bolting shall conform to ASTM A320 grade L7/L7M or ASTM A320 grade L43.
Grade L7 is typically specified for diameters up to 50 mm (2 in) and Grade L43 for
diameters up to 100 mm (4 in).
c. ASTM A320 Grade L7M shall be specified for external bolting that may be exposed to
sour environments due to joint leakage (e.g., beneath thermal insulation, as required by
NACE MR0175/ISO 15156-2, paragraph A.2.2.4).
d. Maximum individual hardness values of low alloy steel fastener materials exposed to
seawater shall be specified as 34 HRC and verified by sample testing to a procedure
approved by BP.
It is preferable to specify bolting and nut materials with “M” designation, limiting
hardness of material to 22 HRC, but the design strength of such materials may be
inadequate, and there may be significant weight and cost impact.
ISO 13628-1 and Norsok M-001specify maximum hardness of low alloy steel bolts of
32 HRC. These limits may be applied. However, BP is unaware of any failures
occurring at hardness levels up to and including 34 HRC.
EEMUA IS 39 has recommendations for establishing assurance protocols with
fastener suppliers. IS 39 references the BS 6001 series for a testing frequency to
achieve a 98,7% confidence that all products meet the specified hardness values.
e. ASTM A194 grade 7/7M nuts with S3 (low temperature) supplementary requirements shall
be specified.
f. Sealing of bolts, bolt holes, and space between flanges from the external environment and
use of flange protectors and bolt end caps shall not be specified.
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8 February 2012
g. Low alloy steel bolting shall be specified for threaded studs fitted directly into carbon or
low alloy steel components.
Safe use of low alloy steel bolting subsea is dependent on effective CP. A potential of
at least -800 mV (Ag/AgCl/ seawater) needs to be achieved on all points of the bolt.
Factors affecting this potential are:
 Partial immersion - CP is effective only if bolting is fully immersed and there is
an electrical path through water between bolting and anode. Corrosion will
occur if immersion is not continuous (e.g., in splash zones or tidal conditions).
 Geometry - Cathodic potential at any point is dependent on distance from
sacrificial anode, length and width of crevices, and design features causing
shielding of the current through the water.
 Temperature - Increasing temperature will raise the cathodic current density
and reduce the achieved potential, particularly within crevices.
 Coating - Effective external coatings will reduce overall anode current demand,
facilitating achievement of adequate negative potentials in the crevices.
However, thick noncontinuous coatings, such as disbonded thermal insulation,
can shield CP.
 Parent material - Uncoated CRA materials will increase cathode current and
hinder achievement of adequate negative potentials in crevices.
 Burial - Immersion of the connection in mud or silt will reduce the cathodic
potential and, if anaerobic conditions exist, may require more negative CP
potentials for protection (e.g., -900 mV versus Ag/AgCl/ seawater).
 Anode type and water conductivity - Aluminium zinc indium sacrificial anodes
are almost universally used, giving an open circuit voltage of approximately
-1 100 mV (Ag/AgCl/ seawater). If anodes of different type are used or if the
potential is limited, the potential achieved in crevices may be reduced. Salinity
of water (e.g., lower in estuarine conditions) can affect the available cathodic
potential.
These factors should be considered before low alloy steel bolting is selected. If
conditions are outside previous experience, effectiveness of CP should be
investigated (e.g., by finite element analysis or direct experiment).
h. Thin metal coatings (sherardised, hot spun galvanised, zinc nickel electroplate, or zinc
chromate/phosphate) shall be specified to preserve the bolt surface prior to installation and
to aid assembly.
Metallic coatings promote electrical continuity and effectiveness of CP to protect
the fasteners.
i. Nonmetallic coatings shall not be used.
Such coatings (e.g., PTFE) may lead to loss of electrical continuity.
j. Cadmium plating shall not be used.
Corrosion will lead to toxic compounds being released into the sea.
k. If low alloy steel studs and nuts are used for bimetallic steel-titanium flanged joint, studs
shall be electrically isolated from the titanium by ceramic washers or ceramic coated nut
faces but shall be electrically continuous with the steel to ensure receipt of CP.
12.3 Corrosion resistant alloys (CRAs)

a. CRA fasteners shall be specified for:
1. Internal components contacted by process fluids.
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8 February 2012
2. External situations, if CP of low alloy steel materials would be ineffective (e.g.,

splash zones or shielded locations).
b. The following CRAs from Table 1 shall be acceptable:
1. Austenitic stainless steels (all generic types) and nickel alloys in accordance with
GP 36-25.
2. High strength cupronickel.
3. Titanium alloys electrically isolated from CP systems by insulating sleeves, ceramic
washers, or ceramic coated nut faces (e.g., by alumina or alumina titania plasma
spray). Anodising shall be specified if electrical isolation from CP systems cannot be
ensured.
c. Though not the preferred option, 25% Cr duplex SS may also be considered, subject to the
following requirements:
1. Compliance with GP 18-04.
2. Shall be in the solution heat treated condition.
3. Every component shall have microstructure containing 45% ferrite to 65% ferrite, as
demonstrated by Ferritscope testing.
4. Individual hardness not exceeding 28 HRC.
5. Impact testing to demonstrate average of at least 80J -50°C (-58°F) and individual of
at least 60J.
6. With bolt threads formed by rolling.
d. Bolts threaded directly into CRA components shall be of matching materials specification
or near to matching materials specification, if practical, to minimise the threat of galvanic
corrosion.
13 Gaskets
13.1 General
a. Wet made joints shall have 6Mo or alloy 625 gaskets, unless approved otherwise by BP.
b. Metal to metal seals that may be exposed to the external seawater environment without CP
shall be specified in UNS R30035, UNS R30003, alloy 625, or alloy C276.
13.2 Gaskets for wellheads

Gasket materials for wellheads should be type 316 austenitic SS.
Wellhead gaskets are typically 316 type. They are protected by anodes during
installation and wet parking does not occur.
13.3 Gaskets for christmas tree assemblies

a. Gasket materials
1. Gasket materials in subsea hydrocarbon service shall be 6Mo SS, alloy 825, or
alloy 625 in the annealed condition.
Alloy 825 is suitable only for dry made joints.
2. Allowable hardness value shall not exceed 200 HBN.
b. Alloy 825 or alloy 625 shall be specified for HP/HT conditions.
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8 February 2012
c. Alloy 925 may be proposed for alloy 625 weld overlaid joint gaskets, if specified to be
softer than the overlay and subject to BP approval.
d. For non permanent gasket applications, lower grade CRAs may be proposed, subject to BP
approval.
e. Gaskets used in ring grooves overlaid with alloy 625 that may be assembled subsea shall
be specified in alloy 625 or 6Mo SS.
f. Gaskets for treated seawater injection shall be 6Mo SS or equivalent and subject to BP
approval.
g. Gaskets for raw seawater injection shall be compatible with the materials of construction
of associated equipment and shall be subject to BP approval.
h. If gaskets incorporate elastomer “secondary” seals, the elastomer material shall be
compatible with the intended service requirements following the guidance provided in
GN 36-003.
Design of metal gaskets for connections made subsea should have a verified design
that incorporates an elastomer secondary seal, in case hub damage or misalignment
causes problems in obtaining a successful seal after makeup.
13.4 Ring type joint (RTJ) gaskets and other metallic sealing rings
13.4.1 RTJ gaskets

a. Gaskets in ASME RTJ type flanges shall have lower hardness than the base flange
material. Recommended maximum hardness values for RTJ gasket materials in GP 46-01
should be followed.
b. Hardness of alloy 825 RTJ gaskets shall not exceed 200 HBN.
c. If internal corrosion from transported fluids is expected, CRA gasket materials shall be
specified.
d. Type 316 SS and alloy 825 RTJ gasket materials shall be acceptable.
e. Alloy 625 inlay of ring groove shall be specified, unless CRA materials are used for the
base material of the flange.
RTJ type gaskets are a “crush” type gasket and rely on substantial plastic
deformation to maintain sealing integrity. Due to the loading required to effect a
seal, gaskets that are too hard will actually deform the sealing ring groove if there is
not sufficient difference in hardness values.
AV/VX type gaskets do not rely on such high levels of plastic deformation. The seal
relies on sufficient preload to expand the gasket radially with a minimum level of
plastic deformation. During equipment testing, AV/VX gaskets are routinely used
multiple times, whereas an RTJ gasket can be used only once because of the severe
plastic deformation. Because of the nature of this seal, hardness is much less an
issue than the RTJ type gaskets.
13.4.2 Other metallic sealing rings

a. For carbon steel hub connectors, low alloy steels (typically AISI 4130 or AISI 4140) that
conform to GP 36-25 may be specified.
b. For CRA connectors, high strength CRAs in Table 1 that conform to GP 36-25 shall be
specified. Alternate materials may be proposed, subject to BP approval.
Soft metallic coatings, such as silver, are commonly specified to promote gas tight
metal to metal sealing. PTFE type coatings also may be specified.
Page 48 of 58 GP 36-20
8 February 2012
c. If any gasket or metal sealing ring incorporates elastomer “secondary” seals, the elastomer
material shall conform to 13.3h.
13.5 Nonmetallic seals

a. Nonmetallic seals shall be supplied and qualified in accordance with national or
international standards applicable to the equipment in which they are used.
Typically, hydrogenated nitrile (HNBR) and fluoroelastomer (FKM, TFEP, and
FFKM) materials are preferred for elastomer seals. Additional information can be
found on the BP Elastomers website at: http://elastomers.bpweb.bp.com.
Given the complexity of typical topsides and subsea operations and the wide range
of operating temperatures, pressures, and fluids, it is useful to consider rationalising
seal materials selection into a project or asset specific seal selection philosophy,
which details recommended materials against each type of service. This approach is
described in GN 36-015.
b. All elastomer seals shall be fully moulded. Nonmetallic seals shall incorporate
anti-extrusion devices, fabricated in PTFE, PEEK, or appropriate metallurgy, if required.
c. Fluoropolymer encapsulated elastomer O-rings shall not be used.
d. Elastomer seals used in dry gas applications shall have proven capability under rapid
decompression over the appropriate pressure and temperature range.
GN 36-005 provides guidance in selecting seals for gas decompression service.
e. All metallic sealing faces in contact with process fluids shall be weld overlaid with an
appropriate CRA.
14 Hydraulic control and chemical injection systems
14.1 General
a. Materials and their design temperature and pressure limits for hydraulic control and
chemical injection tubing shall be specified in accordance with Table 4.
b. Duplex and super duplex grades to ASTM A789 may be proposed, subject to BP approval.
Duplex stainless steels are not preferred due to susceptibility to hydrogen
embrittlement, given that tubing will be locally cold worked, will not be externally
coated, and will be subject to hydrogen charging from the CP.
14.2 Hydraulic control systems

a. Seamless grades of austenitic and highly alloyed austenitic stainless steels in accordance
with ASTM A269 are acceptable for hydraulic control tubing and associated components.
b. Welded grades may be proposed, subject to BP approval.
c. Zinc and cadmium plated carbon steel components shall not be specified.
d. Aluminium components shall not be specified.
e. Internal hydraulic surfaces (e.g., reservoirs) shall not be painted.
Compatibility of nonmetallic components, such as seals with aqueous control fluids,
is not usually a problem but should be checked. Refer to GP 78-16.
14.3 Chemical injection systems

a. Materials selection for chemical injection duties shall include assessment of:
Page 49 of 58 GP 36-20
8 February 2012
1. Corrosivity of the chemical, either in its intended concentration and purity or if

contaminated by seawater.
2. Effects of contamination of injection chemicals and increased temperatures caused by
backflow of produced fluids.
Following a number of recent significant incidents internal and external to BP
related to corrosion of materials (carbon steel and CRAs) in contact with neat
production chemicals, a GPO High Value Learning (HVL) was issued giving
examples of failures experienced and emphasising the need to ensure production
chemicals are fully compatible with injection system materials. It should be
recognised that corrosion test data provided by a chemical vendor in support of
particular product may not be sufficient and should be checked carefully for the
need to undertake additional and more exacting/specific testing as detailed in
GN 36-024. This is of particular concern if the likely form of attack is localised
corrosion.
b. Austenitic and super austenitic stainless steels may be specified in accordance with 14.2.
c. Corrosion resistant materials, such as alloy 825 and alloy 625, may be proposed, subject to
BP approval.
d. Titanium alloys shall not be used for pure methanol duty. Contact with methanol should be
avoided.
Titanium is susceptible to stress corrosion cracking in pure methanol. The presence
of 5% or more water in methanol inhibits stress corrosion cracking, although
failures have occurred due to accidental contact with undiluted methanol.
e. Nonmetallic seal materials
1. Nonmetallic seal materials shall be selected for individual chemicals, if these can be
specified at the project design stage.
2. Alternatively, materials with good overall chemical resistance, such as FFKM (e.g.,
Chemraz, Kalrez, or spring or pressure energised PTFE), shall be specified.
3. Seals for high pressure shall be designed accordingly (e.g., hard O-rings and plastic
antiextrusion rings).
4. Selection of nonmetallic seal materials should follow the guidance provided in
GN 36-003.
5. Compatibility of nonmetallic materials with particular chemicals shall be
demonstrated following the guidance provided in GN 36-007.
14.4 Hydraulic and chemical injection valves

a. Unless specified otherwise by BP, material selection for valve bodies shall follow that for
associated tubing.
b. Materials for valve internals shall be specified to avoid galling of moving parts.
c. Valve internal components shall not be specified in martensitic or precipitation hardened
grades of stainless steel, such as type 440 and 17-4PH.
Pitting and crevice corrosion of these materials may occur in the event of seawater
contamination.
15 Umbilicals
15.1 Nonmetallic hose conduits

a. Selection of nonmetallic materials for hose construction shall include assessment of:
Page 50 of 58 GP 36-20
8 February 2012
1. Chemical compatibility with hydraulic and injected fluids.

2. Permeation of low molecular weight fluids (especially methanol) through hose liner.
3. Resistance of hoses to internal pressure differential caused by cyclic pressurisation of
conduits.
4. Resistance of hoses to collapse under external hydrostatic pressure, especially in deep
water with low specific gravity fluids.
5. Fatigue behaviour of composite tubes and other metal components in dynamic
umbilicals.
6. End fitting reliability.
Nonmetallic hoses are generally of three part construction:
 Inner extruded thermoplastic liner in contact with pressurising or transported
fluid.
 Synthetic fibre reinforcement layer to contain operating pressure.
 Outer thermoplastic sheath for protection.
b. Acceptable materials for the inner liner are:
1. Polyamide 11.
2. Crosslinked polyethylene.
3. Polyamide 12 with a thin fluoropolymer inner layer.
c. Acceptable material for reinforcement layers is aramid fibre. Other materials may be
proposed, subject to BP approval.
d. Acceptable materials for outer sheaths are:
1. Polyamide 11.
2. Polyether based polyurethane.
e. For polymeric based hoses, material selection shall be based on detailed evaluation of all
fluids to be handled following the guidance provided in GN 36-003 and GN 36-007.
f. Hoses shall be qualified in accordance with API Spec 17E, section 7.9.
For the main production chemical groups:
 Methanol - The impact of plasticiser leaching issues with nylon has been
minimised by the use of methanol-washed grades. Permeation rates for Tefzel
and XLPE are roughly two orders of magnitude better than nylon, and these
should be considered as the primary options for methanol service.
 Scale inhibitors - XLPE or Tefzel are preferred for these slightly acidic water
based polymer solutions.
 Corrosion inhibitors - Water based inhibitors are best handled by XLPE. Nylon
is acceptable if the fluid is not too acidic (pH greater than 4) or if a
hydrocarbon solvent base is used. No compatibility problems reported with
Tefzel.
 Demulsifiers - Typically, these aromatic solvent based fluids can be handled
using nylon hoses, in spite of some history of test failures in corrosion inhibitors
containing aromatic solvents. XLPE is not generally suitable for service in
aromatic hydrocarbons. No compatibility problems reported with Tefzel.
 Wax Inhibitors - Being typically based aromatic hydrocarbons, the same
remarks apply as for demulsifiers.
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8 February 2012
 Wax Dissolvers - If aromatic hydrocarbon based, the same comments apply as

for demulsifiers. Nylon is fine for terpene based solvents, but XLPE is
questionable. No compatibility problems reported with Tefzel.
 Carbonate scale dissolvers (acids) - XLPE and Tefzel have good resistance to
HCl and other inorganic and organic acids. Nylon is not suitable for acidic
scale dissolver service.
 Sulphate scale dissolvers (alkalis) - Strong alkalis are best handled by XLPE or
Tefzel. Nylon has only moderate alkali resistance.
15.2 Metallic tube conduits

The materials requirements of GP 78-19 shall be followed.
Page 52 of 58 GP 36-20
8 February 2012
Annex A
(Normative)
Fabrication sequences
buttering layer, welded to C-Mn steel pup piece, with C-Mn butt weld
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8 February 2012
buttering layer, welded to C-Mn steel pup piece, with alloy 625 butt weld
Page 54 of 58 GP 36-20
8 February 2012
Annex B
(Normative)
BP approval
The need to gain BP approval or guidance for decisions that are beyond or outside specific
requirements contained in this GP but are relevant to its application should in the first instance be
addressed to the designated BP lead materials/corrosion/welding engineer for the job. Depending on
the nature of the request it may require final approval of the materials and corrosion or materials and
welding RPU or GPO TA, as appropriate. If a BP lead materials/corrosion/welding engineer is not
identified for the job then the request should be referred to the materials and corrosion or materials and
welding RPU or GPO TA, as appropriate. For deviations to this GP the approval procedure set out in
the latest version of SRP 5.0-0001, Section 4 – shall be followed.
Page 55 of 58 GP 36-20
8 February 2012
Bibliography
BP
[1] GIS 18-012, Storage and Control of Welding Consumables.
[2] GIS 36-201, BP Global Subsea Standardisation Materials Rating Assessment and Qualification
Requirements.
[3] GN 06-006, Guidelines for Selecting, Testing and Applying Corrosion Inhibitors in Exploration and
Production.
[4] GN 36-002, Super Martensitic Stainless Steel Flowlines and Pipelines - Avoidance of Hydrogen
Induced Stress Cracking.
[5] GN 36-004, Best Practice for Selection of Materials for Downhole Equipment.
[6] GN 36-006, Status of Plastic Liner Technology for Flowline Applications.
[7] GN 36-010, Recommended Practice for Subsea Insulation and Buoyancy Systems.
[8] GN 36-015, Project Guidelines for Selecting Seals.
[9] GN 36-019, Guidelines for Selecting Downhole Tubing Materials for Injection Wells.
[10] GN 36-024, Test Methods/Protocols for Assessing Materials/ Production Chemicals Compatibility.
[11] GP 10-50, Engineered Equipment.
[12] GP 32-15, Quality Management, Inspection and Test Requirements for Purchased Equipment and
Materials - Valves.
[13] GP 32-17, Quality Management, Inspection and Test Requirements for Purchased Equipment and
Materials - Subsea Equipment.
[14] GP 36-15, Materials Selection for Surface (Topsides) Equipment in Oil and Gas Production Facilities.
[15] GP 65-75, Design of Unbonded Flexible Pipe Risers and Flowlines.
[16] GP 78-10, Design, Fabrication, Transportation, and Installation of Subsea Manifolds.
[17] GP 78-11, Subsea Chemical Injection System Design and Operation.
[18] GP 78-16, Subsea Control Fluid Selection.
[19] RD 78-001, Hydraulic Piping and Small Bore Fittings for Control Systems.
[20] RD 78-002, Identification, Traceability and Certification Requirements for Subsea Production System
and Umbilicals, Risers, and Flowlines Equipment.
American Petroleum Institute (API)

[21] API RP 6HP, Design of High Pressure Equipment.
[22] API RP 14B, Design, Installation, Repair and Operation of Subsurface Safety Valve Systems.
Page 56 of 58 GP 36-20
8 February 2012
[23] API RP 14E, Recommended Practice for Design and Installation of Offshore Production Platform
Piping Systems (ISO 13703).
[24] API RP 17A, Design and Operation of Subsea Production Systems.
[25] API RP 17B, Flexible Pipe.
[26] API Spec 5LD, CRA Clad or Lined Steel Pipe.
[27] API Spec 14A, Subsurface Safety Valve Equipment.
[28] API Spec 17F, Subsea Production Control Systems.
American Society of Mechanical Engineers (ASME)

[29] ASME Boiler and Pressure Vessel Code Section VIII - Rules for Construction of Pressure Vessels
Division 3 - Alternative Rules Construction of High Pressure Vessels.
American Society for Testing and Materials (ASTM)

[30] ASTM A193, Alloy-Steel and Stainless Steel Bolting Materials for High Temperature or High
Pressure Service or Other Special Purpose Applications.
[31] ASME B31.8, Gas Transmission and Distribution Piping Systems.
British Standards Institute (BSI)

[32] BS 6001-0, Sampling procedures for inspection by attributes. Introduction to the BS 6001 (ISO 2859)
series of standards for sampling for inspection by attributes.
Det Norske Veritas (DNV)

[33] DNV-OS-F101, Submarine Pipeline Systems.
[34] DNV-RP-F201, Design of Titanium Risers.
The Engineering Equipment and Materials Users’ Association (EEMUA)

[35] EEMUA IS 39, Improving Quality Assurance of Industrial Fastener Materials in Critical Applications.
European Federation of Corrosion (EFC)

[36] EFC 39, The Use of Corrosion Inhibitors in Oil & Gas Production.
International Organisation for Standardisation (ISO)

[37] ISO 10433, Petroleum and natural gas industries - Drilling and production equipment - Specification
for wellhead surface safety valves and underwater safety valves for offshore service.
[38] ISO 13628-6, Petroleum and natural gas industries - Design and operation of subsea production
systems - Part 6: Subsea production control systems.
[39] ISO 14313, Petroleum and natural gas industries - Pipeline transportation systems - Pipeline valves.
[40] ISO 15156-1 Petroleum and natural gas industries - Materials for use in H2S-containing environments
in oil and gas production - Part 1: General principles for selection of cracking-resistant materials.
[41] ISO 15156-3 Petroleum and natural gas industries - Materials for use in H2S-containing environments
in oil and gas production - Part 3: Cracking-resistant CRAs (corrosion-resistant alloys) and other
alloys.
Page 57 of 58 GP 36-20
8 February 2012
NACE International (NACE)

[42] NACE TM0177, Laboratory Testing of Metals for Resistance to Sulfide Stress Cracking and Stress
Corrosion Cracking in H2S Environments.
Norsk Sokkels Konkuranseposisjon (NORSOK) Norwegian standards association

[43] NORSOK M-001, Materials selection.
[44] NORSOK M-630, Material data sheets for piping.
[45] NORSOK M-710, Qualification of nonmetallic sealing materials and manufacturers.
Page 58 of 58 GP 36-20
8 February 2012

GP 36-20 - Materials Selection For Subsea Equipment

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Group Practice

Materials Selection for Subsea Equipment

Copyright © 2012 BP International Ltd. All rights reserved.

10.3 Production and injection risers .................................................................................. 37

a. This GP provides requirements, recommendations, and possibilities for selection of

 External coating and cathodic protection designs (refer to category 06

• For dated references, only the edition cited applies.

GN 36-016 Piping Materials Data Sheets.

American Petroleum Institute (API)

American Society of Mechanical Engineers (ASME)

American Society for Testing and Materials (ASTM)

British Standards Institute (BSI)

Det Norske Veritas (DNV)

International Organisation for Standardisation (ISO)

NACE International (NACE)

3 Terms and definitions

Carbon Equivalent International Institute of Welding (CEIIW)

High pressure/high temperature (HP/HT)

Quality heat treatment

Includes final austenitisation, quench from final austenitisation, tempering or

4 Symbols and abbreviations

CRA Corrosion resistant alloy.

ELI Extra low interstitial.

ENP Electroless nickel plating.

ERW/HFI Electric resistance welded/high frequency induction.

FEA Finite element analysis.

FFKM ASTM designation for perfluoroelastomers.

FKM Viton type fluoroelastomers.

HAZ Heat affected zone.

HBN Brinell hardness number.

HDT Heat distortion temperature.

HIC Hydrogen induced cracking.

HIP Hot isostatic pressed.

HNBR Hydrogenated NBR (nitrile butadiene rubber).

HP/HT High pressure/high temperature.

HRC Rockwell hardness “C”.

Hv Vickers hardness number.

LME Liquid metal embrittlement.

MDT Minimum design temperature.

NBR Nitrile butadiene rubber.

NDE Nondestructive examination.

PEEK Polyether ether ketone.

PLET Pipeline end termination.

PREw Pitting resistance equivalent (w).

PSL Product specification level.

PWC Preferential weld corrosion.

PWHT Postweld heat treatment.

QA/QC Quality assurance/quality control.

RTJ Ring type joint.

SCC Stress corrosion cracking.

SCR Steel catenary riser.

SMYS Specified minimum yield strength.

SOHIC Stress oriented HIC (hydrogen induced cracking).

SSC Sulphide stress cracking.

Tg Glass transition temperature.

UNS Unified numbering system.

XLPE Cross linked polyethylene.

5 Materials selection philosophy

10. Operational criticality.

6 Principles of materials selection

6.1 Materials selection for process side environment

6.1.2 H2S containing environments

a. Materials for H2S containing environments shall conform to GP 36-25.