Reference Tool for Sour Service Conversion of Existing Carbon Steel Pipelines

October 2004

Alberta Energy and Utilities Board

ALBERTA ENERGY AND UTILITIES BOARD Reference Tool for Sour Service Conversion of Existing Carbon Steel Pipelines

October 2004

Published by Alberta Energy and Utilities Board 640 5 Avenue SW Calgary, Alberta T2P 3G4 Telephone: (403) 297-8311 Fax: (403) 297-7040 Web site: www.eub.gov.ab.ca

Contents
Introduction...................................................................................................................................... 1 1 2 Pipeline Jurisdiction and Application of Requirements ............................................................ 2 Overview ................................................................................................................................... 2 2.1 General Effects of Sour Service Environment on Carbon Steel Pipelines.......................... 2 2.2 Technical Requirements in General.................................................................................... 3 Materials for Sour Service......................................................................................................... 4 3.1 Pipe ..................................................................................................................................... 4 3.1.1 Compliance Criteria .................................................................................................. 5 3.2 Components ........................................................................................................................ 6 3.2.1 Fittings ...................................................................................................................... 6 3.2.1.1 Compliance Criteria ..................................................................................... 6 3.2.2 Flanges ...................................................................................................................... 6 3.2.2.1 Compliance Criteria ..................................................................................... 7 3.2.3 Valves ....................................................................................................................... 7 3.2.3.1 Compliance Criteria ..................................................................................... 7 Design for Sour Service ............................................................................................................ 8 4.1 Stress Level Limitation ....................................................................................................... 8 4.2 Sectionalizing Valves ......................................................................................................... 8 4.3 Pipe-type and Bottle-type Holders...................................................................................... 8 4.4 Internal Corrosion Mitigation and Monitoring ................................................................... 9 4.5 Liners for Carbon Steel Pipelines ....................................................................................... 9 Construction and Nondestructive Inspection for Sour Service ................................................. 9 Macrohardness of Qualification Weld ................................................................................ 9 Nondestructive Inspection of Circumferential Welds....................................................... 10 5.1 Compliance Criteria .......................................................................................................... 10 5.2 Construction Methods Not Acceptable for Sour Service.................................................. 10 Pipeline Integrity Verification for Sour Service Conversion .................................................. 11 Additional Criteria for Sour Service Conversion Involving MOP Increase, Pipeline Resumption, and Blending of Fluids ....................................................................................... 11 Additional Criteria for Sour Service Conversion Involving Gas with Greater Than 10 Moles of H2S Gas per Kilomole of Natural Gas ................................................................................ 12 Sampling Criteria .................................................................................................................... 13 9.1 Material Verification......................................................................................................... 13 9.2 Integrity Verification ........................................................................................................ 14 9.3 Weld Verification ............................................................................................................. 16

6 7 8 9

Glossary ......................................................................................................................................... 17 References...................................................................................................................................... 21

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

Introduction
This document provides technical information for the sour service conversion of existing carbon steel pipelines. Sour service refers to a service in which combinations of the hydrogen sulphide (H2S) content in the gas phase of the pipeline substance and the maximum operating pressure (MOP) of the pipeline exceed that specified in the Canadian Standard Association (CSA) Standard CSA Z662: Oil and Gas Pipeline Systems. This document refers to the Pipeline Regulation and the CSA sour service requirements, and highlights certain requirements contained in Guide 56: Energy Development Applications and Schedules. CSA Z662 contains sour service requirements for new pipelines. For existing pipelines, prior to a change in service fluid, the licensee is required to conduct an engineering assessment to determine if the pipeline is suitable for the new service fluid. This document provides guidance for engineering assessment related to sour service conversion. By following this document, the licensee will be able to verify and, if requested, provide information on technical compliance with respect to pipeline material, design, construction, and nondestructive inspection, as well as pipeline integrity. In some sections this document recommends a certain action to comply with requirements in CSA or the Pipeline Regulation by using the word should. Where the licensee chooses to demonstrate compliance by other means, it must provide sufficient technical information to demonstrate that the requirement is satisfied. The EUB will carefully evaluate such technical information. When converting pipelines to sour service, the licensee is also required to meet the public consultation and notification requirements in Guide 56, as well as the emergency response requirements in Guide 71: Emergency Preparedness and Response Requirements for the Upstream Petroleum Industry. This document will not be used to re-evaluate existing pipelines that were already licensed for the transportation of sour service natural gas or sour service multiphase oil well effluent fluids. Please direct questions related to this document to Shu Lee, of the EUB Operations Group, at (403) 297-3367.

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

Pipeline Jurisdiction and Application of Requirements

The requirements referred to in this document apply to all pipelines licensed under the Pipeline Act. The licensee requesting sour service conversion must complete a nonroutine application in accordance with Guide 56 and should complete the applicable sections of the Checklist for Minimum Technical Requirements for Pipeline Applications. Additionally, it must address the applicable requirements of this document. Pipelines listed in Part 1 of the Pipeline Act are outside the jurisdiction of the Pipeline Act and need not comply with the EUB requirements respecting pipelines. Existing pipelines currently licensed to transport sour service natural gas or sour service multiphase oil well effluent fluids may continue to operate in the same service conditions. However, the EUB requires an application for any conversion of these pipelines to transport natural gas containing greater than 10 moles of H2S gas per kilomole of natural gas, which must be supported by an engineering assessment demonstrating compliance with the sour service requirements of the current edition of CSA Z662. CSA Z662 allows the option for the design and construction of compressor and pump station piping to be in accordance with ASME Standard B31.3 Process Piping. ASME B31.3 does not specifically address sour service requirements. Where there are pipelines other than compressor and pump station piping that were designed and constructed to ASME B31.3 and the licensee wishes to convert these pipelines to sour service, it must evaluate these pipelines and ensure that they comply with the requirements referred to in this document.

Overview
2.1 General Effects of Sour Service Environment on Carbon Steel Pipelines A sour service environment is, in general, considered as any environment containing H2S. H2S in the presence of water may result in damage to carbon steel pipelines in form of corrosion, cracking, or blistering. The effects of H2S on steels could be classified as those that require external stress, such as sulphide stress cracking (SSC), and those that do not, such as hydrogen induced cracking (HIC), and corrosion. The presence of carbon dioxide in the sour environment tends to increase the corrosion rate in the steel; it may also increase the susceptibility of the steel to both SSC and HIC, with the effect on HIC being more pronounced. SSC is characterized by an initial single straight transgranular crack that develops under the application of an external stress, either applied or residual. It may initiate at a corrosion pit (or any other feature that may act as a stress raiser) or through a hydrogen cracking mechanism (e.g., blistering) and then propagate into a brittle fracture perpendicular to the direction of the applied stress. SSC in high-strength steels tends to have considerable branching, while that in low-strength steels shows little. SSC may occur in welds or in the heat-affected zones next to the welds. It usually occurs in carbon steels with tensile strengths greater than 550 megapascals (MPa). However, SSC failures have also occurred in steels with tensile strengths less than 550 MPa. This is primarily due to rapid cooling of weldment, creating localized areas of high hardness. Based on industry experience, a hardness value of RC 22 (or BHN 235) is considered to be the maximum hardness compatible with acceptable resistance to SSC. Other factors that

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

affect the resistance of steel to SSC include the microstructure, heat treatment process, and alloying elements of the steel. In some cases, SSC may have been initiated by HIC where stresses created by the hydrogen blisters reach levels high enough to promote sulphide stress cracks. HIC does not normally occur in welds, but rather in pipe body areas having slag inclusions that would act as sites for the collection of diffusing hydrogen. HIC involves two basic forms, straight cracks and stepwise cracks. It can occur in low-strength steels with hardness values well below RC 22, with or without the presence of an external stress. Corrosion at the steel surface produces atomic hydrogen, which penetrates and diffuses through the steel until it is trapped at naturally occurring irregularities in the metal, such as nonmetallic inclusions and laminations. This atomic hydrogen combines into molecular hydrogen and builds up a gas pressure high enough to surpass the yield strength of the steel, forming blisters. Adjoining blisters may propagate as cracks, normally parallel to the rolling direction of the steel. The blistering mechanism requires no external stresses. When the hydrogen builds to high pressures, the blisters expand, usually towards both the inside and outside surfaces. When two blisters in different planes approach each other, the hydrogen pressure within them creates stresses on the small metal ligament sufficient to break metallic bonds or to fracture the metal. In the absence of an external stress, these stresses are normally located at the blister crack tips, ultimately resulting in tearing between blisters on adjacent planes, or stepwise cracking. Another phenomenon associated with HIC is hydrogen embrittlement in steel pipe and welded joints, which generally denotes a loss in ductility of the metal as a result of hydrogen penetration. The susceptibility to hydrogen embrittlement depends on the chemistry and microstructure of the material. Therefore, different regions of the pipe and weldment may embrittle differently due to the presence of hydrogen. Additional specific information on the effects of sour service environment on steel pipelines may be found in the references listed at the end of this document. 2.2 Technical Requirements in General The intent of this document is to ensure that existing pipelines intended for sour service conversion are in compliance with the current requirements for sour service. The Pipeline Regulation adopts CSA Z662 as the minimum requirements for the design, construction, testing, operation, maintenance, repair, and leak detection of pipelines in Alberta. CSA Z662 contains clauses pertaining to material specifications, design guidelines, and construction and inspection criteria, as well as defect assessment criteria. CSA Z662 also cites CSA Z245 standards for material requirements for pipe, fittings, flanges, and valves and includes specific clauses for the design, construction, and inspection of sour service pipelines. While there are clauses in CSA Z662 that provide guidelines for engineering assessment, Clause 10.11.3 is the only one that applies to change of service. This document provides guidance for engineering assessment related to sour service conversion. Specifically, such an engineering assessment must include considerations of material properties for pipe, fittings, flanges and valves, design stresses, construction, pressure testing and integrity verification. The consideration of construction should include the review of welding

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

procedures and radiographic inspection records of circumferential welds of the pipeline. The EUB has grouped them as follows in Sections 3, 4, 5, and 6: materials, design, construction and nondestructive inspection, and pipeline integrity verification. Additional criteria for sour service conversion that also involves MOP increase, pipeline resumption, blending, and pipelines transporting natural gas that contains more than 10 moles of H2S gas per kilomole of natural gas are in Sections 7 and 8, while sampling criteria are in Section 9. The licensee requesting approval for sour service conversion must ensure that all of the applicable requirements are met.

Materials for Sour Service

Sour service is defined in accordance with the requirements of CSA Z662, Clause 5.4.1. This definition applies to any fluid that contains H2S in the gas phase. CSA Z662 cites CSA Z245.1: Steel Line Pipe, Z245.11: Steel Fittings, Z245.12: Steel Flanges, and Z245.15: Steel Valves, each of which contains a sour service clause. As specified by CSA Z662, Clause 5.4.2.2, the EUB requires that materials intended for sour service comply with the requirements of the sour service clause of the applicable CSA Z245 Standards; where no applicable CSA Standard exists, the material requirements of the National Association of Corrosion Engineers (NACE) Standard MR0175: Sulphide Stress Cracking Resistant Metallic Materials for Oilfield Equipment apply. Table 5.1 and Table 5.3 of CSA Z662 contain limitations and specific information on material notch toughness requirements that are based on fracture initiation and fracture propagation considerations. The licensee should demonstrate that these limitations and requirements are satisfied when sour service conversion is contemplated. Clause 5.2.3.2 of CSA Z662 states that where Category II or III notch toughness properties are required for pipe, the components and valves to be used must have proven Category II notch toughness properties and must also satisfy the limitations as per Table 5.3. Clause 5.2.3.1 states that proven notch toughness properties are not required for steel components and valves smaller than NPS 4 or for valves having a nominal pressure class of PN20, regardless of size. Due to uncertainty about material properties and manufacturing processes of existing pipe of unknown origin, the EUB is not prepared to permit the use of such pipe in sour service. 3.1 Pipe Clause 1.1 of CSA Z245.1 indicates that the standard covers both seamless and welded pipe, hence the sour service requirements described in Clause 16 also apply to those nonCSA seamless pipes listed in Table 5.3 of CSA Z662 (e.g., ASTM A333: Specification for Seamless and Welded Steel Pipe for Low-Temperature Service, or A106: Specification for Seamless Carbon Steel Pipe for High-Temperature Service). Although NACE Standard MR0175 provides comprehensive sour service requirements for pipe material, it does not specifically address microhardness testing, which is required by CSA Z245.1. Therefore the EUB cautions licensees that pipe meeting the NACE requirements alone is not considered as being in compliance with the CSA requirements for sour service. The CSA sour service requirements are:

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

Macrohardness at any location in the pipe, including the seam weld and the heataffected zones for welded pipe, must not exceed 22 HRC or an equivalent value obtained by conversion from another macrohardness scale in accordance with the requirements of ASTM Standard E140: Hardness Conversion Tables for Metals, as stated in CSA Z245.1, Clause 16.4. Microhardness at any location in the pipe, including the seam weld and the heataffected zones for welded pipe, must not exceed 248 HV500, as stated in CSA Z245.1, Clause 16.5. Electric welded (ERW) pipe with an outside diameter of 60.3 millimetres or larger must be subjected to the root guided-bend test in accordance with the applicable requirements of CSA Z245.1, Clause 7.5.2, as stated in CSA Z245.1, Clause 16.6. The acceptance criteria for the dimensions of laminations in the pipe body must be as specified in CSA Z245.1, Clause 16.9. The licensee must assess the susceptibility of pipe materials to HIC and give due consideration in design to material selection and heat treatment, as required by CSA Z662, Clause 5.4.2.1. Where HIC testing is deemed necessary, it must be performed on the pipe body in accordance with the requirements of NACE Standard TM0284: Evaluation of Pipeline and Pressure Vessel Steels for Resistance to HydrogenInduced Cracking, as stated in CSA Z245.1, Clause 16.7.

The above requirements should be met prior to sour service conversion. The EUB applies the microhardness requirement to both welded and seamless pipe. Although material testing for microhardness is not mandatory for seamless pipe, the licensee should evaluate any seamless pipe in its pipeline system and ensure that it meets the microhardness requirement. Conversion from macrohardness to microhardness is not acceptable. 3.1.1 Compliance Criteria

In the engineering assessment of suitability for sour service conversion, the licensee should demonstrate compliance by providing either (a) or (b) of the following or a combination of both: (a) (i) for CSA pipe, a certificate of compliance from the manufacturer stating that the pipe was manufactured, sampled, tested, and inspected in accordance with the current CSA Z245.1 requirements for sour service, or a letter accompanied by an engineering assessment and stamped and signed by a professional engineer representing the manufacturer or the designer, confirming that the pipe meets the current CSA Z245.1 requirements for sour service, or (ii) for non-CSA pipe that is listed in Table 5.3 of CSA Z662 (e.g., ASTM A333, ASTM A106 or API 5L, Specification for Line Pipe), a letter accompanied by an engineering assessment and stamped and signed by a professional engineer representing the manufacturer or the designer confirming that the pipe meets the current CSA Z245.1 requirements for sour service, or

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

(b)

an evaluation of the results of material testing on cutout pipe samples, along with a letter as described in (a) (i) or (ii) above. Pipe sampling should be done in accordance with the schedule and criteria set out in Section 9 of this document.

Note that if the pipe is dual marked with one marking being CSA Z245.1, it is only considered as meeting general CSA requirements, and should be verified for sour service in accordance with the procedure described in item (a)(i) above. The category of pipe is not related to sour service compatibility. (Refer to CSA Z662, Table 5.1, and CSA Z245.1, Clause 8.4, for notch toughness requirements.) 3.2 Components The term component is defined by CSA as a pressure-containing member of the pipeline system other than pipe; it generally includes fittings, flanges, and valves. Requirements for these components are described in CSA Z245.11, CSA Z245.12, and CSA Z245.15 respectively. Sour service requirements for fittings, flanges, and valves are included in Clause 13 of CSA Z245.11, CSA Z245.12, and CSA Z245.15 respectively, all of which make reference to NACE Standard MR0175. CSA Z662, Table 5.3, covers some non-CSA fittings, flanges, and valves (e.g., ASME B16.5: Pipe Flanges and Flanged Fittings and ASME 16.34: Valves Flanged Threaded and Welding End). These components must also comply with the requirements of Clause 13 of the CSA codes. 3.2.1 Fittings

Clause 13 of CSA Z245.11 provides specific requirements for macrohardness testing of welding procedure qualification welds related to fittings. Any fitting listed in Table 5.3 of CSA Z662 that contains a welded part, either through manufacturing or repair, must comply with the macrohardness requirement. Fittings that contain no welded parts and comply with NACE requirements are considered acceptable for sour service. The above requirements should be met prior to sour service conversion 3.2.1.1 Compliance Criteria In the engineering assessment of suitability for sour service conversion, the licensee should demonstrate compliance by providing either of the following: (a) a certificate of compliance from the manufacturer stating that the fittings were manufactured, sampled, tested, and inspected in accordance with the current CSA sour service requirements or, for fittings containing no welded parts, with the current NACE requirements, or (b) a letter accompanied by an engineering assessment and stamped and signed by a professional engineer representing the manufacturer or designer confirming that the fittings meet the current CSA sour service requirements or, for fittings containing no welded parts, the current NACE requirements. 3.2.2 Flanges

Clause 13 of CSA Z245.12 provides specific requirements for macrohardness testing of welding procedure qualification welds related to flanges. Any flange listed in Table 5.3 of CSA Z662 that has repair done by welding must comply with these requirements.

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

Flanges that contain no welded parts and comply with NACE requirements are considered acceptable for sour service. The above requirements should be met prior to sour service conversion. 3.2.2.1 Compliance Criteria In the engineering assessment of suitability for sour service conversion, the licensee should demonstrate compliance by providing either of the following: (a) a certificate of compliance from the manufacturer stating that the flanges were manufactured, sampled, tested, and inspected in accordance with the current CSA sour service requirements or, for flanges containing no welded parts, with the current NACE requirements, or (b) a letter accompanied by an engineering assessment and stamped and signed by a professional engineer representing the manufacturer or designer confirming that the flanges meet the current CSA sour service requirements or, for flanges containing no welded parts, the current NACE requirements. 3.2.3 Valves

Clause 13 of CSA Z245.15 includes macrohardness and microhardness requirements for valves containing a welded part. It specifically states that macrohardness traverses on a cross-section of the procedure qualification weld must be performed in accordance with the requirements of ASTM Standard E 18: Standard Test Methods for Rockwell Hardness and Rockwell Superficial Hardness of Metallic Materials or E 92: Test Methods for Vickers Hardness of Metallic Materials, as well as CSA Z245.15, Figure 13. It also states that when the weld procedure does not include post-weld heat treatment, microhardness traverses on a cross-section of the procedure qualification weld must be performed in accordance with the requirements of ASTM Standard E 384: Microhardness of Materials and CSA Z245.15, Figure 14. Therefore if valves contain a welded part and the qualification weld procedure does not include post-weld heat treatment, confirmation of NACE compliance, macrohardness, and microhardness is required. Microhardness testing is not required if the qualification weld procedure includes post-weld heat treatment, as confirmed by the manufacturer. Valves containing no welded parts and meeting NACE requirements, as confirmed by the manufacturer, are considered as meeting CSA sour service requirements. Non-CSA valves listed in CSA Z662, Table 5.3, are subject to the same sour service requirements in Clause 13 of CSA Z245.15. The above requirements should be met prior to sour service conversion. 3.2.3.1 Compliance Criteria In the engineering assessment of suitability for sour service conversion, the licensee should demonstrate compliance by providing either of the following: (a) for a CSA valve, a certificate of compliance from the manufacturer stating that the valve was manufactured, sampled, tested, and inspected in accordance with the current CSA Z245.15 requirements for sour service or a letter accompanied by an

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

engineering assessment and stamped and signed by a professional engineer representing the manufacturer or the designer confirming that the valve meets the current CSA Z245.15 requirements for sour service, or (b) for a non-CSA valve listed in Table 5.3 of CSA Z662, a letter accompanied by an engineering assessment and stamped and signed by a professional engineer representing the manufacturer or the designer confirming that the valve meets the current CSA Z245.15 requirements for sour service. Note that if the valve is dual marked with one marking being CSA Z245.15, it is only considered as meeting general CSA requirements, and should be verified for sour service in accordance with the procedure described in item (a) above.

Design for Sour Service

4.1 Stress Level Limitation CSA Z662, Table 4.2, contains location factors used to calculate the maximum allowable stress level for a pipeline. These location factors result in a lower allowable operating stress level for gas piping in sour service. Prior to conversion, the licensee should assess the area where the pipeline is located, and determine if there is a change of class location designation as a result of any land development projects, surface improvements, or subdivisions. The licensee should ensure that the operating stress level for the pipeline, including that at any road crossings, does not exceed the maximum allowable based on the location factors contained in Table 4.2 of CSA Z662. Any exceptions must be accompanied by an engineering assessment to determine if the pipeline is suitable for the change. 4.2 Sectionalizing Valves The licensee requesting sour service conversion for gas piping should consider the use of sectionalizing valves with automatic closing devices to minimize H2S gas release volume, as required in CSA Z662, Clause 4.4.10. The licensee should consider the effects of any change in pipeline operating conditions, and control and activation set-points. Where emergency shutdown devices and ancillary equipment are required, the licensee must annually inspect and confirm the proper operation of such devices and equipment, in accordance with the Pipeline Regulation and CSA Z662, Clause 10.6.5. The Pipeline Regulation, Interim Directive (ID) 81-3: Minimum Distance Requirements Separating New Sour Gas Facilities from Residential and Other Developments, and Section 8 of this document include specific requirements for sectionalizing pipelines transporting natural gas containing more than 10 moles of H2S gas per kilomole of natural gas to meet setback requirements. 4.3 Pipe-type and Bottle-type Holders Prior to conversion, the licensee should evaluate the gas pipeline system and ensure that no pipe-type or bottle-type holders associated with the pipeline system are used for gas storage in sour service, as required in CSA Z662, clause 4.12.1.1.

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

4.4

Internal Corrosion Mitigation and Monitoring EUB Guide 56, Schedule 3, requires that prior to operation, procedures for internal corrosion mitigation and monitoring be implemented. A sour service environment could be more corrosive than a non-sour service environment due to the presence of H2S. Therefore, the licensee requesting sour service conversion should evaluate the operating conditions of the pipeline, the corrosivity of the service fluid, and metallurgical and weld factors and institute, revise, and maintain programs to mitigate internal corrosion in accordance with the requirements of CSA Z662, Clause 9.4. The licensee must also conduct an annual inspection for internal corrosion mitigation, in accordance with the Pipeline Regulation.

4.5

Liners for Carbon Steel Pipelines The licensee may consider the use of liners for internal corrosion mitigation. Depending on the material and pressure rating, a liner could be installed within an existing carbon steel pipeline as an expanded liner or as a free-standing liner. An expanded liner (e.g., high-density polyethylene or nylon) is only a corrosion barrier; it is not acceptable as a pressure-retaining component. The pipeline must have pressure integrity on its own before installing a liner. An expanded liner is not acceptable as a substitute for sour service pipe material; the steel pipe must meet sour service requirements, in accordance with the Pipeline Regulation and CSA Z662. A free-standing liner (e.g., high-density polyethylene, nylon fiberglass, or other composite material) is a pressure-retaining component and may be acceptable as a substitute for sour service pipe if the liner material is suitable and licensing limitations are met. The EUB may consider sour service conversion of existing polyethylene, fiberglass, or composite pipe for gas service in CSA Class 1 location areas limited to a maximum H2S content of 10 moles per kilomole of natural gas and an MOP of 4960 kilopascals (kPa). For fiberglass and composite pipe, the joints should be designed and rated for gas service by the manufacturer, and the previous performance history should also be considered.

Construction and Nondestructive Inspection for Sour Service

Clauses 7.7.11 and 7.10.2.2 of CSA Z662 specify the construction and nondestructive inspection requirements for sour service pipelines. Clause 7.2.5 states that those requirements also apply to pipelines constructed using welding procedure contained in ASME Boiler and Pressure Vessel Code, Section IX: Welding and Brazing Qualifications: Macrohardness of Qualification Weld CSA Z662, Clause 7.7.11, states that for sour service, during qualification of the welding procedure specifications, the macrohardness of the deposited weld metal and heataffected zones, determined in accordance with the requirements of ASTM E 18, must not exceed 22 HRC.

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

Nondestructive Inspection of Circumferential Welds CSA Z662, Clause 7.10.2.2, states that for sour service, all butt welds must be inspected for imperfections or other abnormal indications by radiographic or ultrasonic methods or a combination of such methods for 100 per cent of their circumferences, in accordance with the requirements of CSA Z662, Clause 7.10.4. For existing pipelines, the licensee must conduct an engineering assessment to evaluate the feasibility for sour service conversion, and should assess the extent to which the above requirements are met. 5.1 Compliance Criteria In the engineering assessment of suitability for sour service conversion, the licensee should demonstrate compliance by providing either (a) or (b) of the following: (a) (i) a welding procedure qualification report confirming that the macrohardness of the deposited weld metal and heat-affected zones was determined in accordance with the requirements of ASTM E18 and that it did not exceed 22 HRC, and

(ii) a nondestructive inspection report confirming that all butt welds of the pipeline were inspected for 100 per cent of their circumferences, in accordance with the requirements of CSA Z662, Clause 7.10.4, and were evaluated on the basis of the applicable requirements of Clauses 7.11 and 7.15.10, or (b) an evaluation of the results of material testing on cutout pipe samples, if any of the information in (a) is unavailable. Weld sampling should be done in accordance with the schedule and criteria set out in Section 9 of this document. The licensee should also visually inspect the butt welds of the samples according to CSA Z662, Clause 7.10.3, and evaluate surface imperfections on the basis of the applicable requirements of Clause 7.11. 5.2 Construction Methods Not Acceptable for Sour Service CSA Z662, Clause 7.11, describes the standards of acceptability of indications of imperfections located by nondestructive inspection, and cautions that for sour service, additional restrictions on indications of internal surface imperfections may be warranted. CSA Z662 prohibits or restricts the use of certain welding procedures and construction methods for sour service pipelines. In the engineering assessment of suitability for sour service conversion, the licensee should evaluate the pipeline construction record and joining procedure specification, or conduct weld verification in accordance with the criteria set out in Section 9 of this document, and ensure that no unacceptable welded joints or connections, such as the following, exist on the pipeline: Partial-penetration welds CSA Z662, Clause 4.5.1.4, prohibits the use of partial-penetration welds for gas piping in sour service but does not exclude liquid service. A partial-penetration weld is normally designed to have a joint penetration between 85 and 100 per cent of the nominal wall thickness, leaving a small space near the root that could be subject to internal corrosion or SSC in the event that there is fluid at the steel surface.

10

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

Threaded joints CSA Z662, Clause 4.5.2, notes that threaded joints should be avoided in sour service. The EUB does not allow threaded joints for sour service due to potential leakage and effects of crevice corrosion, erosion, and unusual bending and loading.

Mechanical interference fit (MIF) joints CSA Z662, Clause 4.5.3.4, prohibits the use of MIF joints in above-grade piping or in sour service gas piping, but does not exclude liquid service. MIF joints may be subject to effects of torsional and bending loads, which could potentially cause leakage. Cold-working may also result in susceptibility to SSC.

Explosion-welded joints CSA Z662, Clause 7.16.1.3, prohibits the use of explosion-welded joints for sour service. Explosion-welded joints could result in root defects, lack of uniformity in hardness, and difficulty to do stress relieving and may be subject to crevice corrosion or SSC.

Back-welding Back-welding is not addressed in CSA Z662. Back-welding could cause localized cooling, resulting in lack of uniformity in hardness, and therefore should not be used in sour service.

Pipeline Integrity Verification for Sour Service Conversion

Prior to sour service conversion, the licensee must conduct an engineering assessment to verify the integrity of the pipeline and assess its suitability for sour service, in accordance with the requirements of CSA Z662, Clause 10.11.3. Integrity verification and engineering assessment may be based on results obtained by an internal inspection tool or by examination of pipe samples. The licensee must evaluate any anomalies and repair any defects in accordance with the requirements of CSA Z662, Clause 10.8. Other evaluation techniques or procedures, such as those described in ASME Internationals B31G-1991: ManualDetermining the Remaining Strength of Corroded Pipelines and the Pipeline Research Council Internationals (PRCIs) PR-3-805: 1989, Modified Criterion for Evaluating the Remaining Strength of Corroded Pipe (RSTRENG), may also be acceptable provided that evaluation results and acceptance criteria are documented and made available to the EUB for review upon request. If pipe sampling is chosen for integrity verification, it should be done in accordance with the schedule and criteria set out in Section 9 of this document.

Additional Criteria for Sour Service Conversion Involving MOP Increase, Pipeline Resumption, and Blending of Fluids
Sour service conversion that involves an MOP increase, resumption of abandoned or discontinued pipelines, or blending of gas streams with different H2S contents may be subject to additional requirements in accordance with CSA standards, the Pipeline Regulation and the Checklist for Minimum Technical Requirements for Pipeline Applications, available along with Guide 56 on the EUB Web site www.eub.gov.ab.ca. In

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

11

such situations, the licensee must refer to the relevant sections of these documents prior to conversion and ensure that the applicable requirements are met. MOP Increase The licensee must satisfy the requirements for change in pressure in accordance with the Pipeline Regulation and Clause 10.11.4 of CSA Z662. Pipeline Resumption The licensee seeking approval for sour service conversion that involves the resumption of an abandoned or discontinued pipeline must satisfy the requirements for pipeline resumption in accordance with the Pipeline Regulation and Clause 10.13.2 of CSA Z662. Blending of Fluids Blending generally applies only to gas piping in sour service and is used to ensure compliance related to release volumes, setbacks, emergency response, and public safety in the event of a pipeline failure. Normally, gas pipeline segments in sour service are licensed for the highest H2S content that the pipeline would be transporting. In exceptional circumstances, the licensee may apply for an H2S content that reflects the blended composition of the various streams contributing to the combined fluid stream transported in the pipeline segment. In such circumstances, the licensee must satisfy the requirements for blending in Guide 56 and the Pipeline Regulation and provide details of two independent systems that will ensure that under all situations the licensed H2S content of the connecting pipeline downstream of the blending mechanism will not be exceeded. One system, as a minimum, must provide the process control to achieve the blend ratio, and the other system, as a minimum, must provide monitoring and automatic shutdown, capable of shutting down the stream with the higher H2S content (upstream of the blending mechanism) in the event that the H2S content of the blended stream is near or reaches the licensed H2S content of the downstream connecting pipeline. Where blending involves emergency response procedures or setback restrictions, the licensee must ensure that the requirements in Guide 71 and ID 81-3, as applicable, are met. The EUB will review requests for blending that involves oil well effluent streams and decide if blending is acceptable and control measures are appropriate.

Additional Criteria for Sour Service Conversion Involving Gas with Greater Than 10 Moles of H2S Gas per Kilomole of Natural Gas
While CSA Z662 defines sour service mainly to address suitability of pipeline materials and design considerations, the Pipeline Regulation sets additional requirements, mainly to address safety issues, for pipelines transporting natural gas containing greater than 10 moles of H2S gas per kilomole of natural gas. These requirements must be met prior to conversion: The pipelines must be equipped with check valves or automatically actuated emergency shutdown devices that will limit any release volumes to the amount specified by the pipeline licence. The criteria for setback distances and H2S release volumes are described in ID 81-3.

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EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

Emergency shutdown devices must have fail-close actuators, and once activated, they must remain closed and require on-site human intervention to reopen. Design stress levels must not be greater than 60 per cent of SMYS of the pipe for underground piping and 50 per cent of SMYS for aboveground piping. The use of group pipeline warning signs is prohibited. The pipelines must be tested to a pressure of not less than 1.4 times the MOP in all class locations. The pressure test must be conducted in accordance with the requirements of CSA Z662, Clause 8. The licensee must prepare an emergency response plan if required by Guide 71 and must comply with all applicable requirements identified in that guide.

Sampling Criteria
9.1 Material Verification (a) If material testing is chosen to demonstrate compliance, it should include the following: macrohardness testing on the base pipe metal and, for welded pipe, on the seam weld and the heat-affected zones; microhardness testing on the base pipe metal and, for welded pipe, on the seam weld and the heat-affected zones; root guided-bend test for ERW pipe 60.3 mm OD or larger; inspection and assessment of laminations; and HIC test if deemed necessary by the licensee. (b) Pipe sampling should be distributed along the entire length of the pipeline in order to obtain representative samples for the assessment of material suitability. Where applicable, pipe samples may include a section of pipe for integrity verification, as well as a circumferential weld for weld verification, provided that they satisfy the sampling criteria set out in Sections 9.2 and 9.3 below. (c) As a minimum, and referring to the following flowchart, pipe samples should be collected according to the following schedule: two samples per heat of pipe, or if heat numbers cannot be identified, then - two samples for each pipe specification for pipeline up to 2 kilometres (km) long, - four samples for each pipe specification for pipeline between 2 and 5 km long, and - six samples for each pipe specification for pipeline longer than 5 km.

For the purpose of Section 9, each change in heat number, pipe type, outside diameter, wall thickness, grade, notch toughness category, and source of supply should be considered as a specification change.

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With respect to road crossings, the licensee should determine if all crossings under the licence were of the same pipe specification and collect two samples for each specification. Additional samples are not required if they are of the same specification as the pipeline. If any sample fails the material testing, all of the crossings of that pipe specification should be considered unsuitable for sour service conversion. (d) All pipe samples should pass the material testing criteria, including macrohardness, microhardness, laminations, and the root guided-bend test, if applicable. If two or more of the original samples fail the test, the pipeline should be considered unsuitable for sour service conversion. To be consistent with the requirements of CSA Z245.1, Clauses 7.2.6.1, 7.4.2.1, 7.5.1.2.1, and 7.6.4.1, if any one of the original samples fails the test, a retest on two additional samples taken from a different site should be done. If any of the additional samples also fails the test, the pipeline should be considered unsuitable for sour service conversion. Pipe samples or joints cut out for material testing must be replaced with pipe material and a welding procedure suitable for the service. 9.2 Integrity Verification (a) If pipe sampling is chosen for integrity verification, it should be done in accordance with the schedule and criteria set out in the flowchart. Where applicable, pipe samples may include a section of pipe for material verification and/or a circumferential weld for weld verification, provided that they satisfy the sampling criteria set out in Sections 9.1 and 9.3. (b) Samples should be taken along the entire length of the pipeline in order to obtain representative samples for integrity assessment. They should be collected from areas with unusual soil loading, including but not limited to low or wet spots. These areas would most likely represent locations with possible coating damage or corrosion defects. Surface drainage accumulated in low spots may contribute to external corrosion. Low spots may have also collected service fluids that may contribute to internal corrosion. Samples should not be taken at pipeline ends, as they may not reasonably represent the overall condition of the pipeline. (c) Samples should be inspected for coating condition and for any external or internal corrosion or other anomalies. Anomalies must be evaluated in accordance with CSA Z662 or other techniques allowed by CSA, such as those described in Section 6 of this document. (d) All pipe samples should pass the integrity verification criteria. If two or more of the original samples fail the test, the pipeline should be considered unsuitable for sour service conversion. If any one of the original samples fails the verification, two additional samples should be taken from a different site for further integrity verification. If any of the additional samples also fails the verification, the pipeline should be considered unsuitable for sour service conversion. Pipe samples or joints cut out for the integrity verification must be replaced with pipe material and a welding procedure suitable for the service.

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EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

Flowchart Sampling Criteria for Sour Service Conversion

Does pipeline require material verification?

No Yes and Does pipeline require integrity verification? No Yes Does pipeline require weld verification?

and

No

Yes

No sampling required

Pipeline length < 2 km Sample and test two joints of pipe per heat of steel or two joints where heat is unknown. Sample and examine pipe at two separate locations where corrosion would be most likely to occur. Sample, examine, and test girth welds from two separate locations where corrosion would be most likely to occur.

2 5 km

Sample and test two joints per heat or four joints where heat is unknown.

Sample and examine pipe at four separate locations where corrosion would be most likely to occur.

Sample, examine, and test girth welds from four separate locations where corrosion would be most likely to occur.

> 5 km

Sample and test two joints per heat or six joints where heat is unknown.

Sample and examine pipe at six separate locations where corrosion would be most likely to occur.

Sample, examine, and test girth welds from six separate locations where corrosion would be most likely to occur.

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

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9.3

Weld Verification (a) If material testing is chosen to demonstrate compliance, it should include the determination of macrohardness for the deposited weld metal and heat-affected zones in accordance with the requirements of ASTM Standard E 18, and the macrohardness should not exceed 22 HRC. The licensee should also conduct visual inspection on the butt welds of the samples, as described in Section 5.1 of this document, and provide results to confirm weld quality. (b) Referring to the flowchart, weld samples should be taken along the entire length of the pipeline in order to obtain representative samples for weld verification. Where applicable, samples may include a section of pipe for material verification or integrity evaluation, provided that they satisfy the sampling criteria set out in Sections 9.1 and 9.2 above. (c) All weld samples should pass the macrohardness criteria and weld quality verification. If two or more of the original samples fail the verification criteria, the pipeline should be considered unsuitable for sour service conversion. If any one of the original samples fails the verification, the licensee should take two additional samples from a different site for further testing and verification. If any of the additional samples also fails, the pipeline should be considered unsuitable for sour service conversion. Weld samples or joints cut out for the weld verification must be replaced with pipe material and a welding procedure suitable for the service.

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EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

Glossary
For the purpose of this document: Abandoned pipeline is a pipeline that is permanently deactivated, isolated, and left in a safe condition, whether or not it is removed. Anomaly (as per NACE Technical Committee Report In-line Nondestructive Inspection of Pipelines) is a possible deviation from sound pipe material or weld. Indication may be generated by nondestructive inspection, such as in-line inspection. Back-welding is a repair made by depositing weld metal on the internal surface of the original completed weld. Blending is a situation wherein a licensee applies for an H2S content based on the blended composition of the various streams contributing to the combined fluid stream transported in the pipeline segment. Bottle-type holder (as per CSA Z662) is any bottle or group of interconnected bottles installed at one location and used for the sole purpose of storing gas. Certificate of compliance (as per CSA Z245.11, Z245.12 and Z245.15) is a document that states that the product was manufactured, sampled, tested, and inspected in accordance with the requirements of the applicable CSA standard and the purchase order and was found to have met such requirements. Class location (as per CSA Z662) is a geographical area classified according to its approximate population density and other characteristics that are to be considered when designing and pressure testing piping to be located in the area. Component (as per CSA Z662) is a pressure-retaining member of the piping, other than pipe. Crevice corrosion is a form of corrosion resulting from the action of a corrosion concentration cell that is normally found in crevices or pockets where moisture and other corrosive substances may be trapped and held stagnant. Defect (as per CSA Z662) is an imperfection of sufficient magnitude to warrant rejection based on the requirements of CSA Z662. Discontinued pipeline is a pipeline that is temporarily deactivated, with the licence still remaining in effect, and left in a safe condition. Electric welded pipe (ERW) (as per CSA Z245.1) is pipe having a longitudinal welded seam in which the formed edges were heated by electric induction or electric resistance techniques to the coalescence temperature and then joined by mechanical pressure without the addition of extraneous metal. Emergency response plan (as per EUB Guide 71) is a document developed to ensure quick access to critical information necessary to effectively respond to an emergency.

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Engineering assessment (as per CSA Z662) is a documented assessment of the effect of relevant variables upon suitability, using engineering principles. Explosion-welding (as per ASM Handbook, Desk Edition) is a solid-state welding process that produces coalescence by a controlled detonation, which causes the parts to move together at high velocity. The resulting bond zone has a characteristic wavy appearance. Hardness (as per NACE MR0175) is the resistance of metal to plastic deformation, usually by indention. Heat (as in heat of pipe) (as per CSA Z245.1) is the batch of steel tapped from a melting furnace. Heat-affected zone (as per CSA Z662) is that portion of a weld consisting of base metal that has not been melted but whose microstructure or mechanical properties have been altered by the heat of welding. Heat treatment is generally a stress relief procedure for pipe that involves normalizing, quenching, and tempering of the pipe to soften the hard spots in the heat-affected zones and to result in better resistance to brittle fracture and cracking. Hydrogen blistering is a phenomenon whereby subsurface voids produced by hydrogen absorption in the steels result in surface bulges or blisters. The blisters are associated with nonmetallic inclusions and defects, such as laminations in the steel. Hydrogen embrittlement is a phenomenon whereby the absorption of hydrogen by the steel results in a loss of ductility in the steel. Hydrogen induced cracking (HIC) is a failure process manifested by the development of cracks along the rolling direction of the steel that results from the initial presence or absorption of hydrogen in the steel. Imperfection (as per CSA Z662) is a material discontinuity or irregularity that is detectable by inspection in accordance with the requirements of CSA Z662. Letter of compliance is a document stamped and signed by a professional engineer, and confirming that the product meets the requirements of the current applicable CSA standard based on engineering assessment. Macrohardness (as per ASM Metals Handbook and Hardness Testing ASM) refers to indentation hardness tests made with loads that exceed 1 kilogram. This term is applied to the hardness testing procedure for Rockwell or Brinell hardness tests. Mechanical interference fit joint (MIF) (as per CSA Z662) is a nonthreaded joint for metallic pipe involving the controlled plastic deformation and subsequent mating of the pipe ends or the mating of the pipe ends with a coupling, the resultant joint being achieved through the interference fit between the mated parts. Microhardness (as per ASM Metals Handbook, Desk Edition, and Hardness Testing ASM) refers to indentation hardness tests made with loads that do not exceed 1 kilogram.

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EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

Microstructure (as per NACE MR0175) is the structure of a metal as revealed by microscopic examination of a suitably prepared sample. Nondestructive inspection (as per CSA Z662) is the inspection of piping to reveal imperfections using radiographic, ultrasonic, or other methods that do not involve disturbance, stressing, or breaking of the materials. Normalizing (as per NACE MR0175) is heating a ferrous metal to a suitable temperature above the transformation range (austenitizing), holding at temperature for a suitable time, and then cooling in still air or protective atmosphere to a temperature substantially below the transformation range. Notch toughness (as per CSA Z245.1) is the resistance of the steel to fracture under suddenly applied loads at a notch. Partial-penetration weld is a weld with the joint penetration designed to be between 85 and 100 per cent of the nominal wall thickness and is intended for use only when the heat of full-penetration welding would adversely affect internal linings or associated joint materials. Pipe-type holder (as per CSA Z662) is any pipe or group of interconnected pipes installed at one location and used for the sole purpose of storing gas. Pipeline (as per the Pipeline Act) is a pipe used to convey a substance or combination of substances, including installations associated with the pipe, but does not include (i) a pipe used to convey water other than water used in connection with a facility, scheme, or other matter authorized under the Oil and Gas Conservation Act or the Oil Sands Conservation Act, a pipe used convey gas, if the pipe is operated at a maximum pressure of 700 kPa or less and is not used to convey gas in connection with a facility, scheme, or other matter authorized under the Oil and Gas Conservation Act or the Oil Sands Conservation Act, or

(ii)

(iii) a pipe used to convey sewage. Pipeline resumption is the reactivation of an abandoned or discontinued pipeline upon submission of a formal application in accordance with requirements of Guide 56. Quenching (as per NACE MR0175) is the hardening of a ferrous metal by austenitizing and then cooling rapidly enough so that some or all of the austenite transforms to martensite. Residual stress (as per NACE MR0175) is the stress present in a component free of external forces or thermal gradients. Seamless pipe (as per CSA Z245.1) is pipe manufactured without a welded seam. Sectionalizing valve (as per CSA Z662) is a valve for isolating a segment of a pipeline.

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

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Setback distance is the minimum required distance between a sour gas pipeline and land-use developments, such as surface improvements, individual permanent dwellings, unrestricted country developments, urban centres, and public facilities. Sour service is defined according to CSA Z662, Clause 5.4.1: (a) for gas pipeline systems, service in which the H2S partial pressure exceeds 0.35 kPa, and (b) for multiphase pipeline systems, service in which the combination of H2S in the gas phase and system pressure is in accordance with either of the following: (i) the system pressure is below 1400 kPa and the H2S content in the gas phase is above 50 mole/kilomole, or (ii) the system pressure is at or above 1400 kPa and the partial pressure of the H2S in the gas phase is greater than 70 kPa. Stress level is the maximum operating stress based on nominal wall thickness of the pipe and the licensed MOP and is expressed as a percentage of the SMYS of the pipe. Stress relief (as per CSA Z662) is the heating of a completed weldment in order to reduce stresses produced during the welding process. Sulphide stress cracking (SSC) (as per NACE MR0175) is a brittle failure by cracking under the combined action of tensile stress and corrosion in the presence of water and H2S. The cracks occur at right angles to the stress direction. Tempering (as per NACE MR0175) is the reheating of hardened steel or hardened cast iron to some temperature below the lower critical temperature for the purpose of decreasing the hardness and increasing the toughness. Tensile strength (as per CSA Z662) is the stress obtained by dividing the maximum load attained in a conventional tensile test by the original cross-sectional area of the test specimen. Weld (as per CSA Z662) is a localized coalescence of metals produced by heating the materials to the welding temperature, with or without filler metal. Weldment (as per NACE MR0175) is that portion of a component on which welding has been performed. A weldment includes the weld metal, the heat-affected zone, and the base metal. Welding procedure specification (as per CSA Z662) is a document providing the required parameters for welding in detail. Yield strength (as per CSA Z662) is the stress at which a material exhibits the specified limiting offset or specified total elongation under load in a tensile test as prescribed by the specification or standard to which the material is manufactured.

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EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

References
ASME Standard B31G: Manual for Determining the Remaining Strength of Corroded Pipelines ASME Standard B31.3: Process Piping ASME Standard Boiler and Pressure Vessel Code, Section IV ASME Standard Boiler and Pressure Vessel Code, Section IX ASTM Standard E18: Standard Test Methods for Rockwell Hardness and Rockwell Superficial Hardness of Metallic Materials ASTM Standard E92: Standard Test Method for Vickers Hardness of Metallic Materials ASTM Standard E140: Standard Hardness Conversion Tables for Metals ASTM Standard E384: Microhardness of Materials CSA Standard Z245.1: Steel Line Pipe CSA Standard Z245.11: Steel Fittings CSA Standard Z245.12: Steel Flanges CSA Standard Z245.15: Steel Valves CSA Standard Z662: Oil and Gas Pipeline Systems Checklist for Minimum Technical Requirements for Pipeline Applications Corrosion BasicsAn Introduction, by NACE Corrosion of Steels in Sour Gas Environments, a research report by Atomic Energy Control Board CorrosionSource Book, by American Society for Metals and NACE EUB Guide 56: Energy Development Applications and Schedules EUB Guide 71: Emergency Preparedness and Response Requirements for the Upstream Petroleum Industry EUB Interim Directive (ID) 81-3: Minimum Distance Requirements Separating New Sour Gas Facilities from Residential and Other Developments Hydrogen Embrittlement: Prevention and Control, by ASTM Hydrogen Sulphide Cracking of Linepipes, a report by CANMET

EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines

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Metals Handbook, Desk Edition, by ASM International NACE Standard MR0175: Sulphide Stress Cracking Resistant Metallic Materials for Oilfield Equipment NACE Standard TM0284: Evaluation of Pipeline and Pressure Vessel Steels for Resistance to Hydrogen-Induced Cracking Pipeline Act Pipeline Regulation PRCIs PR-3-805, 1989: Modified Criterion for Evaluating the Remaining Strength of Corroded Pipe (RSTRENG) Weld Integrity and Performance, by ASM International

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EUB Requirements for Sour Service Conversion of Existing Carbon Steel Pipelines