Petroleum Development Oman L.L.C.: Materials Selection & Corrosion Control For Surface Operating Process Facilities

8/16/2019 SP-2161 Materials Selection & Corrosion Control for Surface Operating Process, Sep 14 - Final
Revision: 0
Petroleum Development Oman LLC
Effective: September-2014
Petroleum Development Oman L.L.C.
Materials Selection & Corrosion Control for Surface Operating

Process Facilities
Document ID SP-2161
Document Type Specification
Security Restricted
Discipline Materials & Corrosion
Owner UEOC
Issue Date September 2014
Version 0
Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole
nor any part of this document may be disclosed to others or reproduced, stored in a retrieval system,
or transmitted in any form by any means (electronic, mechanical, reprographic recording or
otherwise) without prior written consent of the owner.
Page 1 of 63
http://slidepdf.com/reader/full/sp-2161-materials-selection-corrosion-control-for-surface-operating-process 1/63
Revision: 0
Appr ov al an d Is su e Recor d
Description
Issu Au th or Ap pr ov ed
Date (see Revisio n Record f or
e No details) (name) (name)
Pedro Rincon
Original issue under PDO Steve Jones
1 September-14 Nasser Behlani
SP-2161 Janardhan Saithala
Cheng Ai Khoo
Revisio n Record
Issue No Descrip tion of Revisio n
0 Original Issue under PDO SP-2161
Page 3 of 63
Revision: 0
Table of Contents
1 INTRODUCTION...................................................................................................................................... 6
1.1 PURPOSE .............................................................................................................................. 6
1.2 SCOPE................................................................................................................................... 6
1.3 SPECIFICATION OWNERS RESPONSIBILITY ............................................................................. 7
1.4 R EVISION AND CHANGES TO THE DOCUMENT ....................................................................... 7
1.5 DEFINITION OF TERMS .......................................................................................................... 7
1.6 ABBREVIATIONS & ACRONYMS ........................................................................................... 8
2 HIERARCHY OF STANDARDS ........................................................................................................... 10
3 MATERIALS SELECTION PROCESS ................................................................................................ 11
3.1 GENERAL ........................................................................................................................... 11
3.2 TECHNICAL I NTEGRITY ASPECTS ........................................................................................ 11
3.2.1 Health safety and environment .......................................................................................... 11
3.2.2 Sustainable development ................................................................................................... 11
3.2.3 Philosophy ......................................................................................................................... 11
4 MATERIALS SELECTION METHODOLOGY ................................................................................. 14
4.1 I NFORMATION R EQUIREMENTS FOR MATERIALS SELECTION STUDY .................................. 15
4.2 DELIVERABLES OF MATERIALS SELECTION IN VARIOUS PROJECT PHASES ........................... 17
4.3 FACTORS AFFECTING MATERIALS SELECTION .................................................................... 25
4.3.1 Information required and review of factors affecting materials selection ......................... 25
4.4 APPLICATION OF CARBON STEELS....................................................................................... 25
4.5 DEGRADATION MECHANISMS ............................................................................................. 25
4.6 ECONOMIC ASPECTS OF MATERIALS SELECTION ................................................................. 30
4.7 NON- OPERATIONAL CONSIDERATIONS ............................................................................... 30
5 GENERAL MATERIALS DESCRIPTION AND SPECIFIC REQUIREMENTS ........................... 31
5.1 GENERAL R EQUIREMENTS FOR SPECIFIC MATERIALS GROUP ............................................ 31
5.1.1 Sour service ....................................................................................................................... 31
Alloy UNS N0625 ....................................................................................................................................... 33
5.2 SPECIFIC REQUIREMENTS.................................................................................................... 34
5.2.1 Metallurgically bonded clad plates ................................................................................... 34
5.2.2 Welding including clad and overlay equipment ................................................................ 34
5.3 PROTECTION AGAINST CATASTROPHIC FAILURE MECHANISMS ........................................... 34
5.3.1 Chloride stress corrosion cracking ................................................................................... 35
5.4 PROTECTION OF STAINLESS STEELS FOR CORROSION U NDER I NSULATION (CUI) WITH
ALUMINIUM. 35
EALING MATERIALS
5.6
5.5 S ..........................................................................................................
AMENDMENTS TO ISO 15156 ............................................................................................. 35 35
6 MATERIALS SELECTION BY EQUIPMENT SYSTEMS ................................................................ 37
6.1 INTRODUCTION ............................................................................................................. 37
6.1.1 General .............................................................................................................................. 37
6.2 VESSELS AND PIPING .......................................................................................................... 37
6.3 PIPING, FITTINGS VALVES AND OTHER COMPONENTS .......................................................... 40
6.4 SMALL BORE INSTRUMENT, HYDRAULIC AND CHEMICAL INJECTION TUBING ...................... 40
6.5 HEAT EXCHANGERS ............................................................................................................ 40
6.5.1 Shell-and-tube heat exchangers ......................................................................................... 40
6.5.2 Plate coolers ...................................................................................................................... 42
6.5.3 Air cooled heat exchangers ............................................................................................... 43
6.66.5.4
Compact coolers (printed
GLYCOL DEHYDRATION circuit heat exchangers)........................................................... 44
SYSTEM ........................................................................................ 44
6.7 FLARE & RELIEF SYSTEMS .................................................................................................. 44
6.8 R OTATING EQUIPMENT ....................................................................................................... 44
Page 4 of 63
Revision: 0
A) COMPRESSORS FOR PDO SHALL BE DESIGNED FOR SOUR SERVICE . .................................... 44

6.9 PUMPS ................................................................................................................................ 44
6.10 BOLTING ............................................................................................................................ 45
6.11 ELASTOMER SEAL SELECTION ............................................................................................ 45
6.12 PIPELINES ........................................................................................................................... 45
6.14
6.13 D RY HYDROCARBON FLOW LINES: ..................................................................................... 47
FLOWLINES ........................................................................................................................ 47
6.15 WATER I NJECTION FLOW LINES .......................................................................................... 49
6.16 FLEXIBLES .......................................................................................................................... 49
6.17 MULTI SELECTIVE VALVES (MSV’S) ................................................................................ 49
6.18 UTILITIES ........................................................................................................................... 50
6.19 STEAM I NJECTION SYSTEMS ............................................................................................... 50
6.20 ENHANCED OIL RECOVERY (EOR) ............................................................................ 50
7 MATERIALS SELECTION STUDY ROLES & RESPONSIBILITIES ............................................ 51
8 CONTENT OF MATERIALS SELECTION REPORTS .................................................................... 51
8.1 SELECT PHASE ................................................................................................................. 51
8.2 DEFINE PHASE ................................................................................................................. 51
8.3 EXECUTE PHASE ............................................................................................................. 52
9 CORROSION MANAGEMENT FRAMEWORK ............................................................................... 52
APPENDIX A: BASIC INFORMATION REQUIRED AND FACTORS EFFECTING MATERIALS
SELECTION .................................................................................................................... 53
APPENDIX B: RISK ASSESSMENT ............................................................................................................. 56
APPENDIX C: CMF TEMPLATE .................................................................................................................. 58
APPENDIX D: FEED AND DETAILED DESIGN MSR MINIMUM STANDARD REQUIREMENTS
TEMPLATE ..................................................................................................................... 59
APPENDIX E: TEMPLATE FOR REQUIRED PROCESS INFORMATION IN MATERIALS
SELECTION REPORT. ................................................................................................. 62

APPENDIX F: MATERIALS SELECTION DIAGRAMS (MSD) ............................................................... 63
Page 5 of 63
Revision: 0
1 Introduction
1.1 Purpose
The document provides the requirements on the process of materials selection and corrosion control
for surface equipment that shall be used during project life cycle to ensure technically proven and
economically acceptable materials selection for PDO projects. This specification also addresses
some of the roles and responsibilities of projects, function, designers, contractors and vendors to
ensure materials are designed, manufactured, procured and constructed to meet Company specified
technical requirements within agreed delivery timeframe.
The objective of this document is to achieve designs where materials are selected to maximise the
likelihood of no loss of containment for the design life at lowest life cycle cost by:
1. Ensuring acceptable corrosion rate at lowest life cycle costs

2. Minimise corrosion by using resistant materials as the primary barrier
3.
4. Design
Design not to use at
to ensure chemical treatment
least one primary as a barrier
barrier forsecondary
or two on plot facilities
barriers (e.g. CRA or
corrosion inhibitor and corrosion allowance)
Materials selection and corrosion control are elements of corrosion management, and this guideline
develops further clarification and interpretation of CP-208 Corrosion Management Code of Practice
and DCAF requirements.
This Specification is intended for use by Petroleum Development Oman LLC (PDO), its
Contactors/Subcontractors and Design Consultants and vendors for all PDO equipment and facilities.
This specification covers all surface equipment from the connecting flanges to the Christmas tree.
“ If you are reading a hard copy of this standard, you should consider it uncontrolled and refer
instead to the version cur rently on th e PDO intr anet live link or appropri ate search database.”
1.2 Scope
The scope of this specification is to cover the surface facility materials selection for different phases
of the project from identify to operate phase.
This specification shall be read in conjunction with other Company, Shell and International standards
such as DEP 39.01.10.11-Gen, 39.01.10.12-Gen and DEP.30.10.02.15 . This document provides
further requirements on other company specifications (SPs), Shell DEPs and MESC SPEs and
International Standards for materials selection process and requirements.
In case of any conflict between this specification and other standards, this specification shall take
precedence.
This standard defined the minimum Company requirements for selecting materials of construction
and corrosion control measures to support the corrosion management strategy for a facility within the
company. It addresses requirement for identifying and evaluating all applicable corrosion threats,
materials deterioration mechanisms, selecting optimum materials of construction, corrosion control
measures and appropriate corrosion monitoring measures and the data necessary to ensure the
requirements of this standard are effectively implemented.
This standard does not cover downhole materials selection requirements. For downhole materials
selection, refer to DEP 39.01.10.02-Gen, DEP 30.10.02.15-Gen and WS 38.80.31.31-Gen.
Page 6 of 63
Revision: 0
1.3 Specification owners responsibili ty
The owner of this specification, UEOC, as CFDH Materials and Corrosion, is responsible for
authorising all proposed deviations or amendments to the specification and for the instigation of
periodic reviews and updates in accordance with Clauses 1.2 and 1.5.
The requirements of this specification shall remain in force indefinitely unless superseded by an
authorized revision.
The range of business areas and various life cycle stages of projects to which this standard applies
as below:
Al l PDO Dev elo pm ent /Pro jec ts
Busin ess Segment Upstream
Identify As ses s Select Define Execute Operate

Stage
√ √ √ √ √ √
1.4 Revis ion and changes to the docu ment
This specification will be reviewed and updated as and when required. The review authority will be
UEOC, (CFDH Materials and Corrosion).
1.5 Defin iti on of Terms
Company The term Company shall refer to Petroleum Development Oman L.L.C.
The party which carries out all or part of the design, engineering,
Contractor procurement, construction, commissioning or management of a project, or
operation or maintenance of a facility.
The word 'shall' used throughout this specification indicates a Contract
Shall
requirement.
The word 'should' used throughout this specification indicates a
Should
recommendation.
Technical Authority Level 1 (TA-1) for Materials, corrosion and integrity
UEOC
discipline appointed by the Technical Director (TA0).
Sour Service As stipulated in SP-2041
Page 7 of 63
Revision: 0
1.6 Abbreviations & Acronyms
Term Definition
AC Atmospheric Corrosion
AL ARP As Low As Reasonably Practicable
BfD Basis for Design
CAPEX Capital Expenditure
CE Carbon Equivalent
CFDH Corporate Function Discipline Head
CMF Corrosion Management Framework
CORRAT Shell proprietary corrosion modelling computer program for corrosion
rate: for calculating single point calculation corrosion rates (the most
basic option in HYDROCOR)
CP Cathodic Protection
CRA Corrosion Resistant Alloy
CS Carbon Steel
CSCC Chloride Stress Corrosion Cracking
CUI Corrosion Under Insulation
DEP Design Engineering practice
EFC European Federation of Corrosion
FEED Front End Engineering Design
FMEA Failure Modes and Effects Analysis
GRP Glass Reinforced Plastic (fibreglass). Also known as Fibre Reinforced
Plastic (FRP) (fibre reinforced plastic) or Glass Reinforced Epoxy
(GRE) (glass reinforced epoxy)
HE Hydrogen Embrittlement
HEMP Hazards and Effect Management Process
HIC Hydrogen Induced Cracking. Also known as SWC
HRC Rockwell Hardness
HSE Health Safety Environments
HV Vickers Hardness
HYDROCOR Shell proprietary corrosion modelling Shell computer program for

calculating corrosion rates
HRC Rockwell Hardness
MatHelp Shell proprietary system for accessing materials and corrosion
information
MCI Materials, Corrosion and Inspection
MDMT Minimum Design Metal Temperature
NACE National Association of Corrosion Engineers
OCTG Oil Country Tubular Goods
OPEX Operating Expenditure

OPMG Opportunity and Project Management Guide
OR&A Operations, Readiness & Assurance
Page 8 of 63
Revision: 0
Term Definition
PDO Petroleum Development Oman
PFP Passive Fire Protection
PTE
Principal Technical Expert
PWC Preferential Weld Corrosion
RAM Risk Assessment Matrix
S-RBI Shell Risk Based Inspection (methodology)
SCC Stress Corrosion Cracking
SLC Service Life Corrosion - (total estimated wall thickness reduction of
carbon steel over the life of a project the equipment)
SME Subject Matter Expert
SOHIC Stress Oriented Hydrogen Induced Cracking
SSC Sulphide Stress Cracking

SWC Step Wise Cracking. Also known as HIC
TOL Top Of Line
WPS Welding Procedure Specification
Page 9 of 63
Revision: 0
2 HIERARCHY OF STANDARDS
1. PDO Standards
• SP-2161 (2014): Materials Selection and Corrosion Control for Surface Operating
Process
• SP-2041(2014): Selection of Cracking Resistant Materials for H2S-Containing
Environment
• SP-1246: Specification for Painting and Coating of Oil and Gas Production Facilities
• SP-2156 - Specification for use of non metallic materials in PDO
2. DEPs
• DEP 39.01.10.11-Gen: Selection Of Materials for Life Cycle Performance
(Upstream Facilities) - Materials Selection Process
• DEP 39.01.10.12-Gen: Selection of Materials for Life Cycle Performance (Upstream
Facilities) - Equipment
• DEP 30.10.02.14-Gen: Carbon Steel Corrosion Engineering Manual for Upstream
Facilities
• DEP 30.10.02.15-Gen: Materials for Use in H2S Containing Environment in Oil and
Gas Production (Amendments/Supplements to ISO 15156:2009)
3. International Standards
• 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
containing environments in oil and gas production-Part 2: Cracking-resistant carbon
and low alloy steels, and the use of cast irons
containing environments in oil and gas production-Part 3: Cracking-resistant CRA’s
(corrosion-resistant alloys) and other alloys
Page 10 of 63
Revision: 0
3 MATERIALS SELECTION PROCESS
3.1 General
Materials selection is primarily a process of short-listing technically acceptable materials for an

application and then selecting the technically viable option with lowest life cycle cost for the required
operational life, bearing in mind Health, Safety and Environmental aspects, Sustainable
Development, Technical Integrity and operational constraints. This is a multi-variable process, which
might require several iterations before an optimal solution can be obtained. Part of this process
should also be to assess which systems require materials optimisation and which can use standard
materials selection guidelines.
The materials selection process shall follow the Corrosion Management Framework (CMF) as
described in DEP. 39.01.10.11-Gen section 2.2.3.
3.2 Techni cal Integrit y aspects

3.2.1 Health safety and envir onm ent
Materials selection shall be in accordance with the HSE Hazards and Effect Management Process
(HEMP). This process identifies and assesses HSE hazards, implements control and recovery
measures, and maintains a documented demonstration that major HSE risks have been reduced to a
level that is As Low as Reasonably Practicable (ALARP). This shall be done for the full lifecycle of
assets and operations and uses the Risk Assessment Matrix (RAM). For High Risk and/or Severity
hazards bow tie diagrams with links to relevant details should be used to demonstrate tolerability and
ALARP.
3.2.2 Sustain able develop ment
Sustainable development principles shall be applied as part of the materials selection process.
During the past decade it has become clear that the availability of materials and the manufacturing
capacity for materials and products is rapidly becoming a major constraint on construction
capabilities and hence, on energy production and development. Therefore, it is important to use
materials that are readily available and in ways that facilitate standardisation. Thus, one of the
considerations should be to avoid mixing materials in such a way that they cannot be separated
easily as this downgrades their value and limits their availability in the longer term.
3.2.3 Philosophy
Materials selection shall be based on the project life cycle and Basis for Design (BfD) document as
defined in Section 4.1 of this standard.
Materials of construction shall be selected to achieve a balance of minimum CAPEX with reduced
operating costs (OPEX) to maximise project value and minimise risks. The CAPEX shall be the raw
material and fabrication/construction costs. The OPEX shall be the corrosion protection and
inspection/maintenance cost.
The materials selection process shall reflect the overall philosophy regarding design and operating
conditions, design life time, cost profile (CAPEX/OPEX), inspection and maintenance philosophy,
safety and environmental profile, failure risk evaluations, remnant life assessments of existing similar
equipment, lessons learnt via integrity studies, compliance with local and international regulations
and other specific project requirements.
Page 11 of 63
Revision: 0
General Princip les
A high level materials selection, aimed at identifying unusually high cost materials is carried out
during the project Select phase and feeds into the Level 1 (CAPEX and OPEX) cost estimate (+40
%/–25 %). For main process stream items, initial materials selection is carried out in the Select phase
of a project.
Define phaseMaterials
as part selection for secondary
of the Front processDesign
End Engineering streams is usually
(FEED). carried
During the out in the
FEED, project
materials
selection may be optimised, with the approval of the Materials and corrosion Function, as more
information becomes available in order to reduce costs to a minimum in line with specific project
parameters and risk philosophy. At this stage, more refined judgements on corrosion rates, life
predictions and risk assessments shall be carried out to ensure that the proposed materials selection
will be fit for purpose. For long-lead and/or bulk items (e.g. Line pipe), key materials decisions should
be made as early as possible in the project, preferably during the Select phase, i.e., ahead of FEED.
If the new project will make use of and tie into existing installations, the materials in place and their
current condition should be ascertained in the Select phase. Operations personnel shall be included
in the project team or consulted for these types of developments.
Materials selection is a risk based decision making process with the aim of selecting materials that
give rise to major accident hazard risks that are tolerable and ALARP. The tools of materials
selection decision making and the means of assuring (calibrating) the decision are summarised in the
diagram from SP-2062. - HSE Specification: Specifications for HSE Cases:
Figure 1: Risk based decision making process
The materials selection philosophy should be one that will not require PDO values to be called upon,
i.e. acceptance can be achieved by no more than internal (including Shell) peer review. In practice,
the majority of materials selection decisions will be driven by reference to the GU-611 PDO codes of
practice, specifications, procedures and guidelines; that is to say, the ‘standard materials selection’
option described in this document.
The selection process is structured based on:

a) Standard materials selection
Guidance on the selection of technically proven and economically acceptable materials
selection for most equipment is given in Section 6 of this standard. Selection is based upon
the statedisinformation
selection onthe
used to fill in thedetails
environmental conditions
for the systems that for eachrequire
do not system. Standard
materials materials
optimisation.
Some optimisation may be required on some process systems, if conditions are encountered
that are not adequately covered in this standard, or if it is required to consider other materials
Page 12 of 63
Revision: 0
choices, in the interest of potential cost savings. This will generally require justification based
on a life cycle cost analysis and a technical integrity verification.
For carbon steel applications, the process of corrosion control option selection, corrosion
control system availability and corrosion allowance selection shall follow the requirements of
DEP 30.10.02.14-Gen.
b) Experimental evaluation (specialist consu ltation)

Experimental work might be necessary to evaluate materials for specific applications. It shall
be carried out in accordance with the material testing methodology selected for the failure
modes anticipated. Where this is required to assess the suitability of the lowest cost option, it
should be carried out ahead of the Field Development Plan (FDP, in the project select phase).
Page 13 of 63
Revision: 0
4 MATERIALS SELECTION METHODOLOGY
The standard materials selection process includes the following steps:-
a) Define the requirements and the environment

The intended design life of the proposed equipment shall be stated.
The internal and external environments for the equipment shall be defined, including any non -
routine or non-operational conditions that might be encountered. The variables characterising of
the corrosive environment shall be quantified for normal operating conditions and to some extent,
for unusual or upset conditions.
At this point, the operation has to be characterised, e.g., in terms of manning levels, access by
operators, capabilities of operators, in-house or contract operated, access to supplies, spare
parts availability, etc.
b) Assess the applicability of carbon steel and define possible corrosion control options
As an initial step in the materials selection process, the suitability of the potentially low cost
option involving the use of carbon steel should be thoroughly investigated and evaluated to serve
as a baseline against which to compare more corrosion resistant, and possibly more costly,
alternatives. Part of this process will involve the calculation of the Service Life Corrosion (SLC)
for the proposed operating conditions.
For the carbon steel option, possible corrosion control options to protect the steel from premature
failure should be investigated. These could include chemical corrosion control, coatings, cathodic
protection and control of process fluids, e.g., pH stabilization and dehydration. The results of
these studies could lead to a lower value of SLC being appropriate. This will often result in more
than one corrosion control option being taken forward for further consideration (e.g., carbon steel
with a corrosion allowance and inhibition system versus carbon steel with a (different) corrosion
allowance and a dehydration system). The availability of these solutions should be taken into
account. For example, it is notoriously difficult to achieve a consistently high availability of
corrosion inhibitors, so if this is considered, the training and organizational responsibilities should
be realized.
c) Make materials choic es

Typical materials shall be selected with the aid of the guide tables for each type of equipment
(see Section 6 of this standard). While a material included is technically acceptable, it will not
necessarily be the most cost-effective choice. This will often lead to more than one technically
acceptable materials being taken forward for further consideration (e.g., carbon steel with a
corrosion allowance versus one or more alternative corrosion-resistant materials).
d) Develop corro sion management framework

See Section 9 of this standard.
e) Assess economic s of choic es

In the final analysis, selection of the corrosion control option (which includes materials selection)
is often an economic decision, assessing the total cost of each alternative over the total life of the
system, including quantification of the risks and uncertainties (life cycle cost). These include the
risk of failure of corrosion control, the economic impact of corrosion control, RBI, sand
management, inhibition and the possibility of market changes, whereby certain materials could
become more or less economic. Where the risk of failure of corrosion control is high, the
consequences should be taken into account, e.g., enhanced corrosion control measures, and
enhanced inspection and repair. These will be reflected in the economic consequence of failure,
as assessed in S-RBI. Operations personnel should be involved in the life cycle cost assessment
Page 14 of 63
Revision: 0
to ensure all operating costs are considered. This work shall be completed as part of the
corrosion control options selection report and the materials selection report. It is the responsibility
of the project engineer to complete the life cycle costing. The Life cycle cost shall be completed
as per DEP.82.00.10.12-Gen Life cycle costing.
f) Maintain live documents

The Corrosion Management Manual, RBI Plan and Maintenance Reference Plan are live
documents for the lifetime of the facility. These shall be updated whenever there are (approved)
materials substitutions (e.g., during procurement and fabrication), changes to the corrosion
control system and changes to the operation and process, and as monitoring, inspection and
maintenance data are collected during the lifetime of the facility. Service company personnel
often carry out this type of data collection. Personnel involved shall be made aware of the
importance of this work.
The activities associated with the materials selection process can be represented by the flow chart
shown in Figure 2.
Figure 2: Standard materials selection process
Activity 1
Activity 2
Activity 3
Activity 4
Activity 5
Activity 6
4.1 Inform ation Requir ements for Materials Selecti on Study
SELECT Phase
It is expected that the initial inputs will come from the defined DCAF deliverables of the Assess phase
as per the PDO DCAF Description. The process may be initiated with this information and constantly
revisited as the inputs are further refined and the Select phase deliverables are matured ready for
Define. Materials, corrosion and Inspection (MCI) TA2 will define the required deliverables for each
project.
• Production Profile – possibly Hydrocarbon Production Forecast (DCAF

Acti vi ty 1: Define
requirements and environment
24 → DCAF 1482)
• Water Management Assessment (DCAF 18, GU-672 Assess and
Select)
Page 15 of 63
Revision: 0
• Operations & Maintenance Philosophy (DCAF 216 and 218)

• Risk Management Plan & Risk Register (DCAF 84 → DCAF 201)
• Pipelines Flow & Flow Assurance Study (focus on scale and sand
management) – Preliminary (DCAF 33 → DCAF 110 Pipelines Flow &
Flow Assurance Strategy Reports)
• Pipeline & Flowline System Conceptual Design Report (DCAF 117)
• Heat & Materials Balance Report (DCAF 108)
• Process Flow Schemes (DCAF 112)
• Chemicals Requirement Report – Preliminary (DCAF 1272)
• Utility Flow Schemes (DCAF 1360)
• Equipment Listing (DCAF 1496)
Acti vi ty 2: Determine threats • Section 4.5
and barriers for carbon steel
and other materials (FMEA)
for all materials
• SP-2041
• DEP Specification 30.10.02.14-Gen
Acti vi ty 3: Assess feasibility of
• DEP Specification 30.10.02.31-Gen
corrosion allowance and
• If the operating conditions are beyond currently qualified corrosion
corrosion control
inhibitors, the likelihood
assessed using the NACE ofpaper
successfully qualifyingetan
by A Crossland, al. inhibitor may be
• Section 4.5 of this standard
Acti vi ty 4: Assess CRA and
• SP-2041
non metallic options and rerun
• DEP Specification 39.01.10.12-Gen (as amended by this document)
threats and barriers
DEP Specification 30.10.02.15-Gen
Acti vi ty 5: Identify gaps and
opportunities for qualification • Project Schedule – Level 2 (DCAF 186)
testing
• Concept Selection Report (DCAF 99)
Acti vi ty 6: Make materials • Equipment specifications (PDO and DEP)
choices and develop corrosion • Facility Status Reports/Current Status Reports (for brownfield projects
management framework – see CP 114)
• DEP 31.38.01.84-Gen
• DEP 30.10.02.11-Gen
DEFINE Phase
• Basic design package (DCAF 235)

• Chemical requirements Report (DCAF 250)
• Operations and maintenance philosophy (DECAF 363)
• Process flow scheme (PFS) (DCAF 242)
• Process engineering flow scheme (DCAF 243)
• Utilities flow scheme (UFS) (DCAF 1390)
• Utilities engineering flow scheme (DCAF 1391)
• Equipment listing (DCAF 1497)
Acti vi ty 1 to 6 • Pipelines flow and flow assurance design and operability report.
(DCAF 248)
• Operations and maintenance philosophy (DCAF 363)
• Rotating equipment type selection report (DCAF 273)
• Pipeline design report (DCAF 315)
• Reliability, availability and maintainability report (DCAF 332)
• Performance standards & assurance tasks for safety critical
elements/equipment (DCAF 384)
• Maintenance and integrity strategy (DCAF 409)
EXECUTE Phase
• Operations and maintenance philosophy (DCAF 49)

Acti vi ty 6 • Chemical requirement reports (updated) DCAF 1224)
• Heat and materials balance report final (DCAF 420)
• Pipelines flow and flow assurance report final (DCAF 679)
Page 16 of 63
Revision: 0
• Process flow scheme (DCAF 1213)

• Process engineering flow schemes (PEFS & P&IDs), (DCAF 1214)
• Utility flow schemes (UFS) (DCAF 1435)
• Utilities engineering flow schemes (UEFS/P&IDs), (DCAF 1449)
• Equipment listing (DCAF 1498)
• Vibration assessment report (DCAF 487)
• Detailed HAZOP report (DCAF 449)
• Asset Reference plan (DCAF 438)
• Reliability, availability and maintainability report (DCAF 486)
• Process control (DCAF 46)
• Process control narrative (DCAF 683)
• Line List
OPERATE Phase
Assu ran ce • Assurance process (design conditions vs actual and future

operating conditions. Including IOW
• Assessed corrosion rate
4.2 Deliv erables of materials selection in various proj ect phases
The following MCI deliverables and requirements shall be implemented for any project regardless of
the scope and value. These are as per PDO version of DCAF.
Table 1: Mandatory deliverables and requirements for Select phase from Materials Corrosion and
Inspection discipline
ORP Acc ou nt abl e
ID Name Description
Phase Discipline
• SP-2161
• DEP 39.01.10.11-Gen
• DEP 39.01.10.12-Gen (MC CFDH)
• Materials and Corrosion Engineer specifies
the acceptable velocity ranges for materials
of construction with respect to corrosion. The
Erosive velocity calculation is done by the
process engineers.
• At this stage the overall philosophy should be
Materials defined together with the integrity impact and
Erosion Management
Select 47 Corrosion and need to interface with other disciplines. The
Philosophy (DG3a)
Inspection detailed materials selection and details of
inspection techniques will be covered later in
the Preliminary Corrosion and Erosion
Management Manual in the define phase
(ID300).
• Provide input on the materials limitation with
respect to erosion velocity. And input into
Preliminary Corrosion and Erosion
Management Manual in the define phase
(ID300).
• CP 208 - Corrosion Management Code of
Practice
Corrosion Materials • Mandatory for all projects.
Select 60 Management Corrosion and • Recommendation made in Corrosion
Philosophy (DG3a) Inspection Management Strategy shall be embedded in
the Corrosion Management Philosophy
including inspection requirements.
Page 17 of 63
Revision: 0
• SP-2161
• DEP 39.01.10.11-Gen
• DEP 39.01.10.12-Gen (MC CFDH)
• DEP 30.10.02.14-Gen
• CP 208 - Corrosion Management Code of
Practice
• Mandatory for all projects.
• The corrosion management strategy
including initial failure mode effect analysis
and the preliminary (high level) materials
selection reports are based on are based
information provided by the project that shall
Initial Materials include the required minimum
Selection Report Materials information/deliverables as per DCAF for this
Select 210 (including Corrosion Corrosion and phase of the project (e.g. H&MB, etc.).This
Management Inspection should normally consist of referring to the
Strategy) (DG3a) applicable standards and mention any
important choices that are made, e.g. carbon
steel + corrosion inhibition versus corrosion
resistant alloy. This also includes the
deliverable of materials threats analysis and
the erosion management philosophy.
• Materials selection reports shall be prepared
by function (UEOC) for any project. The
report shall be peer reviewed and signed off
by at least two Materials and Corrosion
Engineer TA2s from the Function other than
the author of the report.
• External peer review shall be completed for
projects above 1 bln
Table 2: Mandatory deliverables and requirements during the Define phase for Materials Corrosion
and Inspection discipline
ORP ID Name Acc ou nt abl e Description

Phase Discipline
• SP-2161
• DEP 39.01.10.11-Gen
• DEP 39.01.10.12-Gen (MC CFDH)
• Mandatory for all projects to be made part of
MCI Failure Modes Materials the materials selection report. The report
Define 64 and Effects Analysis Corrosion and shall be endorsed and approved by Materials
Report Inspection and Corrosion Engineer TA2 from Function.
• This is an FMEA of the corrosion control
systems; for each mode of operation and
corrosion risks, analysis looks at the barriers
and monitoring that need to be in place.
• SP-2161
• DEP 39.01.10.11-Gen
• DEP 39.01.10.12-Gen (MC CFDH)
• Mandatory for all projects
• Based on the preliminary report (ID 210), this
report shall include detailed assessment to
ensure the agreed materials selection for all
Materials aspects of the projects is properly
Materials Selection documented independently from the Select
Define 297 Corrosion and
Report - updated phase report based on the updated design
Inspection
basis.
• The updated Materials selection shall be peer
reviewed by PDO Materials and Corrosion
Engineer TA2 other than the author of the
report and Materials and Corrosion Engineer
TA2 from Function. The final endorsement
and approval shall be by Materials and
Corrosion Engineer TA2 from Function.
Page 18 of 63
Revision: 0
• For projects more than 100 mln USD or for

new field development including EOR/severe
sour environments, the Materials selection
reports shall be endorsed and approved by
Materials and Corrosion Engineer TA1.
• For projects 1 billion and above, materials
selection shall be endorsed by DRB1.
• This is one of Materials, Corrosion &
Inspection key deliverables which requires
interaction with many disciplines.
Presentations to key disciplines are
recommended to ensure everyone is aware
of the choices and implications. The
consequence of materials selection must be
understood / agreed by the Operator.
Philosophy should be presented to
Operations representative and if necessary to
the Operator’s Management to ensure all
consequences are understood / agreed. The
control also includes deliverable of pipeline
preservation / transportation / storage and
etc.
• Long lead items finalized at FEED stage shall
be endorsed and approved by Materials and
• Materials selection report shall be aligned
and verified with the HAZOP, and ALARP.
MCI TA shall participate in HAZOP and
ALARP assessment.
• DEP 30.10.02.14-Gen
• DEP 31.01.10.10-Gen
• PR 1103 - Chemical Injection
•

•
Mandatory
Materials for all projects
selection whereidentifies
report applicablethe
requirement of corrosion inhibitor. Unless a
Corrosion Inhibition Materials corrosion inhibitor (CI) application duplicates
Define 298 System Design & Corrosion and an existing application, tests are required to
Test Proposal Inspection qualify the CI. Corrosion inhibition testing
protocol and the test results shall be
evaluated by Materials and Corrosion TA2.
• This document defines the use of availability
requirements for corrosion inhibitors, test
program and an update of ID 301 the
Preliminary Chemical Compatibilities Matrix.
Page 19 of 63
Revision: 0

• Corrosion Management Framework (CMF)
covers corrosion risks, means of mitigation,
monitoring and demonstrating integrity. There
is synergy with the CMF, Safety Critical
Elements / Technical Integrity Framework
and RBI. Incorporates data from Performance
Standards for Safety Critical Elements (ID
384), the Materials Selection report (ID 297)
and the CI System Design (ID 298). It
includes deliverables of critical flow velocity
report, erosion mgt manual, integrity mgt
philosophy, CP designs and for sour systems
sulphur depositions evaluation, oxygen
ingress into the pipeline, potential corrosion
Corrosion implications such as:-
Materials
Management a) Execute Failure Mode and Effects
Define 300 Corrosion and
Framework - Analysis
Inspection
Preliminary b) Produce preliminary Corrosion
Management Framework
c) Pipeline Integrity Management
Philosophy
d) Include erosion and sand handling
e) Corrosion and inspection integrity
management philosophy
f) Inspection strategy shall be
included.
• This report shall be reviewed by PDO
Materials and Corrosion Engineer TA2 other
than the author of the report and Materials
and Corrosion Engineer TA2 from Function.
The final endorsement and approval shall be
by Materials and Corrosion Engineer TA2
from Function.
•
Shall refer to PDO welding and NDT
specifications
• Generate welding and weld inspection
Welding & Weld Materials specifications (or instruct contractor to do
Define 302 Inspection Corrosion and such).
Specifications Inspection • For CRAs materials grades not listed in SP-
1173, the specifications shall be developed
and approved by Materials and Corrosion
Engineer TA2 from Function.
Table 3: Mandatory Deliverables and requirements during the Execute phase for Materials corrosion
and inspection discipline
ORP Acc ou nt abl e
ID Name Description
Phase Discipline

• Materials selection peer review sessions shall
be organized by the Materials and Corrosion
Engineers from the projects or the author of
the report and ensuring participation from
Process, Mechanical, Rotating and Pipeline
engineering. This report shall be approved by
Updated Materials Materials and Corrosion Engineer TA2 from
Local
Execute Materials Corrosion and Function.
Rule
Selection Report Inspection • For projects more than 100 mln USA or for
new field development including EOR/severe
sour environments, the Materials selection
reports shall be endorsed by TA1.
• A final Materials selection report shall be
generated during Execute phase to ensure
the outcome of the FEED and DD
assessment is included in the final
Page 20 of 63
Revision: 0
deliverable. This report shall be approved as

indicated in Section 8.
• This report should be completed and peer
reviewed before material is procured.
• Long lead items finalized at FEED stage shall
be endorsed and approved by Materials and
• Prove that all corrosion control equipment is
working and operators understand the
Set-up and
Materials procedures; demonstrate that corrosion is
Optimisation of
Execute 51 Corrosion and under control. This first requires the corrosion
Corrosion
Inspection and erosion monitoring systems to be tested
Control System
and accepted.
• To be signed off by Corrosion Control TA2
from Function.
• There are many different CIMS used in the
Shell Group, e.g. Pacer, IMSA, etc (see
toolbox). The correct system has to be
Corrosion
Inspection Materials selected for the operating region, the system
has to be set up and populated with
Execute 77 Management Corrosion and
equipment and a baseline generated.
System Selection Inspection
Communicate with business unit to determine
and Population
who has ultimate responsibility and what the
requirements and expectations are.
• To be signed off by Materials Corrosion &
Inspection TA2 from Function.
• Mandatory for all projects and new
equipment.
• Developed from the philosophy document
Corrosion Materials (ID60), and the Corrosion Management
Execute 79 Inhibitor Corrosion and Framework (1194) and linked to Performance
Selection Report Inspection Standard for Safety Critical Elements (ID
452).
• To be signed off by Corrosion Control TA2
from Function.
Approval by
Function -
Materials
Inspectors & • Mandatory for all projects if the material is
Execute 82 Corrosion and
Jointers for Non applicable for the project.
Inspection
metallic for
contractor staff
Approval by
Materials
function:- • Mandatory for all projects if the material is
Calculation of PE applicable for the project.
Inspection
Liner thickness
Approval by
function:- use of
external MCI Materials
• Mandatory for all projects if the material is
Execute 88 consultancies, Corrosion and
applicable for the project.
test laboratories Inspection
and test
requirements
Approval by
Function - Materials
Execute 168 operators for Corrosion and
specialized NDT Inspection
processes
Approval by
Function -
Execute 170 Contractors Materials
Corrosion and
welding applicable for the project.
Inspection
Engineers & NDT
level III
Page 21 of 63
Revision: 0
Approval by
Function:- GRE
Materials
1000 hrs test • Mandatory for all projects if the material is
pressure, applicable for the project.
Inspection
material and type
of joints type
Approval by
function:- New Materials
Execute 173 coating Corrosion and
applicators or Inspection
coating products
Approval by
Materials
function:- New • Mandatory for all projects if the material is
coating testing applicable for the project.
Inspection
program
Approval by Materials
Execute 175 function:- New Corrosion and
shrink sleeves Inspection
All specialized
Materials
material and • Mandatory for all projects if the material is
weld qualification Inspection applicable for the project.
testing
Approval by
function:- CP
Materials
design for buried • Mandatory for all projects if the material is
pipelines, tanks applicable for the project.
Inspection
and submarine
loading liners
Approval by
function:-
Materials
Approval of Well • Mandatory for all projects if the material is
casing corrosion applicable for the project.
Inspection
protection
strategy
Review
approval of and the
corrosion Materials
Execute 182 monitoring plans Corrosion and
for corrosion Inspection
inhibitors, CP,
DCVG, CIPS
Approval of
pipeline and
Materials
equipment • Mandatory for all projects if the material is
integrity report applicable for the project.
Inspection
including RBA
and RBI reports
Approve Materials
Execute 217 Assessed Corrosion and
corrosion rate Inspection applicable for the project.
• Developed from the Corrosion Management
Framework (ID300, Define Phase and
ID1194, Execute Phase) and linked to
Field Inspection
Performance Standard for Safety Critical
Plan / RBI Plan /
Materials Elements (ID 452 - Execute Phase. This
Baseline
Execute 484 Corrosion and includes the selection and population of
Inspection /
Inspection CIMS (Corrosion Inspection Management
CIMS (for
System and the Field Inspection Plan / RBI
Operate)
Plan.
• Inspection plan shall be included.
• To be signed off by Material Corrosion &
Inspection TA2 from Function.
Page 22 of 63
Revision: 0
• PQR, WPS, NDT procedures, heat treatment

procedures shall be authorised at project
levels except for below mentioned areas. To
be signed off by Welding and NDT.
TA-2.
• PQR, WPS, heat treatment procedures
involving for CRAs (25% Cr and above), low
temperature applications, >X65 steels (within
Welding, the standards) shall be approved by the
Materials
Fabrication and material and corrosion function (UEOC). To
Inspection be signed off by Specialized Welding & NDT
Inspection
Procedures TA-2.
• Advanced NDT technique procedures such
as AUT, Phased Arrays, TOFD, and
radioscopy. To approved and signed off by
Specialized Welding & NDT TA-2.
• Non-metallic, bonding procedures, PE lined
fusion bonding procedures shall be approved
by and signed Materials and Corrosion TA2
in Non-metallic from Function.
Corrosion Materials • Update of the preliminary document,
Execute 1194 Management Corrosion and developed in the Select phase (ID 300) and
Framework Inspection Performance Standards for Safety Critical
Elements (ID 384).
Materials
Final Material • Update of the preliminary document.
Execute Corrosion and
selection Report • To be approved by Materials and Corrosion
Inspection
TA2 from function.
Table 4: Mandatory Deliverables and requirements during the operate phase for Materials corrosion
and inspection discipline
ORP Acco un tab le

ID Name Description
Phase Discipline
• Mandatory for all operations.
• Risk Based Inspection (RBI) covers the
verification of the integrity of the assets. It
includes analysis (using S-RBI see toolbox),
inspection planning and work pack
development for internal and external
corrosion, non-intrusive inspection (NII)
analysis, inspection execution, storing the
Materials data in CIMS (see toolbox), inspection data
Risk Based
Operate 25 Corrosion and analysis, fitness for purpose assessment,
Inspection
Inspection external corrosion analysis and modelling
(using ECM/EXCOR see toolbox), corrosion
modelling. Local legislation requirements for
inspection (review and reporting), reporting to
asset custodian and feedback of data into the
CMF (ID NEW above).
• RBI shall be approved by Materials Corrosion
and Inspection TA2 from Function.
Page 23 of 63
Revision: 0
4.3 Facto rs affectin g Materials selection
4.3.1 Information requir ed and review of factors affecting materials selection
Shall be as per DEP.39.01.10.11-Gen, Section 2.3.3 with the following amendments:-
a) Section 2.3.3.2. Replace Table 1 with the Table A.1 in Appendix A of this document.
b) Remove reference to EFC 17 as worst case for chloride when not other information is
available.
c) Add the following:
Chlorides carry over evaluation:
For gas production environments (produced gas or without produced water) and downstream
of separator. Salt accumulation scenarios shall be evaluated as part of materials selection
process.. Presence of formation water shall be included in the evaluation. Assumptions of
lower Chloride
approved levels
by the can only technical
respective be determined with authority
discipline a proper salt materials
(process) andbalance studies
supported by
operation and maintenance philosophy.
d) Section 2.3.3.4 and Appendix E Table E.1 for low temperature requirements shall be
replaced by DEP.30.10.02.31-Gen.
4.4 Appl icatio n of carbon steels
Shall be as per DEP 39.01.10.11-Gen, Section 2.4. and DEP 30.10.02.14-Gen
4.5 Degradation mechanisms
A standardised checklist of corrosion threats is compiled by reference to DEP 39.01.10.11, API RP

571 and the Energy Institute (EI) Guidance for Corrosion Management. Materials and Corrosion
Engineer shall be consulted to ensure all the degradation mechanisms are evaluated including all the
normal and upset operating scenarios.
The following table contain the possible damage mechanisms that shall be evaluated during
materials selection process and the mandatory requirements associated to each damage
mechanism.
Damage Description
Mechanism
CO2 corrosion is one of the most common forms corrosion resulting in wall
thickness loss in carbon steel oil / gas preproduction systems. CO 2 corrosion is
caused by electrochemical reactions between the steel and carbonic acid.
The Hydrocor model has been developed for predicting the likely ‘worst case’
corrosion rate of carbon steel. Hydrocor is a model for quantifying the
corrosivity of the operating environments associated with the production and
CO2 Corrosion
transportation of water-wet hydrocarbons in carbon steel facilities. The
predicted corrosion rate is used to identify Service Life Cycle (SLC) and to
determine the appropriate corrosion allowance for a carbon steel system or
whether
corrosion Corrosion Resistant
mitigation method Alloy (CRA),
is required. non-metallic model
The HYDROCOR materials or other
(Appendix F)
or an alternative model approved by TA1 shall be used for corrosion modelling
in systems containing CO2. The aim of calculating the CO2 corrosion rate is to
Page 25 of 63
Revision: 0
establish the SLC and thereby decide what corrosion allowance might be
needed or whether a CRA is required.
Welds and their surrounding heat-affected zones may have lower resistance to
CO2 corrosion than the parent metal. This phenomenon is known as
Preferential Weld Corrosion (PWC). This may arise for a number of reasons,
partly geometrical, partly chemical and partly metallurgical. Corrosion control by
means of inhibition has been shown to prevent PWC, provided that a suitable
corrosion inhibitor is selected and injected to provide a sufficiently high
concentration. See also DEP.39.01.10.11 (Appendix B). It should be assumed,
for sweet production systems, that the corrosion rate of the weld and heat
affected zone is three times that of the surrounding parent steel.
For more details information, refer to:

• DEP 39.01.10.11-Gen Informative, Section 2.4.3
• EI Guidance, Annex B1
• API RP 571, Section 4.3.6
• NORSOK M-601
Compared to CO2 corrosion of steel, H2S may not cause severe metal weight
loss corrosion because the corrosion product, iron sulfide (FeS) usually forms a
protective film on the steel surface. However, whenever the film is imperfect or
damaged, a corrosion cell is set up between FeS covered surface and the bare
metal, resulting in very localised, accelerated corrosion (e.g., pitting corrosion).
Therefore, the corrosion failure mode in sour systems is pinhole leaks, which
are extremely dangerous, considering the health risks associated with H2S.
For carbon steel, the Hydrocor model can be used for corrosion rate prediction
in H2S containing systems. The empirical correlation included in Hydrocor for
o
H2S Corrosion sour conditions is only verified up to 50 C and 15 bar ppH2S. Above these
values/levels, the corrosion prediction is not considered reliable. Sour corrosion
modelling typically gives over prediction as Hydrocor model provides a worst
case pitting scenario, depending on factors like whether sulphur is present or
not. Testing shall be carried out to optimise the corrosion assessment with
laboratory testing and reviewing operating field analogues.
For more details information, refer to:-

• DEP 39.01.10.11-Gen Informative, Section 2.4.4.2
• API RP 571, Section 5.1.1.10
The presence of elemental sulphur increases the corrosivity of the environment

for pitting corrosion, stress corrosion cracking and particularly weight loss
corrosion thus assessment for elemental sulphur deposition shall be carried out
for high H2S content reservoir (>2Mol%). The presence of chloride ions greatly
enhances sulphur corrosion.
Where elemental sulphur is likely to form in carbon steel systems, sulphur

solvents shall be used to prevent the sulphur depositing. Hydrocarbon liquids
Elemental
are generally good sulphur solvents. The volume of liquid hydrocarbon present
sulphur
and its capacity to dissolve sulphur should be assessed to determine whether
any additional sulphur solvent is required. In sour systems that contain oxygen,
sulphur can form in situ. All potential sources of oxygen in sour systems should
be reviewed and where required eliminated or minimized.
CRA materials are not immune to elemental sulphur (pitting/cracking). The

application limits in SP/DEP/ISO 15156 for CRA do not include any presence of
Elemental sulphur.
Top-of-Line
Corrosion Top
DEPof line corrosion isSpecification,
39.01.10.11-Gen due to condensation
Table 2rate

Amin e Cor ro si on • API RP 571, 5.1.1.1,
Page 26 of 63
Revision: 0
• EFC 46
• DEP 39.01.10.11-Gen Informative, Appendix D;
Erosion-
• EI Guidance, Annex B12;
Corrosion
• API RP 571, 4.2.14
In aqueous corrosion, oxygen is a more corrosive gas than CO 2 and H2S. For
bare carbon steel system, pitting corrosion will occur when exposed to
seawater even with only traces amount of oxygen, but the rate of corrosion is
proportional to the mass transfer rate of dissolved oxygen to steel surface. If
oxygen is continually maintained at < 10ppb, a bare carbon steel or lower grade
CRA should be acceptable with minimum expected corrosion downstream of
the oxygen removal point. However, during upset conditions, which are
unavoidable in almost all cases, the dissolved oxygen concentration can reach
fully aerated levels. For carbon steel systems the corrosion rate is proportional
to the rate at which oxygen reached the steel. For hydrocarbon production
systems oxygen is deemed an operationally avoidable corrodent. Where it may
have an impact is in utility water systems for example. Aqueous oxygen
Oxygen corrosion rates can be predicted with HYDROCOR.
Corrosion
CRA oxygen corrosion is a form of galvanic attack where the normal protective
passive surface oxide film fails at one small point and becomes a small anode
to the surrounding intact surface, resulting in very rapid localised pitting attack.
Oxygen pitting attack on a CRA is often more rapid than on CS, with
penetration rates as much as 6 times higher.
Materials selection for hydrocarbon application does not consider presence of

oxygen in the system. The facilities shall be designed to avoid any potential
ingress of oxygen.
The application limits of CRAs defined in company standards are based on

oxygen free conditions.
Crevice corrosion tends to occur within a tight gap, or underneath deposits (see
Crevice
also UDC) where an occluded environment can develop, e.g. a tube to tube
sheet joint. It can also be considered under flange face corrosion as described
Corrosion
in EI Guidance, Annex B8.
Likelihood of crevice corrosion shall be minimized by materials selection and
design considerations.
Considered separately to pitting caused by other corrosion threats, in this
context it is applied to CRAs with passive films in production and utility
environments. In production environments the key parameters are temperature
Pitting Corrosion
and chloride content, whilst in utility environments it will generally be oxygen
(oxidiser) content, flow rate, temperature and chloride content.
Likelihood of pitting shall be minimized by materials selection and design
considerations.
The deposition of solids creates a shielded environment that provides
conditions for other degradation mechanisms, such as MIC, to occur. Solids in
Under Deposit
straight piping runs are considered to settle out when film velocities are less
Corrosion -1
than 1 ms . Loosely adherent scale can also creates a shielded environment in
(UCD)/dead leg
the same way as settled deposits.
Dead leg corrosion, detailed in EI Guidance, Annex B4, Shall be assessed
during all phases of the project.
Galvanic corrosion occurs when two dissimilar alloys are coupled in the
presence of a corrosive aqueous solution. The more active materials will be the
anode and will be preferentially corroded, while the other, more noble materials
will be the cathode and is protected from corrosion. A large ratio of cathode to
Galvanic anode surface area must be avoided because the galvanic attack is
Corrosion concentrated in the small areas of the anode.
For more details information, refer to

• API RP 571, Section 4.3.1
Page 27 of 63
Revision: 0
Microbiologically Induced Corrosion (MIC) is a corrosion resulting from the

presence of active biological microorganisms from contaminated well operating
fluids, a contaminated reservoir, contamination during construction, surface
commissioning fluids, seawater injection, the design or practice of disposing
surface water in oilfiled pipelines, open drain systems, etc. Microorganisms
tend to attach themselves to solid surfaces, colonise, proliferate and form
biofilms, which can create a corrosive environment at the biofilm / metal
interface radically different from the bulk medium in terms of pH, salts and
dissolved gas. As a consequence, either a galvanic corrosion cell and / or
acidic action may develop causing metal attack. Instead of causing general
corrosion, MIC is a localised attack and may take the forms of pitting corrosion,
Microbial
crevice corrosion, under deposit corrosion, selective dealloying and galvanic
Induced
corrosion.
Corrosion (MIC)
Once bacteria are present in the system it is almost impossible to eliminate
them. Bacterial surveillance program shall be performed during field
commissioning and after any significant new activity. Methods to mitigate
bacteria presence is chemical treatment (commonly with biocide), operational
pigging and robust surveillance program in place. The likelihood of MIC can
also be assessed using HYDROCOR.

API RP 571, Section 4.3.8
Welds and their surrounding heat-affected zones may have lower resistance to
CO2 corrosion than the parent metal. This phenomenon is known as
Preferential Weld Corrosion (PWC). This may arise for a number of reasons,
partly geometrical, partly chemical and partly metallurgical. Corrosion control by
means of inhibition has been shown to prevent PWC, provided that a suitable
Preferential Weld
corrosion inhibitor is selected and injected to provide a sufficiently high
Corrosion concentration.

• DEP 39.01.10.11-Gen Informative, Appendix B
Principally occurring in austenitic stainless steels it is characterised by attack
Intergranular
along grain boundaries where precipitation of chromium carbides, nitrides or
Corrosion
intermetallics has reduced the corrosion resistance of adjacent materials. This
effect is known as ‘sensitisation.’
Strong Aci d (Well
See DEP 39.01.10.11-Gen Specification, 3.3 for mandatory requirements. Post
Workover)
stimulation mitigation and management approach are given in RMP
Corrosion
31.40.00.50 (for sour service).
Internal Cracking
SP-2041; DEP 39.01.10.11-Gen Specification, 2.4.4.3; EI Guidance, Annex B2;

API RP 571, 5.1.2.3, ISO 15156.
SSC is a rapid form of cracking that can cause catastrophic failure. Control of
this form of cracking SHALL [PS] be through selection of materials not
susceptible to cracking under all expected modes of operation (including start
Sulphide Stress
up and shutdown). Materials selection shall be carried out using DEP
Cracking
30.10.02.15 AND SECTION 5 of this SP.
Many of the requirements of DEP 30.10.02.15-Gen. are related to hardness

restrictions, and it uses both Rockwell C (for non-welded materials) and Vickers
10 kg (22 lb) (for welded materials). Approximate hardness conversion tables
are given in ASTM A370. Note that the conversion factors do not apply to all
types of materials. For hardness conversions of martensitic and
Page 28 of 63
Revision: 0
austenitic/ferritic materials the Principal shall be consulted.

SP-2041; DEP 39.01.10.11-Gen Informative, 2.4.4.4; EI Guidance, Annex B2;
API RP 571, 5.1.2.3 Where no HIC testing for certain product forms is required
by Table 4 the need for such testing should be evaluated based on the criticality
of the components in question.
Hydrogen
Induced Cracking
HIC requirements SHALL be as per SP-2041. SP-2041 replaces HIC
requirements in section 2.4.4.4 of DEP.39.01.10.11. The test method has been
shown to be very sensitive to small variations; therefore a control sample of
known HIC sensitivity shall be included in HIC tests to make sure that the
results are calibrated against a standard.
Stress Oriented
Hydrogen EI Guidance, Annex B2; API RP 571, 5.1.2.3
Induced Cracking
Am in e Str ess
Corrosion API RP 571, 5.1.2.2; EFC 46
Cracking
Hydrogen DEP 39.01.10.11-Gen Specification, 2.4.4.6; API RP 571, 4.5.6
Embrittlement
Chloride Stress
Corrosion
Cracking EI Guidance, Annex B11; API RP 571, 4.5.1
Liqui d Metal API RP 571, 4.5.5

Embrittlement
Corrosion API RP 571, 4.5.2
Fatigue
External co rrosion
At mo sp her ic EI Guidance, Annex B9; API RP 571, 4.3.2

Corrosion
Corrosion Under EI Guidance, Annex B10; API RP 571, 4.3.3
Insulation
Crevice and EI Guidance, Annexes B9 and B11
Pitting Corrosion
Galvanic EI Guidance, Annex B5; API RP 571, 4.3.1
Corrosion
High temperature API RP 571, 4.4.1
oxidation
API RP 571, 4.4.2
Sulphidation
Applicable to such items as flare tips operating with H2S
Soil Corrosion
API RP 571, 4.3.9. Including MIC corrosion.
External Cracking
Chloride Stress
Corrosion EI Guidance, Annex B11; API RP 571, 4.5.1
Cracking
Hydrogen
DEP Specification 39.01.10.11-Gen, 2.4.4.6; API RP 571, 4.5.
Embrittlement
Liqui d Metal API RP 571, 4.5.5
Embrittlement
Corrosion API RP 571, 4.5.2
Fatigue
Mechanical Degradation
Page 29 of 63
Revision: 0
Erosion by Solids DEP Informative 39.01.10.11-Gen, D.2.1, D.2.2; EI Guidance, Annex B12; API
and Liquids RP 571, 4.2.14
External DEP Specification 31.38.01.29-Gen

Ab ras io n & Wear Issues that may fall under this categorisation are: piping clashes, fretting and
wear at pipe supports.
Fatigue Cracking API RP 571, 4.2.16 and 4.2.17; Energy Institute Process Pipework Fatigue
Guidelines
High Temperature Creep and Stress Rupture
High API RP 571, 4.2.8

Temperature
Creep and Stress
Rupture
Thermal Fatigue API RP 571, 4.2.9
Low Temperature DEP Specification 30.10.02.31-Gen; API RP 571, 4.2.7
Embrittlement
Long Running DEP 31.40.00.10-Gen Specification, 8.1.6
Ductile Fracture Applicable to gas and multiphase pipelines where fluid decompression
characteristics can drive initiated cracks for substantial distances
Galling Galling is a form of adhesive wear and occurs by dynamic metal-to-metal
contact between two surfaces sliding relative to one another when there is poor,
or non-existent, lubrication. It can occur at flange/gasket interfaces and lead to
poor sealing.
Non-Metallic Seal DEP 39.01.10.12-Gen Specification, Appendix C
Degradation Rapid gas decompression is a major cause of elastomeric seal failure in high
pressure gas service. Seals can also fail by ageing where the service
environment induces chemical or physical changes. Supporting information for
study is given in UK HSE Research Reports 320 and 485.
Refer to DEP30.10.02.13 for non metallic testing requirements.
4.6 Economi c aspects of materials selection
Shall be as per section 2.5, DEP 39.01.10.11 –Gen.
4.7 Non- operation al cons ideratio ns
Materials selection shall consider all the operating modes including non operational considerations as
per section 3 of DEP 39.01.10.11-Gen.
Page 30 of 63
Revision: 0
5 GENERAL MATERIALS DESCRIPTION AND SPECIFIC REQUIREMENTS
5.1 General Requirements for Specific Materials Group
5.1.1 Sour servi ce

If hydrogen sulfide concentration (H2S) is present in the equipment over the lifecycle in any phase
the service shall be considered as sour service and the requirements of SP-2041 and
DEP.30.10.02.15 shall applied. Concentration of H2S shall be determined in accordance with DEP
25.80.10.18-Gen.
When assessing materials suitability, the pH and H 2S partial pressure shall represent not only normal
life cycle exposures but also exposures as can reasonably be expected to occur during an upset or in
a stratified flow condition (e.g., normal packer fluid pH versus condensing water pH after tubing to
annulus leak, or pH of flowline fluid versus condensing water pH during stratified flow.
For vessels, internal protective coatings are acceptable to protect carbon and low alloy steels against
Hydrogen Induced Cracking (HIC) or stepwise cracking, provided that the coating integrity is ensured
by means of a suitable coating maintenance program and that a program to detect and monitor HIC
formation and growth is in place. (Informative: For practical purposes, this shall only apply to
vessels).
Stainless steels
The production stream phase behaviour SHALL [PS] be reviewed to identify if flashing conditions or
salt deposition from carryover fluids are present, which conditions concentrate fluid salinity. In the
event flashing conditions are present, either a salinity of 250 g/l (expressed as NaCl) or the greater
value equivalent to salt saturation in water at operating conditions shall be assumed when selecting
and testing the materials. Any testing shall be done in representative water chemistry.
The temperatures given in Table 5.1 shall be used to assess the risk of pitting corrosion, crevice
corrosion and chloride stress corrosion cracking of the most common stainless steel type used in
Upstream in offshore and onshore salt laden environments (e.g. desert environment). The risk for
other stainless steel types shall be referred to the MCI TA2 from Function.
Table 5.1: Typical stainless steel temperature limits.
Stainless Threshold Threshold Negligible Significant

(1)
steel type for pitting for crevice risk of risk of
corrosion corrosion CSCC CSCC
316L(2) 5oC <0oC <50oC >60oC
6Mo 50oC 30oC <100oC >120oC
22Cr
Duplex(3) 40oC 15oC <80oC >100oC
25Cr Super- 60oC 30oC <100oC >110oC
Duplex(4)
(1) Table gives requirements for generic stainless steel types. Specific materials and conditions may influence
the acceptable temperature
(2) Assumes minimum Molybdenum content of 2%. Higher temperatures may be possible at higher Mo
content.
(3) Assumes PREN > 35
(4) Assumes PREN > 40
Contact of zinc with stainless steel items SHALL[PS] be prevented, including zinc coating
contamination and contamination by zinc in fire scenarios from other equipment.
Page 31 of 63
Revision: 0
Ferritic and Martensitic stainless steels such as those of the 13Cr family are susceptible to both
sulphide stress cracking (SSC) and stress corrosion Cracking (SCC) and therefore their application
shall be in accordance to DEP.30.10.01.15.
Au st eni ti c st ain les s st eels containing less chromium, nickel and molybdenum than AISI 316, such
as AISI 304, shall not be used / applied in PDO production facilities as defined in DEP 39.01.10.12-
Gen, Appendix A.
All the austenitic stainless steels wrought, forge and cast products shall be subjected to intergranular
corrosion testing in accordance with ASTM A262 Practice E. The materials shall pass required
criteria stated in ASTM A262 specification. The intergranular corrosion test shall be performed for
each heat in the purchase order.
Au st eni ti c/f err it ic st ain les s s teel s (du pl ex s tai nl ess st eels ) can suffer both SCC and SSC, hence
hardness requirements from DEP 30.10.01.15 shall apply and strict H2S partial pressure limits shall
be followed as given in Part 6 and DEP 30.10.01.15. Both 22 Cr duplex and 25 Cr super-duplex
stainless steels are susceptible to CSCC at 80 °C (176 °F) under drop evaporation conditions, and
their use at points of salt accumulation shall be avoided.
Applications of duplex stainless steels at Lower Design Temperatures (LDT), for which the design
code asks for proof of toughness by impact testing, require an additional specification of the steel
being ordered and confirmation of proven toughness on the steel certificate. Welding procedures
shall be qualified or re-qualified with impact testing included, when required by the design code for
the given LDT. The minimum design temperature of duplex stainless steels is -50°C (-58°F) with
maximum thickness of 40 mm (1.6 in) unless otherwise qualified in accordance with
DEP 30.10.02.31-Gen section 5.4. Duplex stainless steel shall have PREN > 34, with a nitrogen >
0.14%. The super duplex stainless steel shall contain at least 25%Cr and PREN > 40 and nitrogen >
0.2%. Duplex stainless steel and super duplex stainless steel shall comply with DEP 30.10.02.35-
Gen requirements.
All the DSS and SDSS wrought, forge and cast products shall meet following requirements in
addition to requirements stated in respective MESC SPEs and relevant DEPs.
Transverse tensile test:
Transverse tensile testing is not required for the pipe nominal diameter ≤ 6”. Diameters 8” and above
shall be subjected to transverse tensile test.
Pitting Corrosion testing:

The materials shall be capable of passing the ferric chloride test in accordance with ASTM G 48,
Method A, with the following amendments. This corrosion test shall be performed for product
qualification only.
The exposure time shall be 24 hours. The test temperature for “22Cr” duplex (ferritic-austenitic)
stainless steel shall be 25 °C for parent metal and 22 °C for welds.
The test temperature for “25Cr” superduplex (ferritic-austenitic) stainless steel shall be 40 °C for
parent metal and 35 °C for welds.
• The temperature variation shall not exceed ± 0.5 °C.

• The surface finish of the test face shall be ‘as-produced’. Cut faces shall be ground to 1200
grit.
• The evaluation of results shall be via weight loss measurement and macroscopic
investigation of the surface. Macrographs obtained by low magnification microscopy shall be
provided.
The acceptance criteria shall be a weight loss < 4.0 g/m2 and no initiation of localized corrosion >
0.025 mm (1 mil) at the test face. Note that only corrosion (e.g. pitting) at the test face counts. If the
weight loss is > 4.0 g/m2 and it can be positively identified that this is only due to corrosion at the cut
faces, the test will be invalid. In this case re-testing shall be carried out on replacement specimens.
Frequency of testing shall be each heat in the purchase order.
Page 32 of 63
Revision: 0
Super austenitic stainless s teels (>6 % Mo) to ensure corrosion resistance of welds, a nickel alloy
filler with increased Mo, such as alloy 625, shall be used. 6Mo materials shall comply with DEP
30.10.02.35-Gen requirements.
All the UNS S31254 wrought, forge and cast products shall be subjected to ferric chloride test in
accordance with ASTM
shall be 24 hours. G48,specimens
The test Method A.shall
The be
testintemperature shall be
the as-delivered 50 °C and
condition. Thethe
testexposure time
shall expose
the external and internal surfaces. No pitting is acceptable at internal or external surfaces at 20 times
magnification. The weight loss shall be < 4.0 g/m².
Precipitation hardening stainless steels in Appendix A of DEP 39.01.10.12 Gen, such as

UNS S17400 (17-4 PH) and UNS S15500 (15-5PH) shall be prohibited for pressure containment
parts in sour environments. Alloy 17-4 shall be limited to a maximum stress of 50% for compressor
internal components.
Nickel alloys such as UNS N07718 (Alloy 718) shall meet the requirements of
DEP 39.01.10.32-Gen. UNS N07725 (Alloy 725) and UNS N07716 (Alloy 625+ ) shall be specified in
accordance with DEP 39.01.10.30-Gen. These materials may suffer from similar issues to those that
have been observed with Alloy 718, and, as such, care shall be taken during manufacturing and heat
treatment, particularly for critical or highly loaded components.
Al lo y N08825 (Alloy 825) shall be supplied with Ni content greater than 39% and a PREN greater
than 30. Quality assurance in supply chain should be closely monitored.
Intergranular corrosion test in accordance with A262 Practice C. Acceptance criteria shall be weight
loss < 0.9mm/year and intergranular penetration shall not exceed 30 microns average, with minimum
individual maximum 50 microns into the surface that will be exposed to the corrosive environment in
the specific application when measures by micrography shall be performed at an appropriate
magnification in a minimum of eight separate viewing fields average. The intergranular corrosion test
shall be performed for each heat in the purchase order.
For materials cladded with Alloy 825 exposed to post weld heat treatment or other stress relieve
treatment during fabrication shall be subject to corrosion test at simulated worst case process
conditions to evaluate effect on the materials. Test shall include pitting and crevice assessment.
Allo y UNS N0625

All alloy 625 materials wrought, forge and cast products shall be subjected to integranular corrosion
test in accordance with ASTM G28, Method A. The maximum allowed corrosion rate is
0.075mm/month and intergranular penetration shall not exceed 30 microns average, with minimum
individual maximum 50 microns into the surface that will be exposed to the corrosive environment in
the specific application when measures by micrography at an appropriate magnification in a minimum
of eight separate viewing fields average.
Where galling resistance is required, anti-galling compounds, electroplating, or use of different
materials should be used for the two parts that come into contact, e.g., N06625 and N07725.
Molybdenum Disulfide SHALL [PS] not be used. An alternative anti-galling approach that may be
used is to specify and assure a minimum difference in hardness of 25 HRB of the components.
Glass reinforced plastics . The choice of fibre and resin should be selected after full consideration
of the service requirements in accordance with SP-2092 and DEP 30.10.02.13-Gen. GRP pipelines
and piping shall be in accordance with SP- 2092, SP-2156 and DEP 31.40.10.19-Gen.
Note: Proprietary materials might be considered upon successful qualification and approval from MCI
Corporate Function Discipline Head (CFDH).
All the corrosion tests shall be carried out at PDO and ILAC approved laboratory.
Page 33 of 63
Revision: 0
5.2 Specific requir ements
5.2.1 Metallurg ically bonded clad plates

The plate materials used as clad plates (for explosive and roll bonding) shall be subjected to
corrosion testing as indicated for the base materials in section 5.1. If PWHT is applied the corrosion
test shall be conducted with the simulated actual PWHT cycles.
5.2.2 Welding includ ing clad and overlay equipment

All the weld overlay materials (316L and 625) shall be subjected to integranular corrosion testing as
stated in the section 5.1.
Minimum undiluted weld overlay thickness after machining shall be 1mm for the piping components
and minimum clad thickness shall be 3 mm and two pass.
Alloy 825 weld overlay shall not be used for equipments and piping components.
Base material: For the sour service the base Carbon Steel materials shall meet sour service
requirements. Materials composition shall meet the HIC requirement. However, testing can be
exempted. Hardness hardness

the PQR qualification values at testing
the clad/weldoverlay interface
(including PWHT shall
cycles) not
shall beexceed
carried248
out.HV10. Apart from
Welding procedures for ferritic/martensitic materials with austenitic consumables require close
scrutiny, because a hard, brittle zone of relatively high carbon can form in the austenitic material
immediately adjacent to the fusion boundary. This brittle zone is very sensitive to hydrogen
embrittlement (hydrogen-induced stress cracking, sulphide stress cracking) and even brittle fracture
due to stress alone if the critical flaw size (as determined by means of CTOD tests) is exceeded.
Direct exposure of such hard zones to sour conditions and cathodic protection shall be avoided.
Hardness requirements defined in ISO 15156, such as 250 HV 10 is not sufficient, because the brittle
zone is so thin that it cannot be detected with the Vickers method of hardness testing.
A minimum of two layers of weld overlay shall be used. For Alloy 625, the maximum allowed iron
content
mm from duethetoAlloy
dilution
625ofsurface,
deposited Alloy
shall be625 by On
10%. the underlying carbon or
surface, chemical low alloy steel
composition shallatmeet
2.5 tothe
3
original materials specification, including 5% max Iron. Optical electron spectroscopy (OES) shall be
the only method to determine weld dilution. A cross section shall be taken during weld procedure
qualification and OES shall be done at 1 mm increments from the weld metal through the heat
affected zone, to a distance no less than 3 mm from the fusion line.
When carrying out buttering, the closure weld shall be made with UNS N06625 (Alloy 625). Maximum
hardness of 325 HV 10 in the base metal and HAZ are accepted for non-sour and sour service,
provided that the bore is fully clad (Refer to ISO 15156-3, Clause A13.1).
Single layer welding techniques, e.g., electro-slag, shall only be used with prior approval from the
MCI TA2 from Function.
5.3 Protecti on against catastroph ic failu re mechanisms
Sudden failure mechanisms such as stress corrosion cracking, Hydrogen embrittement (corrosion)
fatigue, and low temperature embrittlement shall be prevented by means of proper materials
selection and design. Coatings or corrosion inhibition shall not be used as the primary barrier for
environmental assisted cracking or corrosion-fatigue during design.
Performance tested/qualified Coatings or aluminium foils may be considered for mitigation of Cl-SCC
if the risk is assessed as negligible or manageable, approval from MCI TA2 from Function is required.
Page 34 of 63
Revision: 0
5.3.1 Chloride stress corro sion cracking
Austenitic and duplex stainless steels may suffer from external chloride induced stress corrosion
cracking (CSCC) when exposed to a combination of tensile stresses, chlorides, water, oxygen, and a
temperature threshold. This failure mode, typically caused by exposure to humid marine atmosphere,
may represent a higher risk than the internal service and is generally manifested by a sudden
fracture of pipe or equipment. PDO is operating in desert environment characterised by frequent
sandstorms and deposition of salt laden sand. Therefore the risk of Cl-SCC shall be evaluated and
documented.
Application of stainless steels with significant risk of CSCC above the given temperature shall be
subject to mitigation to an acceptable level (ALARP). Application of stainless steels with risk of CSCC
at high chloride concentration shall be subject to a risk assessment and mitigation if deemed
necessary.
The threshold temperatures which the material has an acceptable risk of external CSCC are shown
in Table 5.1. Above these temperature thresholds (significant risk of CSCC in Table 5.1) austenitic,
duplex stainless steel, super stainless steels and super austenitic stainless steel shall be externally
coated with Thermal Sprayed Aluminium coating (TSA) in accordance to DEP 30.48.40.31-Gen. If
welding is involved, TSA shall be done post welding.
Organic coating qualified for the service life can be applied if ALARP is demonstrated by risk
assessment.
TSA shall not be used for protection of small-bore (<DN 50) (<NPS 2)) components so selecting a
resistant material is the preferred option.
5.4 Protecti on of stainl ess steels for Corros ion Under Insulati on (CUI)
with aluminium.
Stainless steels may be protected against external pitting and crevice corrosion under insulation by
means of coating with Thermally Sprayed Aluminium (TSA). Joints and ends shall be taped with self-
adhesive aluminium tape. This aluminium foil acts as both a barrier coat and inhibitor. The applicable
temperature range for the use of aluminium foil under insulation is 50°C to 200°C (122 °F to 392 °F)
for continuous service and 50°C to 480°C (122 °F to 896 °F) for cyclic conditions.
Only the arc spray application process shall be used for CRA materials and all systems shall be
sealed using a silicone system. TSA shall be applied in accordance with DEP 30.48.40.31-Gen.
5.5 Seali ng materi als

Where metal-to-metal seals are used, there is a potential risk of galvanic corrosion. To prevent this,
the seal surface materials shall be at least as noble as the surrounding surfaces. Elastomer seals are
addressed in DEP 39.01.10.12, Section 3.2.13.
5.6 Amendment s to ISO 15156
DEP. 30.10.02.15-Gen is written as amendments and supplements to the following ISO Standards:
• ISO 15156-1:2009
• ISO 15156-2:2009
• ISO 15156-3:2009
Page 35 of 63
Revision: 0
Wherever reference is made to the above ISO Standards, it shall be understood to mean the
ISO 15156-1:2009, ISO 15156-2:2009 and ISO 15156-3:2009 as amended/ supplemented by DEP.
30.10.02.15-Gen
Materials limits for sour service shall be in accordance with this SP, DEP 30.10.02.15-Gen, and ISO
15156. Remarks made
ppH2s, temperature and in ISO 15156-3
chloride, tables
etc.) shall indicating
not be used for “materials
ANY” combination
selections. of parameters (pH,
Page 36 of 63
Revision: 0
6 MATERIALS SELECTION BY EQUIPMENT SYSTEMS
6.1 INTRODUCTION
6.1.1 General
This Section includes materials for process and utility equipment used in onshore operations for
surface facilities.
The materials selected shall meet minimum toughness requirements at the minimum design
temperature during low temperature events such as blowdown. The low temperature requirements of
materials are covered in detail by DEP 30.10.02.31-Gen. and DEP 31.38.01.15-Gen., which refers to
ASME B31.3.
6.2 Vessels and pipi ng

Shall be in accordance with DEP 39.01.10.12-Gen, Section 3.2.5 with the following amendments.
a) Replace Table 3, with the following Table 6.1 below.
Page 37 of 63
Revision: 0
Table 6.1: Vessels and piping
Internal Environmental conditio ns

Materials
SLC Temp pH 2S selection Piping
Cl (1) Vessel material
for class Comments
mm °C mbar (10)
(in) (°F) (psi) ppm piping

CS with 1 1410,
<1 <200 <3.5
Any* mm (1/32 1450, or As for piping
(<1/32) (<392) (<0.05)
in) CA 1470
CS with 3
<3 <200 <3.5 1430 or
Any* mm (1/8 As for piping
(<1/8) (<392) (<0.05) 1490
in) CA
CS with 3
mm (1/8
(2)
in) CA .
As for piping + glass
CS with (4)
flake lining .
3 to 6 <80 <3.5 glassflake 1430 or
Any* Temperature limit is
(1/8 to 1/4) (<176) (<0.05) lining
only if 1490 for the glass flake
lining.
limited life
is
(3)
required
SSC and
HIC-
resistant
<1 <200 <100 1420 or
Any* steel with As for piping
(<1/32) (<392) (<1.45) 1460
1 mm
(1/32 in)
CA
SSC and
<3 <200 <100 HIC-

resistant
Any* 1440 As for piping
(<1/8) (<392) (<1.45) steel with
3 mm
(1/8 in) CA
SSC and
HIC- As for piping + glass
(4) SLC can be
resistant flake lining .
3 to 6 <80 <100 reviewed based
Any* steel with 1440 Temperature limit is
(1/8 to 1/4) (<176) (<1.45) on inspection
3 mm for the glass flake
frequency.
(1/8 in) CA lining.
(2) 3)
.
CS clad with AISI

≥ <3.5
6
(≥1/4) <120
(<248) (0.05) 120000 AISI 316L 3430 316L
316L or
(5)
solid
or AISI
22Cr
(5)
Duplex
CS clad with AISI

≥6 <60 <15 316L or solid AISI
60660 AISI 316L 3430 (5)
(≥1/4) (<140) (<0.22) 316L or 22Cr
(5)
Duplex
<155 <15 CS clad with AISI

≥6 Limit valid for pH
<37000 AIS 316L 3430 316L or solid AISI
(≥1/4) (<311) (<0.22) >3.8
316L or 22 Cr Duplex
≥6
22Cr
(≥1/4 90 <2.0 165000 3832 Clad AISI 316L pp CO2 < 1.5 bar
Duplex
≥6 22Cr
120 <2.0 170000 3832 Clad AISI 316L pp CO2 < 0.43 bar
(≥1/4 Duplex
Page 38 of 63
Revision: 0
PDO has previous

issues with the
application of
CS clad with AISI
≥6 <200 <10 22Cr (13) 904L grade,
160000 3832 904L or solid 22Cr
(≥1/4) (<392) (<0.15) Duplex (5) CFDH approval is
Duplex
required to select
904L as a material
of construction
<1 g/l CS clad with AISI
≥6 <120 <350 22Cr
(1000 3832 316L or solid 22Cr
(≥1/4 (<248) (<5.08) Duplex (5),
ppm) Duplex
PDO has previous

issues with the
application of
CS clad with AISI
≥6 <200 <20 Super (13) 904L grade,
<160000 904L or solid 22Cr
(≥1/4) (<392) (<0.30) Duplex (5) CFDH approval is
Duplex
required to select
904L as a material
of construction
CS clad with AISI
≥6 <200 <80 Super (13)
<30330 904L or solid 22Cr
(≥1/4 (<392) (<1.16) Duplex (5)
Duplex
≥6 <200 <1,000 <1 Super CS clad with AISI

(≥1/4) (<392) (<14.5) (640 ppm) Duplex 316L or solid 22Cr
Duplex (5)
PDO has previous
issues with the
application of
<20 CS clad with AISI
≥6 <200 Super 904L grade,
(<0.30) <160,000 904L or Alloy 825
(≥1/4) (<392) Duplex CFDH approval is
Clad.
required to select
904L as a material
of construction
Laboratory
qualification tests
have shown 6 Mo
might be
susceptible to
pitting under high
chloride (>50,000
≥6 < 200 CS clad with Alloy ppm) in sour
< 60 < 4000 6Mo
(≥1/4) (120) 825 or solid 6Mo service.
Weld overlay of
alloy 825 shall not
be considered as
material for
vessels and piping
Weld overlay of
alloy 825 shall not
CS clad with Alloy be considered as
≥6 <200 <14,000
<160,000 Alloy 825 825 or Alloy 625 or material for
(≥1/4) (<392) (<203)
solid Alloy 825 vessels and piping
Weld overlay of

Alloy 28 alloy 825 shall not
CS clad with Alloy be considered as
≥6 <200 <36,000 (pCO <25
(≥1/4) (<392) (<522) <160,000 2
bar (363 825 or Alloy 625 or material for
solid Alloy 825 vessels and piping
psi))
Page 39 of 63
Revision: 0
Weld overlay of
alloy 825 shall not
≥6 <240 <30,000 Alloy CS clad with Alloy be considered as
<160,000 (8)
material for
(≥1/4) (<464) (<435) 625 625 or solid Alloy 625
vessels and piping

≥6 <100
(9) Any* Any* GRP GRP
(≥1/4) (<212)
Note: Cladding and weld overlay are two different processes.
6.3 Piping, fitti ngs valves and other components
Shall be in accordance with DEP 39.01.10.11-Gen, DEP 39.01.10.12-Gen, Section 3.2.6 and DEP
30.01.10.15-Gen. All the applicable MESC SPEs shall be followed for piping, fittings, valves and
other components.
6.4 Small bore instru ment, hydraulic and chemical injection tubing
Shall be in accordance with DEP 39.01.10.12-Gen, Section 3.2.7, Table 4.
6.5 Heat exchang ers
If carbon steel plus inhibition is used in upstream piping, the vessel exchanger shall be made of a
suitable CRA.
6.5.1 Shell-and-tu be heat exchang ers
The selection of materials for direct water coolers shall be derived from the materials selected for the
adjacent process piping and the coolant (Table 6.2).
Oxygen contamination of closed circuit cooling systems has been a problem in many cases, and
carbon steel shall only be used if oxygen can be successfully kept out of the system, or where a
sufficient corrosion allowance, based on a good estimate of corrosion rate, can be used. Where Ti is
selected, it SHALL [PS] not be coupled directly to carbon steel.
Glycol reboilers are addressed in DEP 39.01.10.12-Gen, Section 3.2.9, Table 8.
Page 40 of 63
Revision: 0
Table 6.2: Shell-and-tube heat exchangers
Cooling water Incoming pipe Tubes Tubesheet and Shell, baffles

material Channels and

(Table 3) tie-rods
Non-corrosive coolant on Carbon steel Carbon steel Carbon steel Carbon steel
tube side. SLC<1
On shell side closed circuit Carbon steel Upgrade to Carbon steel with Carbon steel
(no 02, inhibited, SLC>1 appropriate corrosion
(6)
monitored) stainless steel allowance, or
(not martensitic). corresponding
stainless steel,
solid or clad.
22Cr Duplex 22Cr Duplex 22Cr Duplex Carbon steel
Super Duplex Super Duplex Super Duplex Carbon steel
316L 316L 316L solid or clad Carbon steel
6Mo 6Mo 6Mo solidor

825 solid orclad
Alloy Carbon steel
(5)
Alloy 625 Alloy 28 Alloy 825 solid or Carbon steel
clad
Alloy 825 Alloy 825 Alloy 825 solid or Carbon steel
clad
Alloy 625 Alloy 625 Alloy 625 clad Carbon steel
Chlorinated aerated Carbon steel Super Duplex Super Duplex Carbon steel
seawater on tube side.
Max. temperature 22Cr Duplex Super Duplex Super Duplex 22Cr Duplex
<30 °C (<86 °F) Super Duplex Super Duplex Super Duplex Super Duplex
6Mo 6Mo 6Mo 6Mo or 825 clad

Alloy 28 Alloy 625 Alloy 625 solid or Alloy 825 clad
(3)
clad

Alloy 825 Alloy 625 625 solid or clad 825 clad
(3)

Alloy 625 Alloy 625 625 solid or clad 625 clad
(3)
(4) (4)
Chlorinated aerated Any C276 or C22 or C276 solid or As inlet pipe,
(3)
seawater on tube side. Ti clad or Ti solid solid or clad
(3)
Max. temperature or clad
>30 °C (>86 °F)
NOTES: (1), (2) Notes not used

(3) Clad tubesheets assume the cladding is on the seawater side and tubes are front welded. The suitability of the
tubesheet carbon steel base metal for exposure to the process fluids shall be considered.
(4) Alloy C276 tubes have been known to fail due to the formation of a crevice under chloride-rich deposits. The
likelihood of the formation of such deposits should be duly considered before selecting a material.
(5) Alloy 28 shall be limited to a pH2S below 36000 mbar (522 psi).
(6) When cooling gas, the definition of non-corrosive service may include an assessment of the gas dew point and
corrosion within the tubes, provided appropriate operating controls are in place. Dew point assessment shall
consider field ramp-up flow rates, duration, and minimum controllable heat transfer capacity.
Page 41 of 63
Revision: 0
6.5.2 Plate coo lers

Table 6.3: Plate coolers
Service Max temp. °C Incoming Plate material

(°F) pipe
Seawater cooling oil or 30 625, 825, 28, 625
produced water (86) GRP
6Mo, GRP 6Mo
All others Super duplex
200 Any Alloy 625, Alloy C276, or titanium
(392)
Closed circuit water cooling 60 AISI 316L subject to the
crude oil/gas (140) environmental limitations given in
(2.2.1)
200
(392) As adjacent Alloy
Otherwise, produced
825, fluid
Alloypiping.
625,
Alloy C276, or titanium
NOTE: See DEP 39.01.10.12-Gen, Section 3.2.9.
Page 42 of 63
Revision: 0
6.5.3 Air cooled heat exchangers

Materials for air cooled heat exchangers shall be per Table 6.4 which refers to external limits. For
internal limits refer to Table 6.1 in Section 6.2.
Table 6.4: Air co oled heat exchangers

Incoming pipe Tube material Header Box materi al Max. temp.
(Table 6.1) °C (°F)
Carbon steel SLC<1 Carbon steel with fully Carbon steel fully coated
extruded aluminium fins with TSA, or upgrade to
appropriate stainless steel
below depending on
maximum temperature
Carbon steel SLC>1 Upgrade to appropriate Carbon steel with
stainless steel below corrosion allowance fully
depending on maximum coated with TSA, or
temperature upgrade to appropriate
stainless steel below,
depending on maximum
temperature
(1)
316L 316L 316L 50 (122)
(1)
22Cr Duplex 22Cr Duplex 22Cr Duplex 80 (176)
(1)
Super Duplex Super Duplex Super Duplex 110 (230)
(2)
316L 316L with fully extruded 316L fully coated with TSA 120 (248)
(2)
aluminium fins or 316L internally clad
carbon steel
(2)
22Cr Duplex 22Cr Duplex with fully (2) 22Cr Duplex fully coated 190 (374)
extruded aluminium fins with TSA
(2)
Super Duplex Super Duplex with fully Super Duplex fully coated 190 (374)
(2)
extruded aluminium fins with TSA
(3)
6Mo 6Mo 6Mo 200 (392)
(3)(4)
Alloy 625 Alloy 28 Alloy 28 200 (392)
(3)
(3)
NOTES (1) The maximum temperatures are dictated by the risk of external chloride SCC, see (2.2.1).
(2) These temperatures only apply to heat exchangers with coated tubes that have fully extruded aluminium
fins.
(3) Likely to have extruded aluminium fins for heat transfer requirements, but not required as part of the
corrosion design as these materials are resistant to Chloride SCC up to at least 200 °C (392 °F).
(4) Alloy 28 ishall be limited to a pH2S below 36000 mbar (522 psi)
If extruded aluminium fins are used on tubes, no external corrosion allowance is required. There shall
be no exposed steel tube area for both CS and CRA tubes. Achieving no exposed steel at the
tubesheet end is often problematic and requires special attention. For the fins, aluminium Alloy 5083
(UNS A95083) has the best reported performance.
If coating is required on the header boxes, the tubesheet shall be TSA coated prior to inserting the
tubes in the tubesheet, with any repairs to the coating carried out as each row of tubes is inserted.
Page 43 of 63
Revision: 0
6.5.4 Compact coolers (printed circu it heat exchangers)
Printed circuit heat exchangers have very fine channels, which restricts them to relatively clean
duties (such as gas or NGL cooling). Upstream filters shall be specified and maintained to reduce the
risk of channel plugging.
Materials shall be selected to withstand erosion in the small channels and also crevice corrosion at
the anticipated service condition.
Material choice is limited by the Manufacturers and the manufacturing method to AISI 316L, 22 Cr,
Cu or Ti.
6.6 Glycol dehydration syst em
Shall be in accordance with DEP 39.01.10.12-Gen, Section 3.2.9, Table 8. For severe sour service,
materials selection shall be peer review and approved by TA2 MCI from function.
6.7 Flare & relief sys tems
Shall be in accordance with DEP 39.01.10.12-Gen, Section 3.2.10, Table 9.
6.8 Rotating equipment
Shall be in accordance with DEP 39.01.10.12-Gen, Section 3.2.11.
Add the following table in the first paragraph related to rotating equipment
a) Compressors for PDO shall be designed for sour service.

b) For dry gas environment confirmed by process. Carbon steel suitability to be
defined based on corrosion assessment vs. % of incidental wet scenarios (upset
conditions leading to free water presence).
c) For wet or significant SLC, CRA materials shall be specified in sour service as per
Table 5.
6.9 Pumps
Centrifugal pumps shall be in accordance with DEP 31.29.02.30-Gen.
Page 44 of 63
Revision: 0
6.10 Bolting
Shall be in accordance with DEP 39.01.10.12-Gen, Section 3.2.12, Table 10 and Table 11.
Add the following notes after second paragraph:

• PTFE coating may be used up to an operating temperature of 200 °C (392 °F).
• Quality control procedures shall be developed to cover PTFE handling during
transportation, storage and installation to avoid coating damage.
• Cadmium plated bolts shall not be used.
6.11 Elastomer Seal Selection
Shall be in accordance with DEP 39.01.10.12 -Gen, Appendix C.
6.12 Pipelines
Pipelines materials selection shall cover the construction materials for below systems:-
a) Process pipelines
b) Dry hydrocarbon pipelines
c) Water injection pipelines
Carbon steel is widely used for pipelines with or without corrosion inhibition. The corrosion allowance
shall be calculated using DEP 30.10.02.14-Gen. There are two applicable standards for carbon steel
linepipe, according to whether it is critical or non-critical service. Carbon steel line pipe shall conform
to the following standards as appropriate:
• Critical Service DEP 31.40.20.37-Gen.
• Non-Critical Service DEP 31.40.20.35-Gen.
Guidance on the evaluation of pipeline service criticality is given in DEP 31.40.00.10-Gen.
For linepipe that is required to be resistant to external CSCC, refer to Section 5.3.1in addition to the
information contained in DEP 31.40.20.37-Gen.
When required by the design or welding code, the strain aging shall be applied as part of the weld
procedure qualification program.
CRA line pipe shall conform to the following standards:
Table 6.5: CRA Line pipe standards
Solid Pipe: Duplex and Super Duplex Stainless Steel Line DEP 31.40.20.34-Gen.
pipe
(1)
Solid Pipe: Weldable Martensitic Stainless Steel (13Cr and DEP 31.40.20.36-Gen.
Super 13Cr linepipe). production.
All applications of weldable martensitic steel shall
have materials testing of welded product form to
confirm resistance against embrittlement and
stress corrosion cracking. The Principal's
materials and corrosion expert shall be consulted.
Page 45 of 63
Revision: 0
Clad Pipe: Metallurgically bonded clad layer DEP 31.40.20.32.Gen

CRA Lined CRA lined (mechanically bonded) steel pipe will
Pipe: require a supplementary project specification in
addition to DEP 31.40.20.32-Gen.
NOTES (1) Weldable Martensitic stainless steel materials is not considered suitable
materials option for PDO due to high chloride and H 2S
Suitable materials for process pipelines are given in Table 6.6 and shall be in accordance with DEP
39.01.10.11-Gen, DEP 39.01.10.12 and DEP 30.01.10.15-Gen.
Table 6.6: Process pipelines
(1)
Item Conditions
SLC Temp. pH 2S Cl Material
mm (in) °C (°F) mbar (psi) g/l
(2)
Onshore/subsea <8 <200 <3.5 Any CS with appropriate
pipelines (<3/8) (<392) (<0.05) corrosion allowance
<8 < 200 < 100 Any SSC and HIC resistant CS
(<3/8) (<392) (<1.45) with appropriate corrosion
allowance
N/A <140 0 <100 Weldable martensitic
(6)
(<284) (0) stainless steel
N/A <200 0 <12 Weldable martensitic
(6)
(<392) (0) stainless steel
N/A < 120 <3.5 <120 CS clad with AISI 316L
(<248) (<0.05)
(4)
N/A <200 <10 <150 22Cr Duplex

(<392) (<0.15)
(3)
N/A <155 15 <38 CS clad with AISI 316L
( <311) (<0.22)
N/A 60 15 60 CS clad with AISI 316L
(140) (<0.22)
N/A <200 <20 <150 Super duplex

(<392) (<0.29)
N/A <200 <80 <30 Super duplex
(<392) (<1.16)
(4)
N/A <200 <350 <0.6 22Cr Duplex
(<392) (<5.08)

N/A <200 <1,000 <0.6 Super duplex
(<392) (<14.50)
N/A <200 <22,000 <120 CS clad/lined with Alloy 825
(<392) (<319)
(<464) (<435)
N/A <100 N/A N/A GRP (see flowline non
(<212) metallic table)
N/A <60
(<140) N/A N/A RTP (Reinforced
thermoplastic pipes) (see
flowline non metallic table
6.7
Page 46 of 63
Revision: 0
(1)
Item Conditions
SLC Temp. pH 2S Cl Material
mm (in) °C (°F) mbar (psi) g/l
N/A <60 N/A N/A Thermoplastic lined CS
(<140) (see flowline non metallic
(5)
table 6.7
(<392) (<319)
(<392) (<319)
Notes: (1) For some Corrosion Resistant Alloys, e.g., AISI 316L, more detailed sour service SCC limits can be
found in DEP Part 4.
(2) If there is any chance of H2S increase during the lifetime (e.g., due to reservoir souring) order SCC
and HIC resistant CS, even if the pH2S is below 3.5 mbar (0.05 psi).
(3) These limits are valid for pH ≥ 3.8.
(4) The recent CP studies completed revealed that the optimum CP level in DSS lines is recommended to
be adjusted to a potential no less negative than -650 mV. This value is in the range recommended by
ISO 15589 and DEP 30.10.7310 for DSS structures. Previous level ranged from -850 to -1150 mV
increased the risk of internal stray current. This value will reduce significantly the amount of internal
stray current, reducing the risk of failures in the IJ.
(5) Higher temperature applications are possible – refer to DEP 31.40.30.34-Gen. for higher temperature
thermoplastic liners.
(6) Higher temperature applications are possible – refer to DEP 31.40.30.34-Gen. for higher temperature
thermoplastic liners.
6.13 Dry Hydrocarbon flow lines:
6.14 Flowlines
Flowline material selection philosophy shall be as per section 2.1 of SP-2156. For non-metallic flow
line material selection shall be performed in accordance with Table 6.7. For metallic materials
flowlines shall be as pipeline Table 6.6.
Table 6.7: Limitations of non-metallic materials
FBE coated CS Reelable Pip es

GRE HDPE lin ed CS
Required Service Flow lines
(DEP
(SP-2092) (SP-2094)
(SP-2416) 31.40.1020-Gen)

Water Y Y Y Y

Oil Y Y Y Y

Wet Gas Y X X X

Multiphase Y Y Y Y

Dry gas X X X X
2 (add
H2S Region 1 as per Max 1 mol%
Max 7 mol% Max 3 mol% permeation issue)
ISO 15156
CO2 Corrosivity < 3

No limit No limit 1 No limit
mm/year.
Page 47 of 63
Revision: 0
Chlorides Corrosivity < 3 2

No limit No limit 1 No limit
mm/year.
>1% Acid e
exposure ♦ ♦ X ♦
pH 3 3 Corrosivity < 3 3
3.5 to 12 3.5 to 12 1 3.5 to 12
mm/year.
Sand > 10 g/m3 5 5 5 5

X Y X Y
GOR Limited by rapid

No specified limit 300 300
decompression
Production

Chemical Y Y Y Y

Wax and Asph alt 5 5
Y
Y Y X
4 m/sec liquid
Up to 10 m/sec Up to 10 m/sec
velocity
Fluid velocity liquid velocity 2-4 m/sec liquid velocity
10 m/s gas
velocity
Limited by rapid
Design p ressure As per SP2092 Max 180 bar 70bar Max
decompression
70deg C for
water service
65deg C
and 65 deg C for
Design 8
oil service (This refers to
Max 100 deg C 90 deg C Maximum
Temperature (This refers to
operating
Maximum
temperature)
operating
temperature)
Maintenance
X X X X
pigging
Shall be in Liquid Shall be in Liquid Shall be in Liquid Shall be in Liquid
Viscosity
form form form form
Design l ife > 20 years 20 years 10 years Max 2 years
Buried
Y Y Y Y
pipeline/flowlines
Ab ov e gr ou nd
X Y Y Y
pipeline/flowlines
Y limited by Y limited by
corrosion rate corrosion rate and
Manifolds X X
and piping piping
configuration configuration
Y limited by Y limited by
On plot piping Y only water/ corrosion rate corrosion rate and X
burried close drain and piping piping
configuration configuration
Page 48 of 63
Revision: 0
Pressure Vessel X X X As SP 1246 X

Tanks Internal liner X X As SP 1246 X
Notes:
1. For service life corrosion requirements refer to section 4.4.
2. Pipe materials can work however, the connections are metallic and the limitations shall
be checked with Materials and corrosion engineer before use.
3. For fluids having PH out of this range shall be referred to Materials and corrosion TA2 for
review and recommendation.
4. Electrical conductivity of the fluid shall not be less tahn 10,000pS/m
5. Flow assurance study shall demonstrate that the produce sand, wax, asphat, etc. will
not have any erosion effect in pipe service and that solid removal will not be required
during the life time of the project. No test data viable. Any sand production areas it is not
recommended to use the non metallic materials without study. Consult MCI Engineer.
6. Paffin wax and Asphalt deposits may have swelling effect on PE materials. Consult
Materials & Corrosion Engineer before selection.
7. Design pressure changes with size & connections. Max Design temperature changes
with type of curing systems used. Refer to SP2092-1 for more details.
8. Compatibility test shall be carried out
Symbols:
Y – The material may be considered within the boundaries specified in the above table
♦ - No test data or filed experience available. Consult with the PDO materials function TA2 authority
for more details.
X – Shall not be used.
6.15 Water Injecti on flow li nes

6.16 Flexibles
Shall be in accordance with DEP 39.01.10.12-Gen, Section 3.3.6. Corrosion Prevention and Control
for Water Injection Systems shall be per DEP 31.01.10.11-Gen.
6.17 Multi Selecti ve Valves (MSV’S)
S. No. Body Internals Skid piping

1 CS CS CS
2 CS 316L CS
3 CS 825 CS
4 CS+3mm two pass undiluted 316L CS+3mm two pass 316L weld overlay
316L weld overlay or
solid SS316L
or
CS+1mmCA+rotolining
or
Page 49 of 63
Revision: 0
CS+3mmCA + FBE coated

5 CS+3mm two pass undiluted DSS DSS
(1)
625 weld overlay
6 CS+3mm two pass undiluted 625 CS+625 weld overlay
625 weld overlay or
solid 825
or
CS+1mmCA+rotolining
or
CS+3mmCA + FBE coated
7 316L 316L 316L
8 DSS DSS DSS
9 SDSS SDSS SDSS
NOTE (1) DSS weld overlay is feasible but the application requires MIC TA approval.
** Material limits to be in accordance with Table 3 (vessel/piping materials)
6.18 Utilities
Materials selection for utilities shall be in accordance with DEP 39.01.10.12-Gen, Section 3.4. Utilities
materials selection shall cover the construction materials for below systems and the criteria for
individual selection is as stated in DEP 39.01.10.12 -Gen
• Water systems
• Fresh potable water
• Brackish/seawater for service water system
• Closed circuit cooling water
• Fire fighting system
• Water injection system
• Tubing materials and completion accessories for water injection and disposal wells
• Seawater caissons and dip tubes
• Inhibitors and other chemicals (shall be in accordance with DEP 39.01.10.12-Gen, Table
22.
• Miscellanies Utilities systems (e.g. air system, instrumentation, etc) shall be in accordance
with DEP 39.01.10.12-Gen, Table 23.
• Diesel fuel systems (shall be in accordance with DEP 39.01.10.12-Gen, Table 24)
6.19 Steam Injecti on syst ems
DEP 39.01.10.12-Gen, Section 3.5. shall not be used for the selections of steam projects. The
construction materials recommendations included in the DEP 39.01.10.12-Gen, Section 3.5.1, Table
25, is based on experience in North America and Canada where continuous high temperature
production of heavy oil with typical low corrosion have been observed. This is not applicable for PDO
steam operations. Materials selection shall be completed based on standard material selection
process as specified in Section.3 of this SP.
6.20 ENHANCED OIL RECOVERY (EOR)

Materials selection for enhanced oil recovery is based primarily on proven operating experience.
Where CRAs are required, process conditions shall be used to determine the type of CRA from the
relevant tables in this standard. The materials selection shall be endorsed by the Principal’s Materials
and Corrosion TA1.
Page 50 of 63
Revision: 0
7 MATERIALS SELECTION STUDY ROLES & RESPONSIBILITIES
Materials selection report for all SELECT phase shall be carried by PDO Materials and Corrosion
engineering discipline (Function).
During the DEFINE and EXECUTE phase, materials and corrosion deliverables shall be prepared by
materials, corrosion and welding specialists that have been assessed and approved by PDO
Materials and Corrosion Engineering discipline (UEOC) prior the start of FEED and DD studies.
FEED and DD materials selection report shall be endorsed and approved by PDO Materials and
Corrosion Engineering discipline (UEOC) in peer review session following the requirements indicated
in Section 4.1. Materials selection peer review sessions shall be organized by the Materials and
Corrosion Engineers from the projects or the author of the report and ensuring participation from
Process, Mechanical, Rotating and Pipeline engineering.
8 CONTENT OF MATERIALS SELECTION REPORTS
8.1 SELECT Phase
Materials selection report shall contain the following but not limited to:
a) Executive Summary
b) Project Introduction and Description
c) Purpose of the document
d) Abbreviations and Definitions
e) Project documents referred to
f) Standard referred to
g) Design Basis
h) Corrosion Predictive Modelling
i) Erosion Assessment
j) Materials Selection Discussion
k) Recommended Materials Selection
l) Specific Materials Manufacturing / Fabrication Requirements
m) Specific Corrosion Control Requirements
n) Threat-Barrier Matrix
o) Outline of Corrosion Monitoring Methods
p) Technical References
q) Attachments / Appendices
8.2 DEFINE Phase
During the DEFINE phase Materials selection report shall include detailed assessments and
specifications to develop required materials and corrosion testing program. The detailed assessment
should be carried out as per the sequences of the process flow diagrams. The materials selection
shall discuss the process description for each system and the basis for the materials selection shall
be documented. All the unknowns identified during select phase shall be addressed, documented
and close.
Typical template with the required content for a materials selection in DEFINE phase is shown in
Appendix D.
Materials selection report shall consider and document all the process information and assumptions
for each stream and shall be presented as per the template included in appendix E.
Page 51 of 63
Revision: 0
8.3 EXECUTE Phase
Required content shall be as per DEFINE phase and shall be updated to as approved for
construction status for handover.
9 CORROSION MANAGEMENT FRAMEWORK
Elements of corrosion management framework and corrosion management manual (CMM) shall be
in accordance with DEP 39.01.10.11- Gen.
Template for typical CMF is shown in Appendix C.
Page 52 of 63
Revision: 0
APPENDIX A: Basic Information requi red and factors effecting m aterials selection
Table A.1: Basic information required and factors effecting materials selection
Basic Information Required for Materials Selection for Hydrocarbon Systems
Field Name
Design Life
Essential Information Required for materials Selection
Equipment Utility Systems Equipment

carrying sea
Carrying water
produced including
fluids water injection
and fire water
Presence of free Water √
Co2 content of Gas mol% √ √
H2S content of Gas mol% √ √
Dissolved H2S ppm √ √
Dissolved Co2 ppm √ √
Elemental sulphur ppm √ √ √
Maximum Operating Pressure Bara √ √ √
Maximum design pressure Bara √ √ √
Maximum Operating Temperature C √ √ √
Maximum deign Temperature C √ √ √
Ambient Temperature C √ √ √
Multiphase/gas/oil
Type of fluid √ √ √
Stratified/ annular/
slug etc
Flow type √ √ √
Gas flow Rate mIn Sm3/d √ √

Oil Flow rate m3/d √ √
Water flow Rate m3/d √ √ √
Liquid Velocity m/s √ √
Debris present yes/No √
Inside diameter m √ √
Length Km √
Water cut % √
GOR √
Reservoir Date
Reservoir pressure √
Page 53 of 63
Revision: 0
reservoir temperature √
Bubble point pressure √
Reservoir fluid density √
Sand and silt production √
Mercury √
Water analysis
type of water Cond/form/iron √ √

saturated
Bicarbonates ppm √ √
Sulphates ppm √ √
chlorides ppm √ √
Dissolved Fe2+ in Water ppm √ √
Total dissolved solids g/l √ √
Oxygen in water ppm √ √
Total suspended solids ppm √ √
pH √ √
Sodium ppm √ √
ORGANIC ACIDS ppm √ √
Formic acid ppm √ √
Acetic acid ppm √ √
Propionic acid ppm √ √
Mercury ppm √ √
Fluid Properties
Gas molecular weight kg/kmol √
Gas compressibility factor √
API gravity √
Oil density kg/m3 √
Oil viscosity @ reference temp Ns/m2 √
Oil viscosity reference temp deg C √
Gas liquid surface tension N/m √
Water solubility in oil C1
Water solubility in oil C2
Ad di ti on al i nf or mat io n r equ ir ed f or ser vi ce l if e co rr os io n c alc ul ati on
The full stream molar composition Whether inhibitor are

√
to be injected.
Water content in glycol (where added for corrosion or
√
hydrate control)
HCO3 content of water √
projected operating pressure and temperature profile
√
over life of project
Page 54 of 63
Revision: 0
Heat transfer coefficient of coating system used

√
(pipeline) reservoir type ( carbonate or sandstone)
for water injection system the anticipated amount and

√
particle size of corrosion products are often require to
manage well sand control efficiency
Inhibition philosophy √
√- Inputs are required
Page 55 of 63
Revision: 0
APPENDIX B: Risk Assessment
Corrosion risk assessment forms an important part of materials selection and risk based inspection.
It is necessary to perform these activities in a structured manner to ensure that all credible materials
and corrosion related threats are evaluated.
The corrosion risk assessment is, essentially, an analysis of the controls in place for preventing the
realisation of a loss of primary containment top event via the corrosion threats that may be identified
by a bow tie analysis as shown in Figure 1. Selection of the corrosion threats can be made from the
listing below. Users must ascertain the threats that apply in each case under consideration, and
positively discount those that do not apply. It is not sufficient to simply disregard a listed threat
without any justifying statement in the MSR.
• Figure 91: Generic bow-tie model
Related Business Control Documents and References
Version
Reference Title
n
API RP 571 Damage Mechanisms Affecting Fixed Equipment in the 2 Edition
Refining Industry
CP-114 Maintenance and Integrity Management – Code of Revision 5.0
Practice
CP-208 Corrosion Management Code of Practice 1.0
Crossland, A., et al Corrosion Inhibitor Efficiency Limits And Key Factors,
NACE Corrosion 2011, Paper 11062
DEP Specification Metallic Materials – Selected Standards February 2013
30.10.02.11-Gen
DEP Specification Carbon Steel Corrosion Engineering Manual For February 2012
30.10.02.14-Gen Upstream Facilities
DEP Specification
30.10.02.15-Gen Materials
Oil And Gas Use In H2S-containing
ForProduction (Amendments Environments
And In February 2013
Supplements to ISO 15156:2009)
Page 56 of 63
Revision: 0
DEP Specification Metallic Materials – Prevention Of Brittle Fracture In February 2013

30.10.02.31-Gen New Assets
DEP Specification Pipe Supports February 2013
31.38.01.29-Gen
DEP 31.38.01.84-Gen Piping Classes – Service And Materials Selection February 2013
Index
DEP Informative Selection Of Materials For Life Cycle Performance February 2013
39.01.10.11-Gen (Upstream Facilities) – Materials Selection Process
DEP Specification Selection Of Materials For Life Cycle Performance February 2013
39.01.10.11-Gen (Upstream Facilities) – Materials Selection Process
Energy Institute Guidance for corrosion management in oil and gas May 2008
production and processing
Energy Institute Guidelines for the Avoidance of Vibration Induced January 2008
Fatigue Failure in Process Pipework
European Federation Of Publication 46 – Amine Unit Corrosion In Refineries 2007
Corrosion EFC
GU-475 Corporate Flowline Materials Selection Guideline Version 1.0
GU-611 PDO Engineering Standards and Procedures 18a
GU-637 Sour Gas Wells Completion Materials Selection Revision 1.0
Guidelines
GU-672 Produced Water Analysis Requirement Revision 0
n
ISO 15156 Petroleum and natural gas industries – Materials for 2 edition with
use in H2S-containing environments in oil and gas Technical
production – All parts Circulars
Smart, J Flow Velocity Required for Solid Particle Movement in
Oil & Gas Pipelines, NACE Corrosion 2009, Paper
09469
SP-2041 Specification for Cracking Resistant Materials in H2S 3.0
Containing Environment
SP-2062 Specification for HSE Cases 1.0
UK HSE Research Report

containment 320: Elastomers
in offshore oil and gas for fluid
production:
Guidelines and review
http://www.hse.gov.uk/research/rrpdf/rr320.pdf
UK HSE Research Report 485: Elastomeric seals for rapid gas
decompression applications in high pressure services
http://www.hse.gov.uk/research/rrpdf/rr485.pdf
Page 57 of 63
Revision: 0
APPENDIX C: CMF template
Typical Template for

CMF.xlsx
Page 58 of 63
Revision: 0
APPENDIX D: Feed and Detailed Design MSR minimum standard requirements

template
Materials Selection Report (MSR)

FEED Stage
INDEX
1. PROJECT INTRODUCTION................................................................................................
2. PROJECT DESCRIPTION...................................................................................................
3. PURPOSE OF THE DOCUMENT .......................................................................................
4. ABBREVIATIONS ...............................................................................................................
5. STANDARDS AND PROJECT DOCUMENTS ...................................................................

5.1 Company Standards and Reference Documents ..............................................................
5.1.1 Company Asset Integrity Management Documents...........................................
5.1.2 Company Standards, Specifications and Procedures........................................
5.2 Project Documents..............................................................................................................
5.2.1 Mechanical .........................................................................................................
5.2.2 Pipelines .............................................................................................................
5.2.3 Piping...................................................................................................................
5.2.4 Process................................................................................................................
5.2.5 Structural .............................................................................................................
5.2.6 Materials & Welding ..............................................................................................
5.3 International, Regional, National and Industry Standards ..................................................
5.3.1 International Standards .......................................................................................
5.3.2 National Standards................................................................................................
5.3.3 Industry Standards ...............................................................................................
5.4 Document References .........................................................................................................
6. FIELD AND PROJECT DESCRIPTION FROM A CORROSION PERSPECTIVE ................

6.1 Existing Facility Experience ..................................................................................................
6.1.1 Corrosion / Leak History........................................................................................
6.1.2 Existing Chemical Treatment & Chemical Performance.................
7. MATERIALS SELECTION AND CORROSION CONTROL BASIS.........................................

7.1 Corrosion Study Basis..........................................................................................................
7.2 Materials Selection Basis.......................................................................................................
7.3 Corrosion Risk Analysis Basis……………………………………………………………………..
7.4 Life Cycle Cost LCC Analysis Basis ………………………....................................................
8. ASSUMPTIONS, UPSETS AND UNCERTAINTIES .............................................................

8.1 Assumptions.......................................................................................................................
8.2 Uncertainties and Impact of Possible Changes ...................................................................
8.2.1 Watercut ...............................................................................................................
8.2.2 CO2 and H2S Levels ..............................................................................................
8.2.3 Temperatures and Pressures................................................................................
8.2.4 Chloride Concentration..........................................................................................
8.2.5 Sand Production.....................................................................................................
8.2.6 Elemental Sulphur .................................................................................................
8.2.7 Organic Acids ........................................................................................................
8.3 New8.2.8 Additionaland

Technologies or Altered Chemical
Basis for Treatments............................................................
Use....................................................................................
9. Corro sio n Thr eats ………………………………………….......................................................

Page 59 of 63
Revision: 0
9.1 Factors Affecting Fluid Corrosivity .......................................................................................

9.1.1 “Sweet” and “Sour” Corrosion Mechanisms .........................................................
9.2 CO2 Corrosion ......................................................................................................................
9.2.1 CO2 Corrosion in Satah Field Production Facilities..............................................
9.3 The Influence of H2S on Corrosion .....................................................................................
9.4 H2S 9.3.1 Control of H2S Corrosion in Satah Field Production Facilities ............................
Cracking.......................................................................................................................
9.5 Oxygen Corrosion ...............................................................................................................
9.6 Microbiologically Influenced Corrosion ...............................................................................
9.6.1 MIC Mitigation.......................................................................................................
9.7 Chloride Stress Corrosion Cracking.....................................................................................
9.8 Erosion and Erosion Corrosion ...........................................................................................
9.9 Atmospheric Corrosion........................................................................................................
9.10 Corrosion under Insulation (CUI) ......................................................................................
9.11 Preferential Weld Corrosion...............................................................................................
9.12 Sour Water Corrosion ........................................................................................................
9.13 Galvanic Corrosion.............................................................................................................
9.14 Vibration Induced Fatigue ..................................................................................................
9.15 Polythionic Acid Stress Corrosion Cracking (PASCC)........................................................
9.16 Flange Face Corrosion........................................................................................................
9.17 Brittle Fracture.....................................................................................................................
9.18 Long Running Ductile Fracture ...........................................................................................
9.19 Degradation of Non-Metallic Seals .....................................................................................
9.20 Sulphidation ........................................................................................................................
9.21 Soil Corrosion......................................................................................................................
9.22 Corrosion Mitigation for Pipelines .......................................................................................
10. EXTERNAL CORROSION CONTROL – COATING..............................................................

10.1 Onshore Plant Facilities .......................................................................................................
10.2 Topside Piping and Equipment ............................................................................................
10.3 Submerged Pipelines ...........................................................................................................
11. CATHODIC PROTECTION.....................................................................................................

11.1 Pipelines.................................................................................................................
11.2 Onshore Buried Piping, Buried Vessels and Vessel Interiors................................................
12. MATERIALS SELECTION PHILOSOPHY FOR VAL VES, INSTRUMENTS AND BOL TING....
12.1 Valves...................................................................................................................................
12.2 Instrument Tubing and Fittings ..............................................................................................
12.3 Bolting ..................................................................................................................................
13. CORROSION INHIBTION AND MICROBIOLOGICAL CONTROL PHILOSOPHY ................

13.1 General..................................................................................................................................
13.2 Basis of Corrosion Inhibition Philosophy..................................................................................
13.3 Inhibitor Effectiveness and Availability.....................................................................................
13.4 Operation and Reliability..........................................................................................................
13.5 Chemical Performance.............................................................................................................
13.6 Delivery System Design............................................................................................................
13.7 Injection Locations and Equipment ..........................................................................................
13.7.1 Injection Location Considerations ..........................................
13.7.2 Associated KPIs ............................................................
13.7.3 Equipment and
Fittings.....................................................................................................
13.8 Chemical Compatibility........................................................................................................
13.9 Inhibitor Type and Indicative Injection Rates ......................................................................
13.10 Batch Inhibitor Treatment..................................................................................................
14. CORROSION MONITORING BASIS AND PHILOSOPHY (DETAILS TO BE COVERED IN CMF

DOCUMENT)
14.1 Aim ....................................................................................................................................
Page 60 of 63
Revision: 0
14.2 Monitoring and Testing Facilities - General .........................................................................

14.3 Corrosion Monitoring Techniques and Equipment................................................................
14.4 Corrosion Coupons ..............................................................................................................
14.5 Electrical Resistance Probes ...............................................................................................
14.6 Permanent UT Monitoring Probes .......................................................................................
14.7
14.8 Bacterial Monitoring ..............................................................................................................
Process Monitoring and Bioprobes .....................................................................................
14.9 Inhibitor Residuals................................................................................................................
14.10 Submerged Corrosion Monitoring ......................................................................................
14.11 Corrosion Monitoring Instrumentation.................................................................................
14.11.1 Recommendation................................................................................................
14.12 Positioning and Spacing of Access Fittings ....................................................................
14.13 Corrosion Monitoring Manual...........................................................................................
15. PIPELINE PIGGING PHILOSOPHY (DETAILS TO BE COVERED IN CMF DOCUMENT)

15.1 General.............................................................................................................................
15.2 Control of Pyrophoric Iron Sulphide Scale..........................................................................
15.3 Operational Pigging Frequency ..........................................................................................
15.3.1 Other operational pigging requirements..............................................................
15.4 Intelligent Pigging Frequency..............................................................................................
15.5 Pigging and Corrosion Control at Low Gas Velocities ........................................................
15.5.1 Effectiveness of Continuous Inhibitor Injection
15.5.2 Capability for Operational Pigging....................................
15.5.3 Capability for Batch Inhibition between Pigs
15.5.4 Intelligent Pigging ................................................................................................
16. MATERIALS SELECTION FOR PROCESS SYSTEMS........................................................

16.1. Corrosion Rate Calculations (Stream wise)………………………………………………………
16.2. Materials Selection Options (Stream wise) ……………………………………………………….
16.3. Life Cycle Cost (LCC) Analysis (For all valid options)……..……………………………………
16.4. Corrosion Risk Analysis (For selected option) …..………………………………………………
17. MATERIALS SELECTION FOR UTILITY SYSTEMS............................................................

17.1. Corrosion Rate Calculations (Stream wise)………………………………………………………
17.2. Materials Selection Options (Stream wise) ……………………………………………………….
17.3. Life Cycle Cost (LCC) Analysis (For all valid options)……..……………………………………
17.4. Corrosion Risk Analysis (For selected option) …..………………………………………………
18. FABRICATION, WELDING AND INSPECTION REQUIREMENTS.....................................
ATTACHMENTS.........................................................................................................................
ATTACHMENT 1 INTERNAL CORROSION PREDICTION MODEL SUMMARY SHEETS........
ATTACHMENT 2 MATERIALS SELECTION DIAGRA MS (see Appen di x F)

ATTACHMENT 3 CORROSION INHIBITOR TEST PROTOCOL ................................................
ATTACHMENT 4 CHEMICAL TREATMENT REQUIREMENT................................
ATTACHMENT 5 INTERNAL MONITORING AND SURVEIL LANCE SYSTEM SPECIFICATION.
ATTACHMENT 6 L INEPIPE AND FIEL D JOINT COA TING SPECIFICATION.................
ATTACHMENT 7 CATHODIC PROTECTION SPECIFICATION.....................................................
ATTACHMENT 8 PIGGING REQUIREMENTS................................................................................
ATTACHMENT 9 TECHNICAL QUERIES......................................................................................
Page 61 of 63
Revision: 0
APPENDIX E: Template for required process information in materials selection

report.
MSR process
data.xlsx

Page 62 of 63
Revision: 0
APPENDIX F: Materials Selection Diagrams (MSD)
The Materials Selection Diagram (MSD) shall be prepared during DEFINE phase and shall include
the information required by NACE SP0407 including the following:-
a) Materials selection and corrosion allowance for components and pipe line/piping systems shall
use an easily recognizable, generic materials description which shall be shown on the MSD.
b) The alloy type and minimum thickness for CRA lining or weld overlay and generic coating type for
an internal coating system shall use an easily recognizable, generic materials description which
shall be shown on the MSD
c) MSD shall be made by marking up each individual system / unit on PFS and should have colour
coding system for materials.
d) Changes in piping materials or corrosion allowances shall be clearly identified - if the change
occurs at a valve, the higher alloy (or corrosion allowance) shall be specified for the valve.
e) Mix points, third party entry points and chemical injection points shall be clearly identified.
f) Corrosion mitigation measures applicable to a particular item or piping system (e.g. chemical
treatment, cathodic protection) shall be clearly identified.
g) If Contractor MSD does not record the above information for package licensor or Vendor units,
the licensor or Vendor shall supply their own MSD to record such information which shall then be
cross referenced in Contractor’s materials selection report.

Petroleum Development Oman L.L.C.: Materials Selection & Corrosion Control For Surface Operating Process Facilities

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Petroleum Development Oman L.L.C.: Materials Selection & Corrosion Control For Surface Operating Process Facilities

Загружено:

Авторское право:

Доступные форматы

8/16/2019 SP-2161 Materials Selection & Corrosion Control for Surface Operating Process, Sep 14 - Final

Petroleum Development Oman L.L.C.

Materials Selection & Corrosion Control for Surface Operating

Document Type Specification

Discipline Materials & Corrosion

Issue Date September 2014

Page 1 of 63

Issue No Descrip tion of Revisio n

0 Original Issue under PDO SP-2161

Page 3 of 63

A) COMPRESSORS FOR PDO SHALL BE DESIGNED FOR SOUR SERVICE . .................................... 44

SELECTION REPORT. ................................................................................................. 62

Page 5 of 63

1. Ensuring acceptable corrosion rate at lowest life cycle costs

Page 6 of 63

1.3 Specification owners responsibili ty

Al l PDO Dev elo pm ent /Pro jec ts

Busin ess Segment Upstream

Identify As ses s Select Define Execute Operate

1.4 Revis ion and changes to the docu ment

1.5 Defin iti on of Terms

Page 7 of 63

1.6 Abbreviations & Acronyms

HYDROCOR Shell proprietary corrosion modelling Shell computer program for

OPEX Operating Expenditure

SSC Sulphide Stress Cracking

Page 9 of 63

Page 10 of 63

3 MATERIALS SELECTION PROCESS

Materials selection is primarily a process of short-listing technically acceptable materials for an

3.2 Techni cal Integrit y aspects

3.2.2 Sustain able develop ment

Page 11 of 63

General Princip les

Figure 1: Risk based decision making process

The selection process is structured based on:

b) Experimental evaluation (specialist consu ltation)

Page 13 of 63

4 MATERIALS SELECTION METHODOLOGY

The standard materials selection process includes the following steps:-

a) Define the requirements and the environment

c) Make materials choic es

d) Develop corro sion management framework

e) Assess economic s of choic es

f) Maintain live documents

Figure 2: Standard materials selection process

4.1 Inform ation Requir ements for Materials Selecti on Study

• Production Profile – possibly Hydrocarbon Production Forecast (DCAF

• Operations & Maintenance Philosophy (DCAF 216 and 218)

• Basic design package (DCAF 235)

• Operations and maintenance philosophy (DCAF 49)

Page 16 of 63

• Process flow scheme (DCAF 1213)

Assu ran ce • Assurance process (design conditions vs actual and future

4.2 Deliv erables of materials selection in various proj ect phases

Page 17 of 63

ORP ID Name Acc ou nt abl e Description

• For projects more than 100 mln USD or for

Page 19 of 63

• Mandatory for all projects.

• Mandatory for all projects.

deliverable. This report shall be approved as

Page 22 of 63