MATERIAL SELECTION &

DESIGN CONSIDERATIONS
Advanced Composite Materials
CH-513
Dr. Zahoor-ul-Hussain
Associate Professor
Department of Chemical Engineering
NED University of Engineering & Technology

Presentation by: Mahmood Sadiq (CH-10)

M. Saleem Chohan (CH-16)
Dated: 26-Sep-2017
CORROSION THREATS IN OIL & GAS:
CO2 Corrosion (Sweet Corrosion)
H2S Corrosion (Sour Corrosion)
Chlorides and Bicarbonates
Corrosion due to Oxygen
Microbiologically induced corrosion
Erosion (Abrasion) corrosion
Corrosion (External) Threats in the
facilities
Corrosion Under Insulation
General metal loss due to the presence of CO2 in the process
fluid.
Localized metal cracking and corrosion due to presence of H2S
in the process fluid.
Cracking in the metal due to the presence of stress and
chlorides in the process fluid.
Oxidation and metal loss due to the contact of metal with
oxygen in the process fluid.
Bacteria that induces corrosion particularly within H2S
Corrosion due to the fluid flow and velocity within the pipe
environments.
External atmospheric corrosion on above ground lines and
corrosion due to soil for buried lines.
External corrosion due to water ingress under the insulating
materials.
MATERIAL SELECTION PROCESS:
1 Identify Corrosion Threats

2 Define The Corrosion Circuits

3 Calculate The Corrosion Rate Per Year

4 Calculate The Service Life Corrosion (SLC) Based On Design Life

5 Consider The Materials Options

6 Carry Out The Life Cycle Costing (LCC) Capex / Opex / Install

7 Review The Materials Selection W.R.T Design / Operating / Constructability

8 Finally Select The Choice Materials

CORROSION RATE (SWEET CORROSION):
CORROSION RATE (SOUR CORROSION):

0.05 psi = 3.5 mbar

MATERIAL OPTIONS:
Metals:
CS With Corrosion Allowance
Stainless Steel
Duplex Stainless Steel
Super Duplex Stainless Steel

Metals + Lining:
CS With Internally Coated FBE
CS With Internal PE Lining
CRA Clad / Lined Materials

Non Metals:
Glass Reinforced Epoxy (GRE)
Polyethylene (HDPE)
MATERIAL SELECTION
FOR LOW-TEMPERATURE APPLICATIONS

A material specialist is responsible for selecting appropriate

material and examining its worthiness for low-temperature
conditions, based on the minimum design temperature (MDT)
as specified by the process engineer.

Generally, as a quick rule of thumb, any process event that

would expose the metal to colder than 20F will necessitate a
low-temperature study to justify use of the proposed material
of construction.
MATERIAL SELECTION
FOR LOW-TEMPERATURE APPLICATIONS
The following upsets can contribute to low-temperature contingency:

Emergency blowdown: An emergency situation such as confirmed fire

and gas detection, the hydrocarbon inventory of
the system has to be vented out within a
specified time to avoid risk of vessel rupture.

Operational blowdown: During planned maintenance, the system needs

to be emptied of its hydrocarbon inventory.

Leaks: Leaks can occur as a result of nozzle gasket or

control valve failure, or pipeline rupture.The
effect sare the same as fromblowdown.

Ambient: The lowest ambient temperature might

jeopardize cryogenic integrity of the material.
MATERIAL SELECTION
FOR LOW-TEMPERATURE APPLICATIONS
INDUSTRIAL INSULATION SYSTEMS

MATERIAL SELECTION FACTORS

To provide the desired functions while being exposed to

harsh environments, insulation material should be carefully
selected and specified to meet the design goals.

The first inch of thermal insulation usually reduces heat loss

by at least 85% and several inches usually reduces it by about
95% compared to what it would be from un-insulated
surfaces. This insulation thermal performance, in turn, allows
the facility owner to achieve several goals.
THANKS FOR YOUR ATTENTION
!