20603E01, Guidelines For Material Selection in O&G Processing Facilities - Jan 2011 PDF

eni spa
COMPANY TECHNICAL STANDARD
GUIDELINES FOR MATERIAL SELECTION IN OIL

AND GAS PROCESSING FACILITIES
20603.ENG.COR.STD
Rev.01 - May 2011
Previous identification code

20603.MAT.COR.PRG
Rev.01 – May 2011
GENERAL NOTE This Re-coding does not affect the document content.
TO THE Documents traceability is guaranteed by the unchanged document
DOCUMENT RE-
number.
CODING
Any cross-reference between documents remains unaffected.
/
La presente ricodifica non ha effetto sul contenuto del documento.
NOTA
GENERALE
La rintracciabilità dei documenti è garantita dal numero di documento
ALLA che resta immodificato.
RICODIFICA I riferimenti incrociati fra i vari documenti rimangono validi.
ENGINEERING COMPANY STANDARD

Documento riservato di proprietà di Eni spa. Esso non sarà mostrato a terzi né utilizzato per scopi diversi da quelli per i quali è stato inviato.
This document is property of Eni spa. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
Eni S.p.A.
Exploration & Production Division
COMPANY STANDARD
GUIDELINES FOR MATERIAL SELECTION IN OIL

AND GAS PROCESSING FACILITIES
20603.MAT.COR.PRG
Rev. 1 – May 2011
1 Correction of Table B.1 TEMM TEMM TEMM 30/05/11

0 Issue TEMM TEMM TEMM 21/03/11
REV. DESCRIPTION COMPILED VERIFIED APPROVED DATE
ENGINEERING COMPANY STANDARD
This document is property of Eni S.p.A. Exploration & Production Division.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
Eni S.p.A. 20603.MAT.COR.PRG
Rev. 1 – May 2011
Sh. 2 of 62
FOREWARD
Rev. 0 ISSUE
The present document supersedes the former ENI Company Standards:

− 03588.MAT.COR.PRG Internal corrosion. Material and material selection criteria.
− 08053.MAT.COR.PRG Materials and corrosion control methods in gathering and treatment oil
and gas plants
Rev.1 Correction of Table B.1

Rev. 1 – May 2011
Sh. 3 of 62
INDEX
1. GENERAL.............................................................................................................................. 4
1.1 Scope..................................................................................................................................... 4
1.2 Exclusions ............................................................................................................................ 5
1.3 Document organization ....................................................................................................... 5
1.4 References............................................................................................................................ 5
1.4.1 ENI Company Standards ....................................................................................................... 5
1.4.2 International standard ............................................................................................................ 6
1.5 Symbols and abbreviations ................................................................................................ 6
2. MATERIAL SELECTION PROCESS .................................................................................... 8
2.1 Introduction .......................................................................................................................... 8
2.2 Oil and gas process and utility facilities ........................................................................... 8
2.3 Material selection as part of the Corrosion Integrity Management ................................ 9
2.4 Corrosion threats identification ....................................................................................... 10
2.5 Corrosion control methods............................................................................................... 11
2.6 Material selection philosophy........................................................................................... 11
2.7 Material options.................................................................................................................. 12
2.7.1 Carbon and low alloy steels ................................................................................................. 12
2.7.2 Corrosion resistant alloys..................................................................................................... 13
2.7.3 Other materials..................................................................................................................... 17
2.7.4 Metal cladding and lining, weld overlay, hard facing ........................................................... 17
2.7.5 Non-metallic materials.......................................................................................................... 18
3. MATERIAL SELECTION FOR PROCESSING UNITS ....................................................... 21
3.1 Criteria for the selection of materials and applicable corrosion
prevention methods........................................................................................................... 21
3.2 Options evaluation and costs comparison ..................................................................... 21
3.3 Material selection procedure ............................................................................................ 22
3.4 Identification of viable materials options ........................................................................ 23
3.4.1 Receiving Facilities .............................................................................................................. 24
3.4.2 Oil treatment (oil separation, degassing and storage) ......................................................... 26
3.4.3 Gas treatment (gas separation, sweetening, compression, dehydration and
storage) ................................................................................................................................ 33
3.4.4 Produced water treatment.................................................................................................... 43
3.5 Water Injection Systems.................................................................................................... 45
3.5.1 Flare and blowdown system ................................................................................................ 46
3.5.2 Closed drain systems........................................................................................................... 48
4. MATERIAL SELECTION GUIDE FOR UTILITIES.............................................................. 50
4.1 Fresh water ......................................................................................................................... 50
4.2 Fire water ............................................................................................................................ 51
4.3 Fresh water for closed circuit cooling water system ..................................................... 52
4.4 Open Drains........................................................................................................................ 52
4.5 Chemicals ........................................................................................................................... 53
4.6 Instrument and plant air .................................................................................................... 54
4.7 Other non-corrosive services ........................................................................................... 55
5. MATERIAL SELECTION FOR MISCELLANEOUS COMPONENTS ................................. 56
5.1 Bolting ................................................................................................................................. 56
APPENDIX A MATERIALS CHEMICAL COMPOSITION............................................................ 58
APPENDIX B RESTRICTIONS IN H2S CONTAINING FLUIDS................................................... 61
Rev. 1 – May 2011
Sh. 4 of 62
1. GENERAL
The objective of this ENI Company Standard is to provide guidance and requirements for the
accomplishment of the material selection process for upstream oil and gas treatment facilities, in
conformity with ENI’s expertise and standard practice.
For oil and gas processing assets, the suitability assessment of materials of construction for
equipment shall start from well-proved and robust candidate material options for the different
services and handled fluids. This assessment shall give due consideration to the corrosivity
resistance, as well as to the required mechanical and physical properties, the suitability for the
required design life, inspection and maintenance philosophy, safety and environmental aspects,
operational reliability and specific project requirements. A procedure to accomplish the material
selection process is addressed by this document.
1.1 Scope
The scope of this document is to provide engineering design criteria and guidelines for the material
selection of primary equipment of processing and service/utility facilities in upstream hydrocarbon
processing plants with due consideration to the transported fluids, based on specified design
conditions.
The document is intended to be used as a Company Standard for the preparation of the typical
Project deliverables dealing with material selection, i.e. the Material Selection Report and of the
relevant Material Selection Diagrams.
For the above scope, in this document reference will be made to:
− typical classes of materials used for upstream hydrocarbon processing systems,
− typical upstream processing and service/utility units.
The typical classes of materials used in upstream processing include:

− carbon steels:
• plain carbon steels,
• low alloy steels,
− corrosion resistant alloys:
• martensitic stainless steels,
• austenitic stainless steels,
• high-alloy austenitic stainless steels,
• duplex stainless steels,
• nickel based alloys,
• other alloys (cast iron, titanium alloys, copper alloys etc.)
− non-metallic materials:
• polymers (thermoplastics, thermosettings, etc.)
• FRP/GRE,
• elastomers.
The typical hydrocarbon processing systems, service and utility units for upstream treatment are
included in the scope of this document. The list of units covered is given in paragraph 2.2.
The material selection of processing units is primarily determined based on the fluid corrosivity
assessment, which shall be carried out following guidance provided by ENI Company Standard
02555.VAR.COR.PRG [Ref./3/].
The material selection of utility systems, on the contrary, is generally not impacted by the
characteristics of the fluid processed, and the components are selected using criteria which relates to
a restricted range of typical material solutions, and the final choice is based on variables such as the
design lifespan required, the characterization of service fluids, the service environment, the
operational context etc.
Rev. 1 – May 2011
Sh. 5 of 62
Material solutions and criteria of choice are provided for the main components: piping, vessels, heat
exchangers, air coolers, pumps etc. Generic material selection guidelines are also provided for
additional components: bolting and instrumentation.
1.2 Exclusions
This document is not intended to cover the selection of materials for:
− seawater handling systems (covered by ENI Company Standard 20019.MAT.COR.PRG [Ref./4/])
− subsea units.
1.3 Document organization

Section 1 Defines the scope of the document and provides general information for its
use.
Section 2 Defines the material selection process scope, purposes and the typical
deliverables. This section provides also an overview of the material options
used in hydrocarbon processing plants, the associated corrosion control
methods and the philosophies followed for selection.
Section 3 Provides a structured procedure for the material selection of the main
components of hydrocarbon processing units and of process-support
service systems.
Section 4 Provides guidance for material selection of service and utility units.
Section 5 Provides guidance for material selection of miscellaneous components.
1.4 References
1.4.1 ENI Company Standards
Ref./1/ 06215.DOC.GEN.SDS Facility functional units.
Ref./2/ 20198.COO.GEN.SDS Item numbering.
Ref./3/ 02555.VAR.COR.PRG Internal corrosion. Corrosion parameters and classification of
the fluid.
Ref./4/ 20019.MAT.COR.PRG Material selection for seawater handling systems.
Ref./5/ 20312.VAR.COR.PRG Guidelines for chemical treatments of pipelines.
Ref./6/ 27591.VAR.PAI.SDS Paint system approved.
Ref./7/ 20550.PIP.COR.FUN External coatings for corrosion protection of steel pipes and
components.
Ref./8/ 20551.PIP.COR.FUN Internal coatings for corrosion protection of steel pipes and
components.
Ref./9/ 20554.PIP.COR.FUN Internal coatings for corrosion protection.
Ref./10/ 20555.VAR.COR.PRG Internal corrosion monitoring.
Ref./11/ 20556.VAR.COR.FUN Internal corrosion monitoring specification. functional
requirements.
Ref./12/ 20557.VAR.COR.SDS Corrosion risk assessment methodology.
Ref./13/ 20602.VAR.COR.SDS Corrosion integrity management.
Ref./14/ 02949.MAT.COR.FUN Clad and Lined Pipe Specification
Ref./15/ 27605.DOC.GEN.SDS Technical documentation required during the project
development phase.
Ref./16/ 20368.PIP.MEC.FUN Carbon Steel Piping Welding
Rev. 1 – May 2011
Sh. 6 of 62
Ref./17/ 20369.PIP.MEC.FUN 3.5% Ni Steel Piping Welding

Ref./18/ 20371.PIP.MEC.FUN Cr-Mo Steel Piping Welding
Ref./19/ 20372.PIP.MEC.FUN 0.5 Mo Steel Piping Welding
Ref./20/ 20370.PIP.MEC.FUN Austenitic Stainless Steel Piping Welding
Ref./21/ 20373.PIP.MEC.FUN Austenitic-Ferritic (Duplex) Stainless Steel Piping Welding
Ref./22/ 20375.PIP.MEC.FUN Nickel Alloy Piping Welding
Ref./23/ 20376.PIP.MEC.FUN Carbon Steel for Low Temperature Application Piping Welding
Ref./24/ 14351.PIP.MEC.SDS Guidelines for the Use of GRP Piping
1.4.2 International standard

ISO 14692 Glass Reinforced Plastics (GRP) Piping
ISO 15156/NACE MR0175 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
Part 2 Cracking resistant carbon and low alloy steels
Part 3 Cracking resistant CRAs
ISO 15663-1 Life Cycle Costing – Part 1 Methodology
ISO 21457 Petroleum, petrochemical and natural gas industries -
Materials selection and corrosion control for oil and gas
production systems
ASTM A-193 Alloy steel and stainless steel bolting materials for high
temperature service
ASTM A-320 Alloy steel bolting materials for low temperature service
ASTM E-527 Standard Practice for Numbering Metals and Alloys (UNS)
NORSOK M-001 Materials Selection
NORSOK M-622 Fabrication and Installation of GRP Piping
DNV OS-C501 Composite Components
1.5 Symbols and abbreviations

Bal. Balance
BEDD Basic Engineering Design Data
CA Corrosion Allowance
CI Corrosion Inhibitor
CMM Corrosion Management Manual
CP Cathodic Protection
CRA Corrosion Resistant Alloys
CSCC Chloride Stress Corrosion Cracking
CuNi Copper Nickel alloy
DLCC Design Life Cumulative Corrosion
DP/DT Design Pressure / Design Temperature
DSS Duplex Stainless Steel
ECTFE Ethylene Chlorotrifluoroethylene
EPC Engineering, Procurement & Construction
Rev. 1 – May 2011
Sh. 7 of 62
FEED Front End Engineering Design

FRP/GRE Fiber Reinforced Plastic / Glass-Reinforced Epoxy
GC General Corrosion
GRVE Glass-Reinforced Vinyl Ester
HAZ Heat Affected Zone
HAZOP Hazard and Operability Study
HDG Hot Dip Galvanized
HE Hydrogen Embrittlement
HIP Hot Isostatically Pressed
HSE Health, Safety, Environment
IEC Internal Epoxy Coating
IGSCC Intergranular Stress Corrosion Cracking
IL/IC Internal Lining / Internal Coating
LC Localised Corrosion
LCC Life Cycle Cost
LTCS Low Temperature Carbon Steel
MIC Microbial Induced Corrosion
MDT Minimum Design Temperature
MSD Material Selection Diagram
MSR Material Selection Report
MSS Martensitic Stainless Steel
NDE Non Destructive Examination
PA Polyamide
PE Polyethylene
PP Polyprophylene
PQR Procedure Qualification Report (Welding)
PREN Pitting Resistance Equivalent Number
PTFE Polytetrafluoroethylene
PVC Polyvinyl chloride
PVDF Polyvinylidene fluoride
PWHT Post Weld Heat Treatment
RBI Risk Based Inspection
SCC Stress Corrosion Cracking
SDSS Super Duplex Stainless Steel
SMYS Specified Minimum Yield Strength
SRB Sulphate Reducing Bacteria
SS Stainless Steel
SSC Sulphide Stress Cracking
UNS Unified Numbering System
WPQ Welding Procedure Qualification
WPS Welding Procedure Specification
YS Yield Strength
Rev. 1 – May 2011
Sh. 8 of 62
2. MATERIAL SELECTION PROCESS
2.1 Introduction
Materials selection is a process whereby practicable and technically acceptable material solutions
are identified. Viable options are evaluated to select recommended solution(s) among technically
proven materials, which best combines aspects as costs, performance, successful track of records,
safety, fabrication and procurement issues, etc.
For the main process-stream items, initial materials selection is carried out at the Conceptual phase
of the Project. For primary equipment and long-lead items, key material decisions should be made as
early as possible, to avoid delays which may adversely affect the Project’s schedule and costs.
During the FEED phase of the Project material selection of primary components is revised and
optimised on a more robust basis of data, and it is detailed extending the material selection process
to secondary components. Corrosion risk assessments studies [Ref./12/] and Hazop studies may be
performed to ensure that the proposed materials are fit-for-purpose.
Experimental work may be required for fit-for-service qualification of specific material solutions, in
which case material testing methodology shall be selected to investigate their suitability for the failure
modes anticipated. In this case alternative material options shall be taken into account until the
qualification process is successfully completed.
2.2 Oil and gas process and utility facilities

This document applies to process facilities for oil and gas upstream treatment and storage, located
both onshore and offshore. For the definition of the process units and relevant codification, reference
is made to the ENI Company Standards 06215.DOC.GEN.SDS [Ref./1/] and 20198.COO.GEN.SDS
[Ref./2/] respectively.
Upstream process units include, but not limited to, the following systems:
− LAUNCHING AND/OR RECEIVING TRAP, (UNIT 190)
− MANIFOLD, (UNIT 130)
− OIL SEPARATION, (UNIT 200)
− CRUDE OIL TREATMENT, (UNIT 210)
− LPG TREATMENT (UNIT 211)
− CRUDE OIL TRANSPORT AND STORAGE, (UNIT 220)
− LPG TRANSPORT AND STORAGE, (UNIT 221)
− FLARE, VENT AND BLOWDOWN, (UNIT 230)
− GAS SEPARATION, (UNIT 300)
− GAS DEHYDRATION, (UNIT 310)
− LIQUID HYDROCARBON RECOVERY, (UNIT 320)
− GAS SWEETENING / ACID GAS REMOVAL, (UNIT 330)
− GAS COMPRESSION, (UNIT 360)
− RAW GAS COMPRESSION, (UNIT 365)
− GLYCOL DEHYDRATION, (UNIT 380)
Most typical utility/service units include:

− FUEL GAS, (UNIT 420)
− DIESEL FUEL, (UNIT 430)
− COMPRESSED AIR, (UNIT 460)
− FRESH WATER, (UNIT 530)
− OPEN DRAINS, (UNIT 540)
− CLOSED DRAINS, (UNIT 550)
− INERT GAS, (UNIT 600)
Rev. 1 – May 2011
Sh. 9 of 62
For the above listed units, the following main components are considered:
− piping,
− vessels,
− exchangers/coolers,
− pumps/compressors,
− tanks.
Subsea units and seawater handling units are excluded from the scope of this document (the latters
are covered by the ENI Company Standard 20019.MAT.COR.PRG [Ref./4/].
2.3 Material selection as part of the Corrosion Integrity Management

In conformity with ENI Company Standard 20602.VAR.COR.SDS [Ref./13/], corrosion assessment
and material selection represent well defined tasks of the corrosion integrity management process.
The timescale of these tasks is located within the Development Phase of the Project.
Material selection is strictly related to the corrosion assessment, which covers:

a) the identification of the expected corrosion threats,
b) their analysis including, corrosion rate predictions, where feasible,
c) the identification of viable corrosion mitigation methods and
d) the definition of the corrosion management philosophy and strategy.
During the design phase of the Project the above issues shall be covered by dedicated Project
documents, which form the tasks of the Integrity Corrosion Management process:
− Corrosion Prevention and Material Philosophy Report;
− Corrosion Assessment Study (may be incorporated in the MSR);
− Material Selection Report (MSR);
− Material Selection Diagrams (MSDs);
− Chemical Treatments (for Corrosion Mitigation) Report;
− Corrosion Monitoring Report;
− Corrosion Management Manual (CMM);
− Cathodic Protection Specifications and Drawings;
− Painting, Coating and Lining Specifications.
The above reports, studies, specifications and manuals may be part of the Project’s Documents
required in accordance with ENI Standards 27605.DOC.GEN.SDS and 20602.VAR.COR.SDS
[Ref./15/ and Ref./13/]. The next figure, extracted from Ref./13/, shows the typical deliverable’s
schedule with reference to the Project’s phases timescale.
Rev. 1 – May 2011
Sh. 10 of 62
Figure 2.1 – Corrosion Integrity Management tasks and project phases – Extract from ENI Standard
20602.VAR.COR.SDS [Ref./13/]
Corrosion evaluations and the materials selection process should be documented in a report for
further use by the project or operations groups.
The Material Selection Report should be structured as follows:

− a description of the project and facilities: e.g. field layout, location, etc.,
− design bases data: including operating conditions during the service life, as: temperatures,
pressure, fluid composition, etc.,
− corrosion assessment section,
− materials selection criteria,
− requirements for corrosion inhibitor efficiency and availability,
− requirements for corrosion control, e.g. CP and coatings,
− requirements for corrosion monitoring,
− identification of uncertainties from a materials perspective, new application for materials, use of
new grades,
− need for material qualification testing.
2.4 Corrosion threats identification

This task shall be accomplished in accordance with ENI Company Standard 02555.VAR.COR.PRG
[Ref./3/]. Reference is primarily made to internal corrosion; additional requirements shall be stated
based on external corrosion issues.
The corrosion threats in upstream hydrocarbon processing facilities may include:

− CO2 corrosion,
− H2S corrosion,
− Localized pitting and crevice corrosion,
− Chloride Stress Corrosion Cracking,
− Sulphide Stress Cracking,
− Hydrogen Induced Cracking,
− Microbial Induced Corrosion,
Rev. 1 – May 2011
Sh. 11 of 62
− Galvanic (or bimetallic) corrosion,

− Oxygen corrosion: in case oxygen contamination (defined as an oxygen content dissolved in the
water phase in excess of 20 – 50 ppbw) is envisaged,
− Amine cracking: for amine-based treatment units,
− Erosion-corrosion: in case of high flow-velocity conditions,
− Wear-erosion: if presence of sand or solid particles associated to the process fluid is envisaged,
− Elemental sulphur: in case presence of elemental sulphur in the process fluid is envisaged
− Mercury: in case presence of mercury in the process fluid is envisaged.
Due consideration shall also be given to the external environment which may affect the selection of
materials and/or of the method(s) chosen to provide protection. External corrosion threats may
include:
− General and localised corrosion,
− Corrosion under insulation,
− External stress corrosion cracking,
− Hydrogen induced stress cracking.
The external exposure conditions shall be considered in addressing the relevant consideration. ISO
21457 mentions the following aspects that need to be covered:
− Normal atmospheric conditions (e.g. marine or on-land),
− Contact with soil or pipe support,
− Ambient temperature and maximum operating or design temperature,
− Presence of external insulation and heat tracing,
− Exposure to UVA and solar heating,
− Presence of water such as flooding by deluge systems.
2.5 Corrosion control methods

The applicability of viable material options often depends on associated corrosion control/prevention
methods, which integrate and make part of the material solution under consideration. These methods
include:
− use of extra thickness as corrosion allowance,
− chemical treatments as corrosion inhibitors, biocides, oxygen scavengers, H2S scavengers, etc.,
− use of internal or external coating or lining,
− application of cathodic protection,
− use of corrosion resistant alloys as metal cladding, lining or weld overlay.
For external corrosion protection, all metallic components should be provided with a suitable coating
system. The task dealing with the selection of the appropriate coating systems shall be carried out in
accordance with the ENI Company Standards 27591.VAR.PAI.SDS and 20550.PIP.COR.FUN
Ref./6/ and Ref./7/.
Metallic components in contact with soil (e.g. the external side of tanks bottom) or buried in soil, shall
be provided with a suitable coating system and cathodic protection. Due consideration shall be given
to the risk of external corrosion of components that, for various reasons, cannot be provided with
external protective coating, in which case the use of inherently resistant material should be
considered.
2.6 Material selection philosophy

As part of the philosophy for the selection of materials and corrosion mitigation methods, a number of
factors shall be preliminarily identified as basic criteria for the material selection process.
These criteria shall be addressed by the Project Management through dedicated Design Premises
Project documents. Examples of factors which may inspire the philosophy for the material selection
process include:
Rev. 1 – May 2011
Sh. 12 of 62
− local legislation aspects,

− applicable local or international standards,
− HSE project requirements,
− constraints for inspection and maintenance activities (in some contexts shall be minimized),
− restrictions for the use of chemicals (in some contexts, use of chemicals is discouraged due to
environmental issues),
− environmental factors (e.g. toughness requirement dictated by low minimal ambient temperature),
− financial aspects: CAPEX versus OPEX considerations,
− desired level of materials reliability: inherent corrosion resistant versus corrosion allowances
adapted to design life requirements,
− confidence on design data (e.g. produced fluids analyses),
− possibility of design life extensions,
− variety of different materials specified (basically it should be minimized),
− local availability restrictions for specific materials,
− fabrication, installation, welding constraints and issues (including local availability of skilled
manpower),
− local tradition and experience with specific material solutions for specific services,
− weight control aspects (typically for topside facilities),
− expected availability and reliability of process or chemical treatments; management of upset
conditions and impact on material selection,
− market availability of materials and cost fluctuations.
2.7 Material options

The metallic materials of construction normally considered for the main processing equipment (e.g.
pipework, vessels, etc.) include:
− carbon and low alloy steels,
− austenitic stainless steels,
− high-alloy austenitic stainless steels,
− duplex stainless steels,
− nickel-base alloys.
Use of martensitic stainless steels is limited to components such as valve trim and compressor/pump
impellers.
Use of other alloys such as cast iron, copper alloys, titanium alloys and cobalt alloys is uncommon
for processing equipment, and is more typical for seawater handling systems, which are covered by
ENI Standard 20019.MAT.COR.PRG [Ref./4/].
Other material solutions include use of internal metal cladding or weld overlay, hard-facing, internal
plastic lining and solid non-metallic materials as thermoplastics, thermosettings, FRP/GRE.
2.7.1 Carbon and low alloy steels

Carbon steel represents the standard reference material considered for most processing equipment.
Carbon and low alloy steels include a number of products providing a wide range of mechanical
properties and applications. From the viewpoint of the resistance to general corrosion, however, they
display a comparable performance. In this document no distinction is made among the specific steel
types or products with respect to corrosion performance. The term carbon steel will be hereinafter
used to intend plain carbon steels and low alloy steels.
Welding of carbon steel piping systems is straightforward; ENI Company Standard

20368.PIP.MEC.FUN [Ref./16/] provides requirements for carbon steel piping welding. Welding of
low alloy steels is more critical, and shall be performed in accordance with welding prescriptions
provided by the applicable ENI Company Standards [Ref./17/, Ref./18/, Ref./19/, Ref./23/].
Rev. 1 – May 2011
Sh. 13 of 62
In hydrocarbon processing environments carbon steels are prone to weight-loss corrosion rather than
localised corrosion. They are susceptible to CO2 weight-loss corrosion which may be acceptable only
in limited amounts of CO2 or in the absence of free liquid water. Corrosion inhibitors or other
chemical treatments for corrosion mitigation can be considered. Corrosion with localised character
may occur in correspondence of scale breakdowns in conditions that promote the precipitation of
stable corrosion products in the form of protective scale.
In presence of H2S carbon steels may undergo sulphide stress cracking “SSC” and hydrogen
induced cracking “HIC”. “Sour service” grades are available for virtually any H2S partial pressure; on
the contrary high-strength non-sour grades are prone to SSC at very low H2S content. The use of
carbon steels in H2S-containing fluids is ruled by NACE MR0175 / ISO 15156-2, which provides
material requirements for sour service grades.
When the minimum design temperature MDT is a concern, low temperature grades (e.g. ASTM A-
333) can be considered, typically down to minus 46°C (LTCS). At MDT lower than minus 46°C
austenitic steels shall be considered.
2.7.2 Corrosion resistant alloys

2.7.2.1 Austenitic stainless steels
Austenitic stainless steels display high ductility, excellent toughness, weight-loss corrosion
resistance, weldability, and excellent formability and castability and for these reasons they are
available in most product forms and represent the most commonly used family of stainless steels.
Austenitic stainless steels are generally put in service in one of the following heat-treatment
conditions:
− solution-annealed and rapid-cooled condition,
− solution-annealed, rapid-cooled, and cold-worked condition.
They cannot be strengthened by heat-treatment but may be supplied in cold-rolled conditions. Cold
deformation during fabrication can increase their susceptibility to environmental cracking. Fabrication
can also produce residual stresses that can result in stress corrosion cracking.
Austenitic stainless steels are easy to weld via the most common welding processes using matching
or over-alloyed fillers. ENI Company Standard 20370.PIP.MEC.FUN [Ref./20/] provides requirements
for stainless steel piping welding.
In presence of H2S and chlorides they are susceptible to stress corrosion cracking which greatly
limits the use in H2S-containing fluids, where these materials shall fully comply with material
requirements and environmental limits specified by NACE MR0175 / ISO 15156-3.
Due to their high susceptibility to chloride-related corrosion mechanisms and their limited mechanical
strength, 22Cr duplex stainless steels should be preferred to AISI 316L stainless steels upstream
separation, whereas they find typical application in gas streams. AISI 316L is also a typical material
considered in cryogenic service or where the low minimum design temperature MDT is lower than
minus 46°C.
UNS numbers, chemical composition, PREN and SMYS of typical austenitic stainless steels are
reported in Appendix A.
Most typical use in processing facilities:

Typical components:
• piping and fittings,
• valves,
• vessels,
• heat exchangers,
• air coolers,
• pumps.
Rev. 1 – May 2011
Sh. 14 of 62
Typical Services:
• corrosive and non-sour (or sour without chlorides),
• cryogenic.
2.7.2.2 High-alloy austenitic stainless steels

High-alloy austenitic grades include a number of alloys with higher contents of chromium, nickel and
molybdenum compared with standard austenitics. The high-alloy stainless steels most commonly
employed in hydrocarbon processing facilities are those characterised by a PREN > 40, also known
as “superaustenitic” stainless steels, which offer the same metallurgical properties of standard
austenitics, e.g. high ductility, excellent toughness, weldability, formability and castability, in
combination with an excellent resistance to localised corrosion, chloride stress corrosion cracking
and, to a certain extent, to sulphide stress corrosion cracking.
These alloys are easy to weld using the same processes of standard austentics. The key properties
of these alloys rely on molybdenum which provides their resistance to corrosion, and for this reason
its segregation during weld solidification shall be avoided using an overmatching composition filler.
UNS numbers, chemical composition, PREN and SMYS of typical high-alloy austenitic stainless
steels are reported in Appendix A.
Most typical use in processing facilities:

Typical components:
• valves,
• vessels,
• air coolers,
• pumps.
Typical Services:
• corrosive with high chlorides, non-sour or sour with limits in chlorides / temperature / H2S
combinations
• cryogenic.
2.7.2.3 Duplex stainless steels

Duplex stainless steels have a balanced austenitic-ferritic microstructure which combines the
properties of austenitic stainless steels (toughness, weldability, formability and castability) with those
of ferritic stainless steels (strength, increased resistance to localised corrosion and stress corrosion
cracking).
Duplex stainless steels display an excellent resistance to localised corrosion and chloride stress
corrosion cracking in the absence of oxygen. In aerated fluids with chlorides, superduplex types are
required to resist localized pitting and crevice corrosion. In presence of oxygen, temperature shall be
limited within 100°C (22Cr) and 120°C (superduplex) for chlorides stress corrosion cracking
avoidance, unless an appropriate coating system is applied. In H2S-containing fluids, they are
susceptible to sulphide stress corrosion cracking application and their use shall be limited to non-
sour or mildly sour environments.
Duplex stainless steels are classified into the following types:

− 22Cr duplex,
− 25Cr superduplex,
− lean duplex,
− hyper duplex.
22Cr types (e.g. UNS S31812) are the standard duplex stainless steel and most common grade of
duplex. Typical grades have 21-23% Cr, 2.5-3.5% Mo and 4.5-6.5% Ni. 22Cr provide a resistance to
localized corrosion and to stress corrosion cracking in chloride containing environments higher than
austenitic type 316.
Rev. 1 – May 2011
Sh. 15 of 62
Superduplex 25Cr stainless steels (typically 40<PREN<45) have an increased content of Cr, Ni and
Mo (about 25% Cr, 4% Mo and 7% Ni) and addition of N, such that the PREN is above 40, which
provide corrosion resistance to aerated and high-chlorides containing fluids.
Lean duplex types are intended to match the properties of standard 22Cr grade by alloy
modifications which minimise the use of expensive alloying elements. The prototype alloy is the
grade known as 2304, with 23% Cr, 4% Ni and 0.2% Mo. The target for lean duplex is to compete
with the austenitic grade type AISI 316L.
Hyper duplex are new alloys with improved mechanical properties and corrosion resistance. With a
PREN which is above 50, they extend the application limit of superduplex to higher temperature. In
processing equipment their application is still limited, and their behaviour in H2S service is not yet
established.
Duplex stainless steels used by the oil and gas industry have a roughly 50/50 austenite/ferrite phase
balance within the range 35% to 65% ferrite. All of the duplex grades have adequate toughness at
low temperatures, with use down to minus 60 °C.
These alloys are generally available in most product forms (e.g., bar, wrought plate, castings, pipe,
forgings, etc.) and are usually supplied in the solution-annealed condition. Complex shapes can also
be produced cost effectively by hot isostatic pressing (HIP).
Duplex steels may be easily welded via various welding processes, following the welding
prescriptions addressed by ENI Company Standard 20373.PIP.MEC.FUN [Ref./21/].
These alloys offer a good range of resistance to corrosion in sweet production environments. 22Cr
duplex has been successfully used at high temperature, under high CO2 content and with high
chloride content. In presence of H2S the applicability of duplex stainless steels is ruled by
MR0175/ISO15156-3 which provides application limits and material requirements for typical duplex
grades in H2S containing fluids.
UNS numbers, chemical composition, PREN and SMYS of typical duplex stainless steels are
Most typical applications of duplex stainless steels in processing facilities include:

Typical components:
• manifolds,
• headers, piping and fittings,
• valves bodies and trims,
• vessels,
• air cooler tubes,
• pumps,
• bolting.
Typical Services:
• corrosive and non-sour or mildly sour.
2.7.2.4 Martensitic stainless steels

The use of martensitic stainless steels in oil and gas processing plants is limited by fabrication
issues, and primarily by the welding difficulties, which restrict their application to forged or cast
components used for valves, compressors or pumps.
They are applicable in sweet and slightly sour environments. They display good resistance to CO2
corrosion. Applicability limitations are represented by their susceptibility to SSC in environments
containing even modest amounts of H2S, and to pitting at higher temperature in chlorides containing
environments. They are highly sensitive to pitting corrosion in oxygen contaminated environments.
Rev. 1 – May 2011
Sh. 16 of 62
Supermartensitic grades, characterised by the alloying with some 2-3% molybdenum, offer a
substantially increased resistance to pitting in chlorides containing environments. They extend the
application limits of 13Cr martensitic stainless steels to higher temperature in presence of formation
water, but they have poor resistance to pitting corrosion in oxygen contaminated environments.
Precipitation hardened grade type 17-4PH find frequent application for valves trim in sweet
environments. It is not applicable in presence of H2S or in environments promoting pitting corrosion
due to its high susceptibility to SSC and localised corrosion.
UNS numbers, chemical composition, PREN and SMYS of typical martensitic stainless steels are
Most typical applications of martensitic stainless steels in processing facilities include:

Typical components:
• valve components (stem, seats)
• compressors (impeller, case)
• pumps (impeller)
Typical services:
• corrosive, non-sour
2.7.2.5 Nickel alloys

Nickel alloys represent a continuum with high-alloy austenitic stainless steels and offer similar
properties and fabrication advantages of austenitic stainless steels. They are immune to general
“weight-loss” corrosion, highly resistant to chloride stress corrosion cracking and sulphide stress
corrosion cracking.
One method to classify nickel alloys, alternative to heat treatment conditions, is based on the level of
1
molybdenum in the alloy, which identifies three groups :
− alloys with some 3%Mo,
− alloys with some 6-9%Mo,
− alloys with 12-16%Mo or higher.
The low molybdenum types (indicatively up to 3-4%) have limited localised corrosion resistance and
may undergo pitting corrosion at unfavourable combinations of temperature, chlorides contents and
pH. In chlorides containing environments they are not resistant to aerated or oxygen-contaminated
environments. In general terms localised corrosion resistance of the 3%Mo nickel alloys group is
comparable with those of duplex 22Cr types. For their high resistant to sulphide stress cracking and
chloride stress corrosion cracking, they find typical application in corrosive and sour services with
limits in temperature / chlorides content combinations.
The 6-9Mo types display an excellent resistant to localised corrosion, which is comparable to
superduplex and high-alloy austenitic steels with similar Mo content, but with the advantage that they
are also fully resistant to stress corrosion cracking and sulphide stress cracking at most conditions
met in the oil and gas upstream process; for this reason they find typical application in corrosive and
severely-sour services with high temperature, high chlorides content and possible oxygen
contamination.
The 12-16%Mo (or higher) display an outstanding resistance to localised corrosion combined with full
resistance to sulphide stress cracking and chlorides stress corrosion cracking. They find application
in severe sour service with elemental sulphur, in highly oxidizing environments such as hypochlorite
service, or with aggressive acids used as chemicals.
Nickel alloys are easy to weld via various welding processes, following the welding prescriptions
addressed by ENI Company Standard 20375.PIP.MEC.FUN [Ref./22/].
1
A further group of nickel alloys is represented by Monels, which are nickel-copper alloys with about 70%Ni, 30%Cu, whose
application in oil and gas processing plants is limited to valve trims.
Rev. 1 – May 2011
Sh. 17 of 62
UNS numbers, chemical composition, PREN and SMYS of typical nickel alloys are reported in
Appendix A.
Most typical applications of nickel alloys in processing facilities include:

Typical Components:
• manifolds,
• headers, piping and fittings
• valves,
• vessels,
• compressors (impellers, case),
• pumps (impeller).
Typical Services:
• corrosive and highly sour
2.7.3 Other materials

Other metallic material solutions, not widely used for processing equipment but which may find
application in specific conditions or for ancillary components include titanium alloys, monel, cast
irons, cupronickel and cobalt alloys.
2.7.4 Metal cladding and lining, weld overlay, hard facing

Corrosion resistant alloys cladding, lining or weld overlay deposit onto a carbon or low-alloy steel
backing substrate is a cost-effective alternative to solid CRA. The backing steel provides the basic-
strength and the CRA layer the corrosion resistance.
The CRA cladding is selected, among those compatible with fabrication technologies, based on the
required corrosion resistance. Nickel alloys are most frequently used for cladding applications:
typically Alloy 825 or Alloy 625. In some cases austenitic stainless steel can be adequate for the
service and selected, typically AISI 316L. Less frequently high-alloy austenitic stainless steel (904L,
Alloy 28 or 6Mo) and other nickel alloys (725, 686, C-276 etc.) are used.
Methods to apply cladding to the substrate include metallurgical bonding or mechanically bonded
(lined-pipe) [Ref./14/]. Metallurgical bonding is obtained via hot rolling of the carbon steel substrate
with the CRA layer and then manufactured to produce seam-welded pipe or vessels. Explosive
bonding and hot isostatically pressed cladding (HIP) are other techniques. In mechanical bonding of
pipes, a liner is inserted into the pipe and expanded to be mechanically bonded to the substrate. Key
issue is weld sealing, to prevent fluid contamination at the ends between the liner and the substrate.
Weld overlay is used for fittings, flanges, valve bodies and vessels internals, and in any case when a
complex geometry is involved. In weld overlay and buttering, impact of dilution effects on corrosion
resistance shall be assessed and dilution measurement, hardness testing, bend testing, and
corrosion testing may be required as part of the qualification process. Dilution of the clad layer by the
base metal may need to be limited, typically imposing a maximum iron content of the weld metal
deposit which shall not exceed 5% or 10% maximum.
Welding between clad components often entail the issues of dissimilar joint [Ref./20/, Ref./22/]. This
may require a buttering layer is deposited onto the steel substrate, whose purpose is to provide a
suitable material that facilitates the joint completion with a CRA consumable safeguarding the
required properties (e.g. toughness, corrosion performance, and resistance to environmentally
assisted corrosion).
Hard facing may be a solution for components that are subject to erosive wear, e.g. valve’s bore
sealing mechanism, enhanced by high flow velocities and/or presence of sand or solid particles in the
flowing fluid. Hard facing consists of a coating deposition technique where a hard coating material is
added to the surface, whereby resistance to the erosive action is provided to the backing material.
The hard facing coating deposition techniques include thermal spray, overlay welding or cladding and
can include a wide range of ceramics or metal/alloys materials. Typical hard facing materials used in
the oil and gas industry include stellite and tungsten carbides coatings.
Rev. 1 – May 2011
Sh. 18 of 62
Most typical applications in processing facilities:

Typical Components:
• manifolds and headers,
• valve bodies and large valve components (e.g. balls),
• vessels,
• compressor’s case or pump bodies,
• heat-exchanger boxes and tubesheets.
Typical Services:
• as per relevant CRA layer material
2.7.5 Non-metallic materials

Plastics or reinforced plastics may be attractive solutions, but in some applications there are serious
concerns about the suitability of these materials. These are mainly represented by:
a) Availability of satisfactory jointing and fabrication procedures.
b) The long term durability under a range of environmental conditions.
c) The vulnerability of the materials in the event of fire.
d) Poor shock-resistance.
Because of these considerations use of plastics should be restricted to non-critical service/utility

systems.
2.7.5.1 Plastic lining and coatings

Plastic-lining consists of a plastic liner fit into a metal carbon steel body, thus combining the
mechanical properties of metal with the inherent corrosion resistance of the plastic liner. The
technology is well established in the chemical process industries, especially for piping and valves
handling corrosive or highly pure fluids.
A number of plastic materials are available; the most common ones are:
− PE (polyethylene),
− PP (polypropylene),
− PA 11, PA 12,
® ®
− PVDF (Kynar , Fluoroline ),
® ®
− ECTFE (Halar , Norton ),
− ETFE (Tefzel®, Chemfluor®),
− PTFE (Teflon®, Fluon®),
Internal organic coating and linings, as glass flake epoxy, are used for internal corrosion protection of
carbon steel vessels, filters and valves. This material solution represents a cost effective option,
often in combination with sacrificial anodes to provide cathodic protection.
Use of organic coatings or lining for valves internal is not recommended, and it may be considered
only for limited service life. Consideration should be given to galvanic issues between valve
components for the following reasons: a) in some valves the applicability of materials used for valve
trim or stem relies on the cathodic protection of the less noble valve body, which will lead to rapid
failure of these component if coated; b) more noble metal used for the valve trim may lead to
accelerated galvanic corrosion and loss of containment of the valve body at coating damages.
Internal lining is a viable option for vessels with simple internal geometry.
Most typical applications of plastic lined pipes in oil and gas process plants include:
• open drain piping systems,
• highly-corrosive chemicals.
Rev. 1 – May 2011
Sh. 19 of 62
Most typical applications of internal lining and coatings in oil and gas process plants include:
Typical Components
• Internal lining/coatings for low pressure vessels,
Typical Services
• LP separation, flare KO drums, closed and open drain drums, storage tanks bottom
(condensate, oil, diesel, any type of water).
2.7.5.2 Fiber reinforced plastic / Glassfiber reinforced epoxy

FRP/GRE, are composite non-metallic materials made of a thermosetting polymeric resin reinforced
with glass fibre. The glass fibre normally used to reinforce is E-glass, consisting mainly of SiO2,
Al2O3 and MgO.
FRP/GRE products are covered by several standards, including:

− ENI 14351.PIP.MEC.SDS
− ISO 14692 (Parts 1, 2, 3 and 4);
− DNV OS-C501;
− Norsok M-622
Different resin types are used, with different properties and temperature limitation (see Table 2.1).
Table 2.1 - Resin types and temperature limitations (from ISO 14692 Parts 1)
Resin type Max. temperature
Polyester 70°C
Vinyl ester 100°C
Epoxy 110°C
Phenolic 150°C
With respect to metallic materials, GRP provides the following main advantages:
− not affected by corrosion,
− allow significant weight and roughness reduction,
− increase thermal insulation.
FRP/GRE find typical application in seawater service, whereas their use in processing plants is
limited to utility/service units. They display good mechanical properties, however the maximum
pressure ratings of GRP pipes should be limited in order to avoid maximum hoop stress in excess of
permissible values that ranges indicatively between 20 MPa and 40 MPa (which may indicatively
correspond to pressure in the order of 10 to 20 bar). In any case the above values are only indicative
and mechanical design, shall be performed in accordance with applicable codes (see also ENI
Company Standard 14351.PIP.MEC.SDS “Guidelines for the use of GRP piping”)
It is recommended to select a unique Contractor for GRP systems covering detail design, fabrication
of the components, installation and commissioning.
Most typical applications of GRE/GRP in oil and gas process plants include:
Typical Components
• piping, vessels
Typical Services
• open drains, closed drains, process water, highly-aggressive chemicals.
2.7.5.3 Thermoplastics
The following thermoplastic types may be considered for solid plastic pipe:
− PVC, polyvinyl chloride,
− PE, polyethylene,
Rev. 1 – May 2011
Sh. 20 of 62
− PP, polypropylene.
Polyethylene pipes "PE" comprises: high density polyethylene "HDPE", which is the most common
type, low density polyethylene "LDPE", and the cross-linked polyethylene "XPE", which extends the
application of polyethylene in hot service.
The advantages of these materials are:

− immune to corrosion,
− do not require protection from external corrosion,
− easy to weld.
Disadvantages include:
− low strength,
− low impact resistance,
− temperature limitations,
− possible long-term material degradation mechanisms, due to UV exposure or ageing.
Temperature limitation are shown in the below table.
Table 2.2 – Typical maximum temperature limitations applied for thermoplastics (from ISO 21457)
Thermoplastic Max. temperature
PVC 70°C
PE 60°C
PP 90°C
Joining of thermoplastic pipes can be carried out through butt welding (butt fusion/electrofusion
socket in pipe length).
An accurate design of thermoplastic pipework systems which takes into appropriate account of any
possible need for thermal expansion, clearances etc. is to be considered. Manufacture of pipework
may be supplied on site in factory tested prefabricated spools.
The use of thermoplastics is more typical for drainage systems.
Most typical applications of thermoplastic piping in oil and gas process plants include:
• open drain system,
• sewage system.
Rev. 1 – May 2011
Sh. 21 of 62
3. MATERIAL SELECTION FOR PROCESSING UNITS
3.1 Criteria for the selection of materials and applicable corrosion prevention methods
Criteria for material selection shall reflect all the requirements detailed in the Project design
Premises.
Hereinafter a number of factors is listed that shall be taken into account in all the design phases for
material selection of any given Project:
− Assessment of the operating corrosion conditions based on:
• process description and requirement, including temporary operations;
• design and operating conditions;
• nature of the fluids and treatments performed;
• environmental conditions;
• any other aspect impacting on corrosion.
− Design life;
− Plant location, if offshore or onshore;
− Environmental conditions.
− Mechanical requirements and fabrication constraints.
− Lowest design temperature, including cooling caused by depressurization conditions further than
minimum ambient temperature (evaluate impact on mechanical properties).
− External corrosion requirements.
− Impact of cathodic protection, where applied.
− Impact of thermal insulation, where applied.
− Occurrence of sour conditions, even if temporary.
− Exposure conditions during hydro-testing and start-up operations.
− Exposure conditions during upsets and shutdowns.
− Maximum allowed corrosion allowance (for carbon steel only).
− Human resources availability for inspections, monitoring, maintenance and repair.
− Safety and environmental issues.
− Compliance to applicable Project Standards.
− Compliance to local Government regulations.
− Cost effectiveness.
3.2 Options evaluation and costs comparison

In case more options are technically acceptable, preference shall be given to the most cost effective
option. Comparison among different material options shall be based on capital and operating costs,
and preferably on the Life Cycle Cost approach.
Capital costs include the following costs:

− material (pipes, sheets, fitting, etc.);
− joining;
− supports;
− transportation and installation;
− chemicals injection system;
− corrosion monitoring system.
Operating costs include the following costs:

− chemicals;
− inspections;
− replacement and maintenance.
Material cost comparisons shall be performed considering the actual thickness calculated for each
option based on relevant mechanical properties and corrosion allowance, if any.
Rev. 1 – May 2011
Sh. 22 of 62
3.3 Material selection procedure

The procedure here proposed if organised in a sequence of steps which encompass the internal
corrosivity assessment, the identification of viable material options and of the associated corrosion
threats and the material selection finalization.
The material selection process starts with the suitability assessment of carbon steel, alone or in
combination with corrosion allowance or corrosion inhibitors. If carbon steel is unsuitable, corrosion
resistant alloys are considered.
Material finalization is then performed by finding the material option which optimises overall
performance, cost, fabrication and installation issues, material availability and procurement issues.
STEP 1 Data collection. Collect from the design basis all information and data necessary to
undertake the corrosion assessment and the material selection process (design data).
STEP 2 Calculations of key parameters. Calculate the water phase pH, the maximum partial
pressure of CO2 and H2S, the flow-induced wall shear stress, etc.
STEP 3 Identification of viable material options. Based on the specific service, with the aid of the
tables reported in this Section, proceed with pre-selection of viable material options to be
considered.
STEP 4 Corrosion threats identification and assessment for viable material options. With the
aid of ENI Company Specification 02555.VAR.COR.PRG [Ref./3/] identify corrosion threats
associated to the given service and calculate corrosion rates where applicable. Abandon
material options that are not suitable for the given service.
STEP 5 External corrosion threats assessment. Ensure due consideration is given also to the
external environment and the relevant external corrosion threats.
STEP 6 Mechanical requirements. Exclusion of material options based on mechanical

requirements such as: strength (SMYS), toughness at low temperature (check material
suitability for MDT).
STEP 7 Assess applicability of carbon steel. If carbon steel is a viable material option according
to the pre-screening table, with the aid of ENI Company Standard 02555.VAR.COR.PRG
proceed evaluating the applicability of carbon steel with an appropriate corrosion
allowance. Ensure suitability for the required design life.
STEP 8 Assess applicability of carbon steels with corrosion inhibition. If carbon steel plus
corrosion inhibition is a viable option according to the pre-screening table, with the aid of
ENI Company Standard 02555.VAR.COR.PRG proceed evaluating the applicability of
carbon steel with an appropriate corrosion allowance plus corrosion inhibition treatment.
Ensure suitability for the required design life.
STEP 9 Selection of alternative materials to carbon steel. With the aid of ENI Company
Standard 02555.VAR.COR.PRG, proceed evaluating suitability for service of CRA or non-
metallic materials prelisted in the pre-screening table. Ensure the viable material option is
suitable for all corrosion threats associated to the given service as well as to other
requirements.
STEP 10 Consider testing for material qualification. In some cases, the application limits of CRA
materials, e.g. with respect to localised corrosion, are not well defined depending from a
variety of parameters related to either: the environment, the material and the application. In
these cases it may be considered the qualification route via laboratory testing to ascertain
fitness-for-service.
Rev. 1 – May 2011
Sh. 23 of 62
STEP 11 Finalisation and life-cycle cost analysis. Finalise material selection considering cost
optimization. Consult material suppliers to ascertain material availability and updated cost
for suitable material options.
3.4 Identification of viable materials options

The following series of tables list the typical material options that are usually considered for the main
components of hydrocarbon processing plant units. The materials included in the tables are not
intended to cover all material options, but the most typical ones. Additional materials may also be
considered and evaluated on a case by case basis.
The tables for the identification of the viable material option to consider for the given service have
been organised as follows:
A. RECEIVING FACILITIES
• Launching/receiving trap (Unit 190),
• Manifold (Unit 130),
B. OIL TREATMENT
• Oil separation (Unit 200),
• Crude oil/LPG treatment (Unit 210/211),
• Crude oil/LPG transport and storage (Unit 220)
C. GAS TREATMENT
• Gas separation (Unit 300),
• Gas dehydration (Unit 310),
• Liquid hydrocarbon recovery (Unit 320)
• Gas sweetening / acid gas removal (Unit 330)
• Gas compression (Unit 360)
• Raw gas compression (Unit 365)
• Glycol dehydration (Unit 380).
Table 3.12 to Table 3.15 cover the following process-support systems:

D. PRODUCED WATER TREATMENT
E. FLARE AND BLOWDOWN SYSTEM
F. GLYCOL REGENERATION SYSTEM
G. CLOSED DRAINS
For the remaining service/utility units, material selection is not influenced by the process fluid
characteristics and for this reason a different approach is followed. Material selection for these units
is covered in Section 4.
The material selection of general hydrocarbon processing units depends on: the system service (e.g.
multiphase well fluid, oil phase, gas phase, produced water phase, or condensate), the presence of
chlorides, free-water etc., the composition of the hydrocarbon phase, particularly the CO2 and H2S
content, the composition of associated formation water and its quantity, the operating and design
conditions.
The well fluid to process is generally rendered corrosive by associated CO2, free liquid water with a
carryover of chlorides and other chemical species in case the water is dragged from the formation or
with a low pH if the water origin is condensation from the saturated wet gas. In case H2S is present,
the use of materials resistant to sulphide stress cracking and other H2S-related issues is required.
Fluids from the reservoir are inherently oxygen-free, which greatly enlarge the applicability of
materials which are otherwise sensitive to localised and/or stress corrosion cracking, especially in
presence of chlorides: for this reason contamination with oxygen or other oxidizing agents shall be
careful prevented. Material upgrading is otherwise required. Other corrosion threats include microbial
Rev. 1 – May 2011
Sh. 24 of 62
induced corrosion (MIC), erosion-corrosion or erosive wear: these issues do not normally drive
material selection, but they require appropriate prevention methods be addressed for their control.
Carbon steel is the base-choice material to assess: a corrosion allowance to accommodate corrosion
is always considered. Corrosion allowances shall be appropriate for the design life requirements, but
in any case a minimum of 1-1.5 mm and a maximum of 6 mm is usually adopted.
For multiphase and liquid streams, corrosion inhibitor is usually an effective and viable method to
mitigate the fluid corrosivity. Corrosion inhibition may be less effective and practical for gas
processing systems.
Due consideration shall also be given to the possible carryover of chloride-containing formation water
in the separated phases, and the effect they may have on corrosion threats even at a low content.
3.4.1 Receiving Facilities

Receiving facilities include the following main units:
− Launching/receiving trap (Unit 190),
− Manifold (Unit 130),
Rev. 1 – May 2011
Sh. 25 of 62
Table 3.1 – Receiving Facilities. Material selection guide table.

Main limitations Typical applications
Service Item Material options
(corrosion threats) remarks
Limitedly corrosive service or design life.
Due consideration shall be given to water
GC (e.g.CO2) (NOTE 1) wetting enhancement, flow effects and
CS+CA(+CI*) erosional contribution to corrosion rate and
SSC (NOTE 2)
to corrosion inhibitor efficiency which
characterised the operating conditions at
manifolds.
Sweet or mildly sour, corrosive service
- May be considered as an alternative to
316L SS LC (Cl ) (NOTE 4,5)
22Cr, especially for limited pressure
or SSC (H2S) (NOTES 2,3)
-
systems and small size piping.
CS+316L clad SCC (Cl /high T) (NOTE 7,8)
Multiphase manifolds and main headers
Traces of chlorides from separator may be

present.
-
LC (Cl ) (NOTE 6) Sweet or mildly sour, corrosive service
Generally preferred to 316L: improved
Hydrocarbon processing systems
22Cr DSS SSC (H2S) (NOTES 2,3)

- mechanical strength, SSC resistance and
SCC (Cl /high T) (NOTE 7,8) LC/SCC resistance
Sweet or mildly sour, corrosive service high
chlorides, high temperature, oxygen
SSC (H2S) (NOTES 2,3)
25Cr SDSS -
contamination (O2>20ppb)
SCC (Cl /high T) (NOTE 7,8)
Resistant to LC and improved resistance to
SCC and SSC compared with 22Cr
Sweet or mildly sour corrosive service, high
6Mo SSC (H2S) (NOTES 2,3) contamination (O2>20ppb)
Resistant to SCC compared with 25Cr
Sour service
Resistant to SSC compared with 25Cr/6Mo,
Alloy 825 or but lower resistance to localised corrosion
-
LC (Cl /O2/T) with chlorides in case of oxygen
CS+825Clad
contamination (O2>20ppb) or high
temperature/chlorides combinations (testing
may be considered).
Alloy 625 or Sour service, high temperature, high

- chlorides, oxygen contamination
CS+625Clad (O2>20ppb)
DLCC shall be estimated based on the
Pig internal corrosivity condition during standby
launcher GC (e.g.CO2) (NOTE 1)
CS+CA(+CI) (normal condition).
/receiver SSC (NOTE 2)
traps Fluid displacement and purging after pig
operation shall be considered.
NOTE 1. CS display limited resistance to general corrosion (GC): a minimum corrosion allowance CA larger than the design
life cumulative corrosion DLCC shall be ensured.
NOTE 2. In H2S-containing fluids, use of this class of materials shall be restricted to sour service grades, in compliance with
material requirements stated in ISO 15156.
NOTE 3. In H2S-containing fluids, this class of materials display limited resistance to SSC and use is restricted within the
application limits specified in ISO 15156-3.
-
NOTE 4. In Cl -containing fluids, 316L SS are sensitive to localised corrosion (LC) in case of oxygen contamination
(O2>20ppb)
-
NOTE 5. In Cl -containing fluids, 316L SS display limited resistance at localised corrosion at extreme temperature/chlorides
combinations even in the absence of oxygen. Qualification via laboratory testing may be considered.
-
NOTE 6. In Cl -containing fluids, 22Cr DSS may undergo localised corrosion (LC) in case of oxygen contamination
(O2>20ppb).
NOTE 7. At high temperature and with chlorides austenitic and duplex SS are sensitive to internal chloride stress corrosion
cracking (SCC) in case of oxygen contamination (O2>20ppb).
NOTE 8. Due consideration shall be given to the risk of external SCC (e.g. painting). The onset temperature for SCC is
60°C for 316L SS, 100°C for 22Cr DSS and 120°C for SDSS.
Rev. 1 – May 2011
Sh. 26 of 62
3.4.2 Oil treatment (oil separation, degassing and storage)

Oil treatment facilities include the following main units:
− Oil separation (Unit 200),
− Crude oil/LPG treatment (Unit 210/211),
− Crude oil/LPG storage (Unit 220)
Principal components include:

− Gas piping,
− Liquid hydrocarbon / water piping,
− Pressure vessels,
− Tanks,
− Heat exchangers,
− Pumps and valves.
GAS
HEATER
1st STAGE
SEPARATOR
2nd STAGE OIL

SEPARATOR
1st STAGE DEGASSING

SEPARATOR COLUMN
WATER
Figure 3.1 – Oil separation and degassing schematic
Table 3.2 – Oil Treatment Facilities. Piping. Material selection guide table.
GC (e.g.CO2) (NOTE 1)
CS+CA(+CI*) *Corrosion inhibition in gas processing
SSC (NOTE 2)
Hydrocarbon processing systems: Oil Treatment
systems should be carefully considered

- May be considered as an alternative to
LC (Cl ) (NOTE 4)
22Cr, especially for limited pressure
316L SSC (H2S) (NOTES 2,3)
-
SCC (Cl /high T) (NOTE 6)
Traces of chlorides from separator may be
present.
Gas piping

SSC (H2S) (NOTES 2,3) Generally preferred to 316L: improved
22Cr DSS -
SCC (Cl /high T) (NOTE 6) mechanical strength, SSC resistance and
LC/SCC resistance
25Cr SDSS - Improved resistance to SCC and SSC
compared with 22Cr
Alloy 825 or
- Sour, corrosive service
CS+825Clad
Alloy 625 or
CS+625Clad
Rev. 1 – May 2011
Sh. 27 of 62

GC (CO2) (NOTE 1)
CS+CA(+CI) Limitedly corrosive service or design life.
SSC (NOTE 2)
-
May be considered as an alternative to
316L LC (Cl ) (NOTE 4,5) 22Cr, especially for limited pressure
or SSC (H2S) (NOTES 2,3) systems and small size vessels.
-
CS+316LClad SCC (Cl /high T) (NOTE 7,8) In presence of chlorides, oxygen
contamination (O2>20ppb) risk represents
Produced water and liquid hydrocarbon piping
an issue.
-
22Cr DSS SSC (H2S) (NOTES 2,3) Generally preferred to 316L: improved
25Cr SDSS -
Sour service
-
CS+825Clad
may be considered)

-
(O2>20ppb).
-
-
(O2>20ppb).
Rev. 1 – May 2011
Sh. 28 of 62
Table 3.3 – Oil Treatment Facilities. Vessels and Tanks. Material selection guide table.
GC (CO2) (NOTE 1)
SSC (NOTE 2)
Corrosive service, limited service life
CS+CA+IL(+CI) GC (at coating breakdown) Low pressure systems. Internal lining
inspection program and refurbishing shall
be considered after 5-7 years of service.
-
316L LC (Cl ) (NOTE 4,5) 22Cr, especially for limited pressure
or SSC (H2S) (NOTES 2,3) systems and small size vessels.
-
CS+316LClad SCC (Cl /high T) (NOTE 7,8) In presence of chlorides, oxygen
an issue.
-
Pressure vessels

25Cr SDSS -
6Mo or chlorides, high temperature, oxygen
SSC (H2S) (NOTES 2,3) contamination (O2>20ppb)
CS+6MoClad
Sour service
-
CS+825Clad
may be considered)
Sour service, high temperature, high
Alloy 625 or
CS+625Clad
(O2>20ppb)
internals
Vessel’s
Superior material may be considered

316L - depending on the internals’ function and
environment
Tanks
CS+CA
- -
(+IL/IEC+CP)
-
(O2>20ppb).
-
-
(O2>20ppb).
cracking (SCC) in case of oxygen contamination (O2>20ppb)
Rev. 1 – May 2011
Sh. 29 of 62
Table 3.4 – Oil Treatment Facilities. Pumps and Valves. Material selection guide table.
Casing Impeller
GC (CO2) (NOTE 1)
CS Non corrosive service.
SSC (NOTE 2)
-
12Cr SS LC (Cl ) (NOTE 4,5)
Sweet or mildly sour, non-corrosive or
CS+CA 316L SS -
mildly corrosive service
(+CI)
Sour, non-corrosive or mildly corrosive
service
-
Alloy 825 LC (Cl /O2/T) -
In Cl containing fluids, Alloy 825 may
undergo localised corrosion in case of
oxygen contamination (O2>20ppb).
-
LC (Cl ) (NOTE 4,5)
316L SS SSC (H2S) (NOTES 2,3) Sweet or mildly sour, corrosive service
-
Pumps
-
22Cr DSS SSC (H2S) (NOTES 2,3) Improved resistance to LC, SSC and SCC
-
SCC (Cl /high T) (NOTE 7,8) compared with 316L.
25Cr DSS -
Sour service
but lower resistance to localised corrosion
-
Alloy 825 LC (Cl /O2/T) with chlorides in case of oxygen
may be considered)
Alloy 625 - chlorides, oxygen contamination
(O2>20ppb)
Body Trim
-
MSS LC (Cl ) (NOTE 4,5) Sweet, non-corrosive or mildly corrosive
(13Cr) SSC (H2S) (NOTES 2,3) service.
-
PH MSS LC (Cl ) (NOTE 4,5) Sweet, non-corrosive or mildly corrosive
(17-4PH) SSC (H2S) (NOTES 2,3) service.
-
LC (Cl ) (NOTE 4,5) Sweet or moderately sour, non-corrosive or
Aust.SS mildly corrosive service.
(316) - Improved resistance to LC and SSC
CS+CA SCC (Cl /high T) (NOTE 7) compared with martensitic SS
(+CI)
-
LC (Cl ) (NOTE 4,5) Sweet or moderately sour, non-corrosive or
Valves

(nitronic) - Improved resistance to SSC compared with
SCC (Cl /high T) (NOTE 7) 316 SS.
Sour, mildly corrosive service
Nickel Specific nickel alloy (usually PH) shall be
-
Alloys selected based on the severity of the
environment.
316L SS -
LC (Cl ) (NOTE 4,5)
or
Aust.SS SSC (H2S) (NOTES 2,3) Sweet or mildly sour, corrosive service
CS+316L -
clad SCC (Cl /high T) (NOTE 7)

22Cr DSS - Improved resistance to LC, SSC and SCC
compared with 316L.
Rev. 1 – May 2011
Sh. 30 of 62

25Cr DSS -
Sour service
but lower resistance to localised corrosion
-
Alloy 825 Ni Alloy LC (Cl /O2/T) with chlorides in case of oxygen
may be considered)
Alloy 625
or Ni Alloy Sour service, high temperature, high
CS+625 (625,718) (O2>20ppb)
clad
-
NOTE 4. In Cl -containing fluids, martensitic SS and 316L SS are sensitive to localised corrosion (LC) in case of oxygen
contamination (O2>20ppb).
-
NOTE 5. In Cl -containing fluids, martensitic SS and 316L SS display limited resistance at localised corrosion at extreme
temperature/chlorides combinations even in the absence of oxygen. Qualification via laboratory testing may be
considered.
-
(O2>20ppb).
Rev. 1 – May 2011
Sh. 31 of 62
Table 3.5 – Oil Treatment Facilities. Heat Exchangers and Air Coolers. Material selection guide table.
Tubes
GC (CO2) (NOTE 1)
SSC (NOTE 2)
-
LC (Cl ) (NOTE 4,5)
316L SS SSC (H2S) (NOTES 2,3) Sweet or mildly sour, corrosive service
-
tubes side: process fluid (NOTES 11,12)
-
shell side: inert fluid (NOTE 9,10),
Heat Exchangers and air-coolers
22Cr DSS SSC (H2S) (NOTES 2,3) Improved resistance to LC, SSC and SCC
-
SCC (Cl /high T) (NOTE 7,8) compared with 316L.
25Cr DSS -
Sour service

Alloy 825
-
LC (Cl /O2/T) but lower resistance to localised corrosion
with chlorides in case of oxygen
temperature/chlorides combinations
Alloy 625 - chlorides, oxygen contamination
(O2>20ppb)
Shell and
tubesheets
GC (CO2) (NOTE 1)
CS+CA (+CI) Non corrosive service.
SSC (NOTE 2)
-
LC (Cl ) (NOTE 4,5)
316L SS or CS+316L
SSC (H2S) (NOTES 2,3) Sweet or mildly sour, corrosive service
SS -
shell side: process fluid (NOTES 10, 11)

22Cr DSS - Improved resistance to LC, SSC and SCC
compared with 316L.
Heat Exchangers

25Cr DSS -
6Mo or chlorides, high temperature, oxygen
CS+6Mo clad
Sour service
Alloy 825 or CS+825 - but lower resistance to localised corrosion
LC (Cl /O2/T)
clad with chlorides in case of oxygen
Alloy 625 or CS+625
clad
(O2>20ppb)
Rev. 1 – May 2011
Sh. 32 of 62

life cumulative corrosion DLCC shall be ensured. NOTE 1. CS for tubes is only applicable in non-corrosive service.
Upgrade to CRA is usually recommended and is required in case some corrosion may occur during upset or
transitory conditions.
-
(O2>20ppb).
-
NOTE 5. In Cl -containing fluids, 316L SS display limited resistance at extreme temperature/chlorides combinations even in
the absence of oxygen. Qualification via laboratory testing may be considered.
-
(O2>20ppb).
NOTE 8. Due consideration shall be given to the risk of external SCC (e.g. painting where practical). The onset temperature
for SCC is 60°C for 316L SS, 100°C for 22Cr DSS and 120°C for SDSS.
NOTE 9. In case shell-side fluid is process fluid, tubes material shall be resistant to both shell-side and fluid-side material.
NOTE 10. In case shell-side fluid is seawater, tubes material and shell/tubesheets material is titanium or 25Cr SDSS / 6Mo
nickel alloy if the maximum temperature is lower than 60°C or lower than 30°C with chlorine.
NOTE 11. In case shell-side fluid is inert fluid, shell material is carbon steel.
NOTE 12. In case tube-side fluid is seawater, tubes material is titanium or 25Cr SDSS / 6Mo nickel alloy if the maximum
temperature is lower than 60°C or lower than 30°C with chlorine.
Rev. 1 – May 2011
Sh. 33 of 62
3.4.3 Gas treatment (gas separation, sweetening, compression, dehydration and storage)
Oil treatment facilities include the following main units:
• Gas separation (Unit 300),
• Gas dehydration (Unit 310),
• Liquid hydrocarbon recovery (Unit 320)
• Gas sweetening / acid gas removal (Unit 330)
• Gas compression (Unit 360)
• Raw gas compression (Unit 365)
• Glycol dehydration (Unit 380).
Principal components include:

• Gas piping,
• Liquid hydrocarbon / water piping,
• Pressure vessels,
• Air coolers,
• Compressors (material selection performed by Supplier),
• Tanks.
Rev. 1 – May 2011
Sh. 34 of 62
Gas separation (Unit 300) and dehydration (Unit 310)

DRY GAS
GLYCOL
GAS WITH WET GAS
CONDENSATES
KO DRUM
GLYCOL
SLUG CATCHER
DEHYDRATION
COLUMN
CONDENSATES
STABILIZED
CONDENSATES
DEGASSING
COLUMN
Figure 3.2 – Gas separation and dehydration schematic
Gas compression (Unit 360/365)
FROM
SEPARATION UNIT
AIR COOLER AIR COOLER
SCRUBBER SCRUBBER SCRUBBER
ST ND
1 STAGE 2 STAGE
COMPRESSOR COMPRESSOR
Figure 3.3 – Gas compression schematic

Rev. 1 – May 2011
Sh. 35 of 62
Table 3.6 – Gas Treatment Facilities. Piping. Material selection guide table.
GC (e.g.CO2) (NOTE 1)
CS+CA(+CI*) *Corrosion inhibition in gas processing
SSC (NOTE 2)
systems should be carefully considered
Hydrocarbon processing systems: Gas Treatment
SSC (H2S) (NOTES 2,3) May be considered as an alternative to

Gas piping (NOTE 6)
316L -
SCC (Cl /high T) (NOTE 4,5) 22Cr, especially for limited pressure
SSC (H2S) (NOTES 2,3) Generally preferred to 316L: improved
22Cr DSS -
SCC (Cl /high T) (NOTE 4,5) mechanical strength, SSC resistance and
LC/SCC resistance
25Cr SDSS - Improved resistance to SCC and SSC
compared with 22Cr
Alloy 825/625 or
CS+825/625Clad
GC (CO2) (NOTE 1)
Condensed water and
SSC (NOTE 2)
liquid hydrocarbon
piping (NOTE 6)

316L - Sweet or mildly sour, corrosive service
22Cr DSS - Sweet or mildly sour, corrosive service
Alloy 825 or Sour service
-
CS+825Clad Resistant to SSC compared with 22Cr.
NOTE 6. In case presence of chloride-containing formation water is expected, e.g. dragged with gas from production
separators, material selection of piping should be carried out following guidance provided by Table 3.2.
Rev. 1 – May 2011
Sh. 36 of 62
Table 3.7 – Gas Treatment Facilities. Vessels and Tanks. Material selection guide table.
GC (CO2) (NOTE 1)
SSC (NOTE 2)
CS+CA+IL(+CI) GC (at coating breakdown) Low pressure systems. Internal lining
inspection program and refurbishing shall
Pressure vessels (NOTE 6)

316L
or - Sweet or mildly sour, corrosive service
CS+316LClad
22Cr DSS - Improved mechanical strength, SSC
resistance and SCC resistance
25Cr SDSS -
Improved resistance to SCC and SSC
compared with 22Cr
Alloy 825/625 or Sour service
-
CS+825/625Clad Resistant to SSC compared with 25Cr/6Mo
internals
Vessel’s
Superior material may be considered

316L - depending on the internal’s function and
environment
Tanks
CS+CA
- -
(+IL/IEC+CP)
separators, material selection should be carried out following guidance provided by Table 3.3.
Rev. 1 – May 2011
Sh. 37 of 62
Table 3.8 – Gas Treatment Facilities. Valves. Material selection guide table.
Body Trim
MSS Sweet, non-corrosive or mildly corrosive
(13Cr) service.
PH MSS Sweet, non-corrosive or mildly corrosive
(17-4PH) service.
Sweet or moderately sour, non-corrosive or
(316) Improved resistance to SSC compared with

CS+CA martensitic SS
(+CI)
Sweet or moderately sour, non-corrosive or
(nitronic) Improved resistance to SSC compared with
316 SS.
Valves (NOTE 6)
Sour, mildly corrosive service

Nickel Specific nickel alloy (usually PH) shall be
-
Alloys selected based on the severity of the
environment.
316L SS
or SSC (H2S) (NOTES 2,3)
Aust.SS - Sweet or mildly sour, corrosive service
CS+316L SCC (Cl /high T) (NOTE 4,5)
clad
22Cr DSS - Improved resistance to SSC and SCC
compared with 316L.
25Cr DSS - Improved resistance to SCC and SSC
compared with 22Cr
Alloy
825/625
Sour service
or Ni Alloy -
Resistant to SSC compared with 25Cr/6Mo
CS+625
clad
separators, material selection should be carried out following guidance provided by Table 3.4.
Rev. 1 – May 2011
Sh. 38 of 62
Table 3.9 – Gas Treatment Facilities. Air Coolers. Material selection guide table.
Tubes
Hydrocarbon processing systems: Gas
GC (CO2) (NOTE 1)
SSC (NOTE 2)
Air-coolers (NOTE 5)

316L SS - Sweet or mildly sour, corrosive service
Treatment

22Cr DSS - Improved resistance to SSC and SCC
compared with 316L.
SSC (H2S) (NOTES 2,3) Sweet or mildly sour, corrosive service

25Cr DSS - Improved resistance to SCC and SSC
SCC (Cl /high T) (NOTE 4) compared with 22Cr
Sour service
Alloy 825/625 -
Resistant to SSC compared with 25Cr/6Mo
NOTE 1. CS for tubes is only applicable in non-corrosive service. Upgrade to CRA is usually recommended and is required
in case some corrosion may occur during upset or transitory conditions.
NOTE 4. Due consideration shall be given to the risk of external SCC (e.g. painting where practical). The onset temperature
for SCC is 60°C for 316L SS, 100°C for 22Cr DSS and 120°C for SDSS.
separators, material selection of tubes should be carried out following guidance provided by Table 3.5.
Rev. 1 – May 2011
Sh. 39 of 62
3.4.3.1 Gas sweetening / acid gas removal - Amine system (Unit 330)
The amine system is typically entirely supplied by the Vendor as a package and material selection is
under its responsibility. The material selected by the Vendor is then submitted to the Company for
approval.
When carbon steel is used in amine service all weldings shall receive an appropriate post weld heat
treatment for stress relieving for amine stress corrosion cracking avoidance.
The schematic of the amine treatment unit is shown in the below figure.
Guidance for material selection of amine treatment system is provided in Table 3.10.
ACID GAS
TREATED GAS
REFLUX
OVERHEAD DRUM
CONDENSER
ABSORBER REGENERATION
COLUMN COLUMN
FLASH DRUM
AMINE TANK
SCRUBBER
COALESCER
Figure 3.4 – Ammine treatment schematic

Rev. 1 – May 2011
Sh. 40 of 62
Table 3.10 – Amine system. Material selection guide table.

SSC (H2S) (NOTES 1,2) Sweet or mildly sour, corrosive
316L SS -
Rich amine piping SCC (Cl /high T) (NOTE 3) service
Alloy 825 - Sour service
Lean amine
CS+CA SSC (H2S) (NOTE 1) -
piping
Acid/sour gas 316L SS -
SCC (Cl /high T) (NOTE 3) service
piping
Shell
CS SSC (H2S) (NOTE 1) -
(top)
Sweet or mildly sour, corrosive
Amine Absorber Shell CS+316L SSC (H2S) (NOTES 1,2)
service
(bottom)
CS+825 - Sour service
Trays 316L SS - -
Shell CS+316L SSC (H2S) (NOTES 1,2)
service
(top)
CS SSC (H2S) (NOTE 1) -
Regenerator
Shell Sweet or mildly sour, corrosive
CS+316L SSC (H2S) (NOTES 1,2)
(bottom) service
Amine Treatment

Trays 316L SS SSC (H2S) (NOTE 2) -
Tubes 316L SS SSC (H2S) (NOTES 1,2)
service
Rich/lean amine (rich)
exchanger
Shell
CS+CA SSC (H2S) (NOTE 1) -
(lean)
CS+316L SSC (H2S) (NOTES 1,2)
Raw (feed) gas Shell service
scrubber
(coalescer)
Internals 316L SS - -
Rich amine flash 316L SS -
drum
Regenerator 316L SS -
reflux drum
Overhead 316L SS -
condenser
Shell CS+CA SSC (H2S) (NOTE 1) -
Reboiler
Tubes 316L SS - -
Amine tank CS+CA - -
Rev. 1 – May 2011
Sh. 41 of 62
3.4.3.2 Glycol dehydration and regeneration unit (Unit 380)

The glycol regeneration system is typically entirely supplied by the Vendor as a package and material
selection is under its responsibility. The material selected by the Vendor is then submitted to the
Company for approval.
The schematic of the glycol dehydration and regeneration system is shown in the below figure.
Guidance for material selection of glycol regeneration system is provided in Table 3.11.
WATER
VAPOUR
DRY GAS OUT
GAS – GLYCOL RICH GLYCOL

HEAT STILL
COLUMN
LEAN
GLYCOL GLYCOL–GLYCOL GLYCOL RIGENERATOR
HEAT EXCH.
LEAN FUEL
GLYCOL GAS
LEAN
GLYCOL
RICH
GLYCOL
H. P.
WET GAS IN FILTER
INTERNAL
SEPARATOR
GAS-COND. –
GLYCOL
GLYCOL
CONTACTOR
PARTICLE ACTIVATED
FILTER CARBON
Figure 3.5 – Glycol regeneration system schematic

Rev. 1 – May 2011
Sh. 42 of 62
Table 3.11 – Glycol regeneration system. Material selection guide table.

DLCC < CA Low corrosivity service and/or limited
CS+CA design lives or water wetting excluded
SSC (H2S) (NOTE 1)
Rich glycol piping SSC (H2S) (NOTES 1,2) Sweet or mildly sour, corrosive
316L SS -
Lean glycol piping CS+minCA SSC (H2S) (NOTE 1) -
316L SS -
Off-gas piping SCC (Cl /high T) (NOTE 3) service
Top: Above the bottom tray (or chimney
SSC (H2S) (NOTE 1)
CS+CA tray with structured packing)
Shell Bottom: Below bottom tray (or chimney tray
CS+316L/ SSC (H2S) (NOTES 1,2) with structured packing)
Glycol contactor 825 Clad
Glycol regeneration
316L SS - Trays
Internals SCC (Cl /high T) (NOTE 3)
Alloy 825 - Structure packing
CS+316L Clad -
Reboiler SCC (Cl /high T) (NOTE 3) service
CS+825Clad - Sour service
316L SS -
Still column SCC (Cl /high T) (NOTE 3) service
316L SS -
Condenser coil SCC (Cl /high T) (NOTE 3) service
Glycol/glycol SSC (H2S) (NOTES 1,2) Sweet or mildly sour, corrosive
316L SS -
exchangers SCC (Cl /high T) (NOTE 3) service
(rich glycol side) Alloy 825 - Sour service
Surge drum CS+CA SSC (H2S) (NOTE 1) -
Flash vessel CS+CA SSC (H2S) (NOTE 1) -
Pumps 316L/316L -
(body/imp.)
Alloy 825/825 - Sour service
Rev. 1 – May 2011
Sh. 43 of 62
3.4.4 Produced water treatment

The principal components included in the produced water treatment unit comprise:
• Oily-water piping,
• Pressure vessels,
• Tanks,
• Heat exchangers,
• Pumps and valves.
Guidance for material selection pre-screening of produced water treatment system is provided in
Table 3.12.
For heat exchangers, pumps and valves see Table 3.4 and Table 3.5.
Table 3.12 – Produced water system. Material selection guide table.

GC (CO2) (NOTE 1)
SSC (NOTE 2)
-
LC (Cl ) (NOTE 4) 22Cr, especially for limited pressure
316L SSC (H2S) (NOTES 2,3) systems and small size vessels.
-
SCC (Cl /high T) (NOTE 6) In presence of chlorides, oxygen
an issue.
-
SCC (Cl /high T) (NOTE 6) LC/SCC resistance
25Cr SDSS contamination (O2>20ppb)
Piping
-
Produced water

Sour service
Resistant to SSC compared with
Alloy 825 or - 25Cr/6Mo, but lower resistance to localised
LC (Cl /O2/T)
CS+825Clad corrosion with chlorides in case of oxygen

Pressure limitations to be verified.
GRE Installation issues to be considered.
Safety issues to be investigated.
GC (CO2) (NOTE 1)
SSC (NOTE 2)
Vessels

GC (at coating breakdown) (unless CP is applied)
CS+CA(+CI)+IL(+CP) Internal CP with sacrificial anodes Low pressure systems. Internal lining
may be considered inspection program and refurbishing shall
Rev. 1 – May 2011
Sh. 44 of 62

-
LC (Cl ) (NOTE 4) 22Cr, especially for limited pressure
316L
SSC (H2S) (NOTES 2,3) systems and small size vessels.
CS+316LClad -
SCC (Cl /high T) (NOTE 6) In presence of chlorides, oxygen
an issue.
-
SCC (Cl /high T) (NOTE 6) LC/SCC resistance
25Cr SDSS -
6Mo chlorides, high temperature, oxygen
CS+6MoClad
Sour service
Alloy 825 or 25Cr/6Mo, but lower resistance to localised
-
LC (Cl /O2/T) corrosion with chlorides in case of oxygen
CS+825Clad
(testing may be considered)
Alloy 625 or
CS+625Clad
(O2>20ppb)
Tanks CS+CA+IEC/IL+CP - -
-
(O2>20ppb), and display limited resistance at extreme temperature/chlorides combinations even in the absence of
oxygen. Qualification via laboratory testing may be considered.
-
(O2>20ppb).
cracking (SCC) in case of oxygen contamination (O2>20ppb) and due consideration shall be given to the risk of
external SCC (e.g. painting). The onset temperature for SCC is 60°C for 316L SS, 100°C for 22Cr DSS and 120°C
for SDSS.
Rev. 1 – May 2011
Sh. 45 of 62
3.5 Water Injection Systems

The water injection system includes the facilities for storage and pumping of injection water to the
water injection wells via the injection network of pipelines. The injected water may consist of:
− seawater or a mixture of seawater and produced water,
− produced water (oxygen-free, CO2 containing water),
− de-aerated water, with residual O2 content lower than 20 ppb (fresh water or produced water),
− aerated water (fresh water or produced water).
Material selection of systems for the injection of seawater, alone or commingled with other water
sources, is covered by ENI Standard 20019.MAT.COR.PRG “Material selection for seawater
handling systems” [Ref./4/].
Guidance for material selection of injection systems handling other injection fluids is provided in
Table 3.13.
Table 3.13 – Injection systems. Material selection guide table.

cO2 < 20 ppb
Piping CS+CA -
SSC (H2S) (NOTE 2)
Deaerated water (residual oxygen content
Tanks CS+IL/IEC+CP - -
-
12Cr LC (Cl ) (NOTE 4) Sweet or mildly sour, non-corrosive or
SSC (H2S) (NOTES 2,3) mildly corrosive service
316L
lower than 20 ppb)
-
SCC (Cl /high T) (NOTE 6) CP from CS casing prevents LC to impeller.
-
LC (Cl ) (NOTE 5)
22Cr SSC (H2S) (NOTES 2,3)
- CP from CS casing prevents LC to impeller.
Pumps CS+CA
(casing/impeller) Ni-resist Sweet or mildly sour, corrosive service high
SSC (H2S) (NOTES 2,3) chlorides, high temperature, oxygen
25Cr - contamination (O2>20ppb)
CP from CS casing prevents LC to impeller.
Sour service
Alloy825 - Resistant to SSC compared with 25Cr/6Mo
CP from CS casing prevents LC to impeller.
Oxygen- Piping use Table 3.2
free
Tanks CS+IL/IEC+CP
produced
water Pumps use Table 3.4
GC (O2) (NOTE 1)
CS+CA Oxygen scavenger Limitedly corrosive service or design life.
Limited service life
-
Aerated water
LC/SCC resistance
Piping
25Cr SDSS -
Pressure and temperature limitations to be
FRP/GRE T < 110°C
verified.
Tanks CS+IL/IEC+CP - -
Pumps Ni-resist 316L - CP from CS casing prevents LC to impeller.
Rev. 1 – May 2011
Sh. 46 of 62

(casing/impeller) - Sweet or mildly sour, corrosive service
LC (Cl ) (NOTE 5)
25Cr SDSS -
-
NOTE 4. In Cl -containing fluids, martensitic SS and 316L SS are sensitive to localised corrosion (LC) in case of oxygen
contamination (O2>20ppb), and display limited resistance at extreme temperature/chlorides combinations even in
the absence of oxygen. Qualification via laboratory testing may be considered.
-
(O2>20ppb).
3.5.1 Flare and blowdown system

During normal production conditions, i.e. when not operating, flare and blowdown system is in
contact with inert gas used for blanketing purposes. In such conditions the environment may be
rendered mildly corrosive by minor leaking of blow down valves. During flaring or blowdown
operations, process fluid is displaced into the system and corrosive conditions may temporary onset.
Material selection of this unit is governed by low-temperature conditions that may occur during
emergency blowdown of pressurised systems (driven by joule-thompson effect dictating material
suitability for low temperature), resistance to sulphide stress cracking with H2S-containing fluids,
resistance to stress corrosion cracking with chlorides-containing fluids or resistance to general
corrosion in pocket area where corrosive fluids may remain trapped.
Guidance for material selection pre-screening of flare and blowdown system is provided in Table
3.14.
Rev. 1 – May 2011
Sh. 47 of 62
Table 3.14 – Flare and blowdown system. Material selection guide table.
GC (e.g.CO2) (NOTE 1) Check suitability for minimum low
(LT)CS+CA SSC (NOTE 2) temperature during emergency blowdown
MDT > -46°C (CS -29°C/LTCS -46°C)
-
LC (Cl ) (NOTE 4)
316L SSC (H2S) (NOTES 2,3)
Suitable for MDT down to -196°C
Piping
-
- Sour service
Alloy 825 LC (Cl /O2/T) (NOTE 7)
Check suitability for minimum low
MDT > -46°C temperature during emergency blowdown
(LT)CS+CA(+IC/IL) GC (e.g.CO2) (NOTE 1) (CS -29°C/LTCS -46°C)
SSC (NOTE 2) Check suitability of internal coating/lining for
Flare and blowdown
corrosion protection
MDT > -46°C
-
LC (Cl ) (NOTE 4) Check suitability for minimum low
(LT)CS+316LClad temperature during emergency blowdown
SSC (H2S) (NOTES 2,3) (CS -29°C/LTCS -46°C)
-
Flare KO Drums
MDT > -46°C Check suitability for minimum low

(LT)CS+825Clad SSC (NOTE 2) temperature during emergency blowdown
-
LC (Cl /O2/T) (NOTE 7) (CS -29°C/LTCS -46°C)
Sweet service
-
LC (Cl ) (NOTE 4) Suitable for MDT down to -196°C
AISI 316L SSC (H2S) (NOTES 2,3) At T>60°C due consideration shall be given
- -
SCC (Cl /high T) (NOTE 6) to the risk of external SCC in Cl containing
atmospheres, if uncoated.
- Sour service
Alloy 825 LC (Cl /O2/T) (NOTE 7)
AISI 310 T < 650°C -
Flare tip
Alloy 800H/HT - -
-
NOTE 5. N/A.
for SDSS.
-
NOTE 7. In Cl -containing fluids, Alloy 825 may undergo localised corrosion in case of oxygen contamination (O2>20ppb);
testing may be considered.
Rev. 1 – May 2011
Sh. 48 of 62
3.5.2 Closed drain systems

The closed drain system is used to displace the liquids from the processing units when they need to
be emptied. Liquids are usually corrosive and for an appropriate material selection it is important to
ascertain if the piping route includes pocket areas where liquid remain trapped after emptying
operation or if the system is “free-drain” by gravity. In the first case, corrosive conditions exists only
during the time required to transfer the liquids to the closed drain drum, whereas in the latter case
dead leg conditions exists on a partially or complete section of the closed drain piping route. In this
dead leg, corrosion inhibitor may lose their effect after some time and highly corrosive conditions
may onset, including bacterial corrosion, corrosion under deposit etc. and corrosion resistant alloys
or non-metallic materials may be required.
Guidance for material selection pre-screening of flare and blowdown system is provided in Table
3.15.
Table 3.15 – Closed drain system. Material selection guidance table.
Additional requirements and
Service Item Material options Remarks
limitations
Due consideration shall be given to
GC (e.g.CO2) (NOTE 1) pocket areas of the piping route, where
CS+CA
SSC (NOTE 2) the fluid may remain in stagnant
conditions.
-
316L SS SSC (H2S) (NOTES 2,3) May be considered as an alternative to
- 22Cr, especially for limited pressure
SCC (Cl /high T) (NOTE 6) systems and small size piping.
Sweet or mildly sour, corrosive service,
-
LC (Cl ) (NOTE 5) high reliability required (e.g. offshore)
-
SCC (Cl /high T) (NOTE 6) mechanical strength, SSC resistance
Piping
and LC/SCC resistance.

Sweet or mildly sour, corrosive service,
high reliability required (e.g. offshore),
SSC (H2S) (NOTES 2,3) high chlorides, oxygen contamination
25Cr DSS - (O2>20ppb)
Resistant to LC and improved resistance
Closed drains
to SCC and SSC compared with 22Cr

Sweet or mildly sour corrosive service,
high chlorides, high temperature,
6Mo SSC (H2S) (NOTES 2,3) oxygen contamination (O2>20ppb)
Safety issues to be investigated. Installation issues to be considered.
FRP/GRE Pressure and temperature limitations to
be verified.
GC (CO2) (NOTE 1)
CS+CA -
SSC (NOTE 2)
Internal CP with sacrificial anodes may
CS+CA+IL GC (at coating breakdown)
be considered
-
Vessels
316L In presence of chlorides, oxygen

CS+316LClad - contamination (O2>20ppb) risk
SCC (Cl /high T) (NOTE 6) represents an issue.
22/25Cr - Sweet or mildly sour, corrosive service
Sweet or mildly sour corrosive service,
6Mo high chlorides, high temperature,
SSC (H2S) (NOTES 2,3) oxygen contamination (O2>20ppb)
CS+6MoClad
Rev. 1 – May 2011
Sh. 49 of 62

Service Item Material options Remarks
limitations
Sour service
Alloy 825 or 25Cr/6Mo, but lower resistance to
-
LC (Cl /O2/T) localised corrosion with chlorides in
CS+825Clad
case of oxygen contamination
(O2>20ppb) or high
Pumps Use Table 3.4
Tanks CS+CA+IL/IEC (+CP) - -

-
-
(O2>20ppb).
for SDSS.
Rev. 1 – May 2011
Sh. 50 of 62
4. MATERIAL SELECTION GUIDE FOR UTILITIES
This Section provides guidance for the material selection of the main components of utility/service
systems.
4.1 Fresh water

Fresh water is used for potable water or service water system. Galvanised carbon steel and AISI
316L stainless steel are typical options for this service. Alternative materials as non-metallic or
copper alloys may be considered if chlorides content is a concern. Guidance for material selection in
fresh water is provided in Table 4.1.
Table 4.1 – Fresh water system. Material selection guide table.

Service Component Material options Remarks
limitations
T < 50°C
CS+CA+HDG -
Cl < 1 g/l
At T>60°C due consideration shall
be given to the risk of localised
- -
316L SS Cl < 100-200 mg/l corrosion at Cl > 100 mg/l and
-
external SCC in Cl containing
atmospheres, if uncoated.
Pressure and temperature
FRP/GRE T < 110°C
Piping limitations to be verified.
Sensitive to erosion-corrosion and
Flow velocity < 3 m/s pitting corrosion if limitations are not
- -
Copper and copper If T > 60°C → HCO3 /SO4 > 1 fulfilled.
alloys T < 120°C Coupling to different metals to be
6 < pH < 9 carefully evaluated to avoid galvanic
corrosion.
Fresh water
Temperature limitations to be
PE/PVC/PP T < 60/70/90°C
verified.
CS+CA+IL/IEC+CP - -
Vessels be given to the risk of localised
- -
316L SS Cl < 100-200 mg/l corrosion at Cl > 100 mg/l and
-
atmospheres.
-
Pumps CS+CA/316L Cl < 100-200 mg/l -
(body/imp.) 316L/316L
-
Cl < 100-200 mg/l -
Al-Bronze - -
Valves -
316L SS Cl < 100-200 mg/l -
Rev. 1 – May 2011
Sh. 51 of 62
4.2 Fire water

Fire water sources herein covered include fresh water or brackish water (fire water systems using
seawater is out of the scope of this document and is covered by ENI Company Standard
20019.MAT.COR.PRG [Ref./4/]). Material selection is based on required design life, system reliability
required and tolerance for repairs, chlorides content of the water. For limited service life carbon steel
with corrosion allowance (and galvanizing for limited temperature and chlorides) is a common choice.
For longer service life or where system reliability is critical and repair cost are high (e.g. offshore
service), corrosion resistant alternative should be considered, including 316L stainless steel for
chlorides-free waters or FRP/GRE or copper-nickel 9010. Guidance for material selection is provided
in Table 4.2.
Table 4.2 – Fire water system. Material selection guide table.

limitations
T < 50°C
CS+CA+HDG - -
Cl < 1 g/l
CS+CA - -
be given to the risk of localised
- -
316L Cl < 100-200 mg/l corrosion at Cl > 100 mg/l and
-
Piping atmospheres, if uncoated.
Pressure and temperature
FRP/GRE T < 110°C
limitations to be verified.
Flow velocity < 3.5 m/s
CuNi 9010 - -
If T > 60°C → HCO3 /SO4 > 1 Sensitive to erosion-corrosion and
pitting corrosion if limitations are not
CuNi 7030 T < 120°C fulfilled
Fire water 6 < pH < 9
CS+CA+IL/IEC+CP - -
Vessels be given to the risk of localised
- -
316L Cl < 100-200 mg/l corrosion at Cl > 100 mg/l and
-
atmospheres.
CS+CA/13Cr - -
Pumps
CS+CA/316L - -
(body/imp.)
-
316L/316L Cl < 100-200 mg/l -
Al-Bronze - -
Valves -
316L Cl < 100-200 mg/l -
Tanks CS+CA+IL/IEC+CP - -
Rev. 1 – May 2011
Sh. 52 of 62
4.3 Fresh water for closed circuit cooling water system

Fresh water, alone or in glycol solutions, is used for closed circuit cooling water systems. The oxygen
contained in water is rapidly consumed by oxidation reaction with carbon steel (or by oxygen
scavenging), which is almost negligible for the effect of corrosion, and becomes non corrosive. The
typical material solution for this system is carbon steel with a minimum corrosion allowance. A batch
of corrosion inhibitor may be included to fresh water additions to fill-up the system.
Table 4.3 – Fresh water for cooling water system. Material selection guide table.
limitations
Piping CS+CA -
Fresh water
for closed Vessels CS+CA -
Corrosion inhibitor (batch)
circuit cooling Heat exchanger CS/CS -
water
(heads/tubes) CS/316L SS -
4.4 Open Drains

Open drain system collects aerated fluids; this system is typically corrosive to carbon steel, which
may be suitable, with corrosion allowance, for limited design service. For critical installation and long
service life other material selections should be considered as indicated in the next table.
Table 4.4 – Open drains system. Material selection guide table.

limitations
CS+CA - -
CS+CA+HDG - -
Piping PE - -
FRP/GRE - Installation issues to be considered.
22Cr DSS - Offshore service, critical assets
Open Drains CS+CA+HDG - -

Vessels
CS+CA+IEC(+CP) - -
Pumps CS+CA / 316L SS - -
(casing/impeller) 22Cr / 22Cr DSS - -
Valves
(body / trim) 25Cr / 25Cr DSS - -
Rev. 1 – May 2011
Sh. 53 of 62
4.5 Chemicals
Typical material solution for storage and handling systems of chemicals used in hydrocarbon
processing plant is AISI 316L stainless steel, unless the chemical type or concentration is such that
higher alloyed materials are required (e.g. high-nickel based alloys or titanium): a typical example is
sodium hypochloride used in electrochlorination unit. Non-metallic materials may be also considered.
Table 4.5 – Chemicals. Material selection guide table.

limitations
Corrosion Piping/vessels/
AISI 316L - -
inhibitors pumps
Scale Piping/vessels/
AISI 316L - -
inhibitors pumps
Piping/vessels/
Was inhibitors AISI 316L - -
pumps
Piping/vessels/
Anti-foam AISI 316L - -
pumps
Piping/vessels/
Demulsifier AISI 316L - -
pumps
Oxygen Piping/vessels/
AISI 316L - -
scavenger pumps
Piping/vessels/
Biocide AISI 316L - -
pumps
Piping/vessels/
Pure glycol CS - -
pumps
Piping/vessels/
Methanol CS/316L - -
pumps
AISI 316L Diluted -
Sodium Piping/vessels/
GRP(GRVE) Tmax = 60°C -
hypochloride pumps
Titanium Concentrated -
Rev. 1 – May 2011
Sh. 54 of 62
4.6 Instrument and plant air

The concern of corrosion in instrument air and plant air systems is not related to the risk of leak but
rather to the need to maintain the transported clean and not contaminated with corrosion products,
which may impair the system functionality. Typical material selection is AISI 316L stainless steel or
HDG carbon steel for wet air upstream essication and filtration; downstream essication and filtration,
AISI 316L is the standard solution for instrument air, and carbon steel with minimum corrosion
allowance (e.g. 1-1.5 mm) for plant utility air.
Table 4.6 – Instrument and plant air system. Material selection guide table.
limitations
CS+minCA+HDG T<50°C -
Piping
316L SS - -
Instrument Air CS+minCA+HDG T<50°C -
Vessels CS+CA+IC/IL - -
316L SS - -
CS+minCA Dry air (downstream essicators) -
Wet air (upstream essicators)
Piping CS+minCA+HDG -
T<50°C
Plant Air 316L SS Wet air (upstream essicators) -
CS+minCA+HDG T<50°C -
Vessels CS+CA+IC/IL - -
316L SS - -
Rev. 1 – May 2011
Sh. 55 of 62
4.7 Other non-corrosive services

Typical non-corrosive utilities in hydrocarbon processing plants include diesel fuel, nitrogen / inert
gas, dry fuel gas, hydraulic oil, lube oil, methanol. In all these cases the transported fluid is non-
corrosive thus the material selection of these systems is mostly based on carbon steel with minimum
corrosion allowance. However, stainless steel may be required in case a fully clean fluid is required.
Table 4.7 – Non-corrosive systems. Material selection guidance table.

limitations
Piping CS+minCA - -
Internal CP of tank bottom with
Tanks CS+IC(+CP) sacrificial zinc anodes is -
Diesel recommended
Filters CS/316 SS - -
Pumps CS/CS - -
Nitrogen/Inert Piping CS+minCA - -
gas Filters CS/316 SS - -
Piping CS+minCA - -
Dry Fuel Gas Filters CS/316 SS - -
Vessels CS+minCA - -
Piping CS+minCA Upstream filters -
Hydraulic oil Filters CS/316 - -
Piping/tubing 316L SS Downstream filters -
Lube/seal oil Piping/tubing 316L SS Sweet -
Piping CS+minCA - -
Methanol
Piping/tubing 316L SS - -
Rev. 1 – May 2011
Sh. 56 of 62
5. MATERIAL SELECTION FOR MISCELLANEOUS COMPONENTS
5.1 Bolting
Material for bolting is selected in accordance with the requirements of the applicable design code for
the connection. The most common standards used in the upstream oil and gas industry for bolts and
nuts are according to the following ASTM standard specifications:
− ASTM A-193 “Alloy steel and stainless steel bolting materials for high temperature service”,
− ASTM A-320 “Alloy steel bolting materials for low temperature service” (see Table 5.1).
Bolting typical material used in hydrocarbon processing plants is low alloy steel. The quenched and
tempered low alloy steels grades AISI 4037, 4137, 4140, 4142, 4145, 4340 and 8740 are applicable
for high strength bolts. Stainless steel bolting is used for diameter 10 mm or lower, e.g. austenitic
stainless steel: e.g. ASTM A-193 grade B8 (AISI 304) or grade B8M (AISI 316).
CRA bolting, not covered by the above ASMT standards, may be considered to connect CRA piping:
this is not a frequent requirement, however it may be considered when long life is desired, where
access is difficult or impossible for inspection, or under thermal insulation. Use of stainless steel
bolting is limited by the risk of chloride stress corrosion cracking: when this risk is envisaged, AISI
316L bolting is to be avoided above 60°C; above this temperature 25Cr duplex stainless steel is
recommended for use up to 120°C.
Corrosion resistant alloy bolting may include:

− Precipitation hardened nickel-copper alloys: e.g. Monel K500, UNS N05500,
− 25Cr duplex stainless steels: e.g. UNS S32550, S32750, S32760,
− Precipitation hardened nickel alloys: e.g. UNS N06625 (Alloy 625), N07718 (Alloy 718) and
N07725 (Alloy 725),
− High-alloy austenitic stainless steel: UNS S31254 (254SMO)
− Precipitation hardened austenitic steel: e.g. ASTM A453 Grade 660 (UNS S66286) with Nitronic
60 (S21800) nuts,
− Copper based alloys: e.g. C51000, C11000, C61400
− Titanium alloys: e.g. Ti 6Al-4 V or Ti β-alloys.
Carbon and low alloy bolting shall be provided with a protection from atmospheric corrosion by hot
dip galvanised, “HDG”, e.g. in accordance to ISO 10684 or ASTM A-153. Alternative to HDG,
chemically converted phosphating treatment, polytetrafluoroethylene (PTFE) based coatings or
suitable paint protection can be considered. Cadmium plating shall be avoided.
Galvanic corrosion, galling issues, and different thermal expansion coefficients shall be considered
when dissimilar metals are used in bolts and materials to be joined. Anti-galling compounds (nickel-
based anti-seize) can be applied to the threads and also to the nut/flange contact face (but not to the
gaskets). Molybdenum sulphide (MoS2) and copper-based based anti-seize compounds shall not be
used due to the risk of stress corrosion cracking these products can cause to many materials
commonly used in oil and gas processing plants.
Rev. 1 – May 2011
Sh. 57 of 62
Table 5.1 – Boltings. Material selection guidance table.

Temperature
Material Sour/Non-sour Material options ASTM Spec.
requirements
Bolt ASTM A-193 Grade B16
MDT > -29°C Non-Sour
Nut ASTM A-194 Grade 7
Bolt ASTM A-193 Grade B7
Non-Sour
Nut ASTM A-194 Grade 2H
Low alloy C-Mn steel MDT > -46°C Bolt ASTM A-193 Grade B7M
AISI 4140, 4142, 4145 Sour ASTM A-194 Grade 7M
Nut
(quenched and ASTM A-194 Grade 2HM
tempered)
Bolt ASTM A-320 Grade L7
Non-Sour
Nut ASTM A-194 Grade 7/S4
MDT > -100°C Bolt ASTM A-320 Grade L7M
Sour ASTM A-194 Grade 7M/S4
Nut
ASTM A-194 Grade 2HM/S4
Bolt ASTM A-320 Grade B8M
Austenitic stainless steel Non-Sour
Nut ASTM A-194 Grade 8M
(AISI 316) MDT > -196°C
or nickel based alloy Bolt Alloy 625
Sour
Nut Alloy 625
Rev. 1 – May 2011
Sh. 58 of 62
APPENDIX A MATERIALS CHEMICAL COMPOSITION
Table A.1 – Austenitic stainless steels
Common C Cr Ni Mo Mn Si P S Other SMYS

UNS
name max% % % % max% max% max% max% % ksi
J92600 CF8 0.08 18-21 8-11 1.50 2.00 0.04 0.04 - 205
J92900 CF8M 0.08 18-21 9-12 2.0-3.0 1.50 2.00 0.04 0.04 - 205
S30400 304 0.08 18-20 8-10.5 2.00 1.00 0.045 0.030 - 205
S30403 304L 0.03 18-20 8-12 2.00 1.00 0.045 0.030 - 170
S31600 316 0.08 16-18 10-14 2.0-3.0 2.00 1.00 0.045 0.030 - 205
S31603 316L 0.030 16-18 10-14 2.0-3.0 2.00 1.00 0.045 0.030 - 170
S31000 310 0.25 24-26 19-22 2.00 1.50 0.045 0.030 - 205
S31700 317 0.08 18-20 11-15 3.0-4.0 2.00 1.00 0.045 0.030 - 205
S32100 321 0.08 17-19 9-12 2.00 1.00 0.045 0.030 Ti 5/XC min. 205
S34700 347 0.08 17-19 9-13 2.00 1.00 0.045 0.030 Cb 10XC min. 205
S20153 201LN 0.03 16-18 4-5 6.4-7.5 1.00 0.045 0.015 N 0.1-0.25 310
N 0.2-0.4,
S20910 Nitronic 50 0.06 20-23 11.5- 1.5-3.0 4.0-6.0 1.00 0.040 0.030 Nb 0.10-0.30, 380
13.5 V 0.10-0.30
Cu 3-4,
N08020 Alloy 20 0.07 19-21 30-38 2.0-3.0 2.00 1.00 0.045 0.035 Nb 8xCmin.,1.0 240
Cu 0.75
N08800 Alloy 800 0.10 19-23 30-35 1.50 0.75 0.045 0.030 Al 0.15-0.60, 205
Ti 0.15-0.60,
Fe 39.5 min.
Table A.2 – High-alloy austenitic stainless steels

Common C Cr Ni Mo Mn Si P S N Other SMYS
UNS PREN
name max% % % % max% max% max% max% % % ksi
19.0- 0.10
N08904 904L 0.02 23.0 4.0-5.0 1.00 1.00 0.045 0.035 Cu1-2 32.2 240
23.0 max.
26.0-
N08028 Alloy 28 0.03 28.0 2.00 2.50 1.00 0.030 0.030 Cu0.6-1.4 35.9 214
28.0
20.0- 0.18-
N08367 Al6XN 0.03 30.0 3.0-4.0 2.00 1.00 0.040 0.030 Cu0.75max. 42.7 220
22.0 0.25
20.0- 0.16-
J94651 CN3MN 0.03 34.0 1.40 2.00 1.00 0.040 0.010 Cu0.75max. 42.4 260
22.0 0.26
Alloy 25- 19.0- 0.15-
N08926 0.02 23.5 6.0-7.0 2.00 0.50 0.030 0.010 Cu0.5-1.5 41.2 295
6Mo 21.0 0.25
19.5- 0.18-
S31254 254 SMO 0.020 25.5 6.0-7.0 1.00 0.80 0.030 0.010 Cu0.5-1 42.2 310
20.5 0.22
Cast 254 19.5- 0.18-
J93254 0.025 23.5 1.20 1.00 0.045 0.010 Cu0.5-1 42.2 260
SMO 20.5 0.24
20.5- 0.30-
S31277 27-7Mo 0.020 25.5 max. 3.00 0.50 0.030 0.010 Cu0.5-1 46.8 360
23.0 0.40
22.0- 0.45-
S32654 654 SMO 0.020 24.0 6.0-7.0 1.00 0.50 0.030 0.005 Cu0.3-0.6 52.3 430
24.0 0.55
Rev. 1 – May 2011
Sh. 59 of 62
Table A.3 – Duplex stainless steels
TYPE UNS Common NOMINAL COMPOSITION (wt%) PREN SMYS

Name
ksi
Fe Cr Ni Mo N Cu W
Lean S32101 LDX 2101 Bal 21 1.5 0.5 0.16 0.5 - 25 450
S32304 2304 Bal 23 4 0.3 0.16 0.3 - 26
S32003 Al 2003 Bal 20 3 1.7 0.16 - >30
Standard S31803 2205 Bal 22 5 3 0.16 - - 35 450

22Cr DSS
S32205 Bal 22 5 3.2 0.16 - - 35
Superduplex S32750 SAF 2507 Bal 25 7 3.5 0.27 0.2 - >40 550
SDSS S32760 Zeron 100 Bal 25 7 3.5 0.25 0.7 0.7 >40
S32520 UR52N+ Bal 25 7 3.5 0.25 1.5 - >40
S39274 DP3W Bal 25 7 3 0.26 0.5 2 >40
Hyperduplex S33207 SAF 3207HD Bal 32 7 3.5 0.5 >50 750
Table A.4 – PREN calculated for main austenitic and duplex stainless steel.
PREN
UNS Type Material
min max nominal
Austenitic 316L
S31603 24 29 25
Stainless Steel
S31803 Duplex (22Cr) 31 38 35
2205
S32205 Stainless Steel 34 38 35
S32750 2507 38 44 42
S32760 Superduplex Zeron 100 40 46 44
S32520 Stainless Steel 52N+ 37 48 44
S39274 DP3W 39 47 44
S32304 Lean duplex 2304 24 30 25
S32101 Stainless Steel LDX 2101 29 32 30
Hyper duplex
S32707 2707 - - 49
Stainless Steel
S31254 6Mo High-Alloy 6Mo (254SMO) 42 45 43
Austenitic Stainless
S32654 Steel 654SMO - - 54
High-Alloy Austenitic
N08904 904L 32 40 35
Stainless Steel
Rev. 1 – May 2011
Sh. 60 of 62
Table A.5 – Martensitic stainless steels

Common C max Cr Ni Mo Mn Si P S N Other
UNS
name % % % % max% max% max% max% % %
11.5-
S41000 410 0.15 - - 1 1 0.04 0.03 -
13.5
12.0- 0.06-
S41425 S/W 13Cr 0.05 4-7 1.5-2 0.5-1 0.5 0.02 0.005 Cu0.3
15.0 0.12
11.5- Ti0.01-0.05;
S41426 S13Cr 0.03 4.5-6.5 1.5-3 0.5 1 0.02 0.005 - V0.5
13.5
S42000 420 0.15 12-14 - - 1 1 0.04 0.03 - -
S42400 F6NM 0.06 11.5-14 3.5-4.5 0.3-0.7 0.5-1 1 0.03 0.03 - -
Nb0.15-0.45
S17400 17-4PH 0.07 14-16 6.5-7.75 1 - 1 0.04 0.03 - Cu3-5
J91150 CA 15 0.15 11.5-14 1 0.5 1 1.5 0.04 0.04 - -
J91151 CA 15M 0.15 11.5-14 1 0.15-1 1 1 0.04 0.04 - -
J91540 CA6NM 0.06 11.5-14 3.5-4.5 0.4-1 1 1 0.04 0.03 - -
Table A.6 – Nickel based alloys

Common C max Cr Ni Mo Nb Fe Mn Si P S Other
UNS
name % % % % % max% max% max% max% max% %
N06625 Alloy 625 0.1 20-23 Bal. 6-9 3.15- 5 0.5 0.5 0.04 0.03
4.15
N08825 Alloy 825 0.05 19.5- 38-46 2.5-3.5 - Bal. 1 0.5 0.03 Ti0.6-1.2
23.5
W3-4.4
N06686 Alloy 686 0.01 19-23 Bal. 15-17 - 5 0.75 0.08 0.04 0.02 Ti0.02-0.25
15.5- W3-4.5
N10279 Alloy C-276 0.12 Bal. 15-17 - 4-7 1 0.08 0.03 0.03 V0.35
17.5
N07716 Alloy 716 0.03 19-22 57-63 7-9.5 2.75-4 Bal. 0.2 0.2 0.015 0.01 Ti1-1.6
N07718 Alloy 718 0.08 17-21 50-55 2.8-3.3 4.75-5.5 Bal. 0.35 0.35 0.015 0.015 Ti0.65-1.15
N07725 Alloy 725 0.03 18-27 45-60 2.5-5.5 2.75-4 Bal. 0.35 0.2 0.015 0.01 Ti1-1.7
Al0.4-1
N07750 Alloy X-750 0.08 14-17 70min - 0.7-1.2 5-9 1 0.5 - 0.01 Ti2.25-2.75
Cu bal.
N05500 Alloy K500 0.25 - 63-70 - - 2 1.5 0.5 - - Al2.3-3.15
Rev. 1 – May 2011
Sh. 61 of 62
APPENDIX B RESTRICTIONS IN H2S CONTAINING FLUIDS
In presence of H2S, the applicability of candidate materials for this environment (sour service) shall
be ensured. The governing code for application of materials in H2S-containg fluids is the NACE
MR0175 / ISO 15156 Standard which provides the material requirements and the application limits
for a large variety of materials. For convenience, the application environmental limits for the most
popular materials and various processing plant application as prescribed by the code are
summarised in the below table. Reference is here made to the code version in force at the time this
document is written, i.e. the 2009 2nd edition, and any updating in form of amendments, corrigenda
and new editions shall be used to update the limits reported in Table D.1.
In H2S-containg fluids, full compliance with the material requirements and the application limits
specified by NACE MR0175 / ISO 15156 is mandatory for a material selection to be in compliance
with the present ENI Standard. Furthermore, the additional limitations and amends apply:
• For martensitic stainless steels used for valve bodies and VBSM, the same limits specified
for generic component is recommended, unless it can be demonstrated that the part is
subject to pure compression stress only.
• The use of martensitic type 17-4PH for VBSM is not recommend in presence of H2S.
• The use of martensitic type 17-4PH for compressors shall be subject to positive
qualification testing at worst-case service conditions.
• The use of Inconel X-750 springs in in presence of H2S is not recommended.
Rev. 1 – May 2011
Sh. 62 of 62
Table B.1 – Environmental limits in H2S service for principal class of materials according to ISO
15156 / NACE MR0175 Second Edition 2009
H2S max. max T max Cl- Typ. YS

Materials Component min pH
bar psi °C mg/l ksi
Carbon and Low

generic no limit no limit no limit no limit no limit 52-65
alloy steels
generic 0.1 1.5
Martensitic SS
type 410 / F6NM / valve bodies no limit no limit no limit no limit 3.5 60-75
weldable SMSS
VBSM* no limit no limit
VBSM* 0.035 0.5 no limit no limit 4.5 90-105

17-4 PH M.SS
compressor
no limit no limit no limit no limit no limit
component
Duplex SS Generic 0.1 1.5 no limit no limit no limit 65
Superduplex SS Generic 0.2 3 no limit no limit no limit 80
no limit no limit no limit 50 no limit
Generic 1 15 60 no limit no limit

Austenitic SS
25-35
type 304/316
316L 0.1 1.5 150 1,000 4.0
316 0.1 1.5 93 5,000 5.0
Generic 1 15 66 no limit no limit

Austenitic SS
type S20910
VBSM* no limit no limit no limit no limit no limit
no limit no limit no limit 50 no limit
High-alloy austenitic 7 100 120 5000 no limit

(PREN > 40) Generic 30-35
type 904L (N08904) 3.1 45 150 5000 no limit
1 15 170 5000 no limit

High-alloy austenitic
(PREN > 40) generic 7 100 120 65’000 3.5
6Mo (N08926)
2 30 no limit
any part 14 200 204

PH Nickel Alloy
no limit no limit 90-135
types 718, 925
27 400 150
no limit no limit 135
10 150 no limit
any part 21 300 220

PH Nickel Alloy
no limit no limit 65-75
types 725, type 625+
41 600 204
no limit no limit 177

SS Nickel Alloy
any part no limit no limit no limit no limit no limit 35-75
types 625, 825
*Valve Bore Sealing Mechanism: gate/ball/plug, seat, choke trim

20603E01, Guidelines For Material Selection in O&G Processing Facilities - Jan 2011 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

20603E01, Guidelines For Material Selection in O&G Processing Facilities - Jan 2011 PDF

Uploaded by

Copyright:

Available Formats

eni spa

COMPANY TECHNICAL STANDARD

GUIDELINES FOR MATERIAL SELECTION IN OIL

Previous identification code

ENGINEERING COMPANY STANDARD

GUIDELINES FOR MATERIAL SELECTION IN OIL

1 Correction of Table B.1 TEMM TEMM TEMM 30/05/11

ENGINEERING COMPANY STANDARD

This document is property of Eni S.p.A. Exploration & Production Division.

The present document supersedes the former ENI Company Standards:

Rev.1 Correction of Table B.1

The typical classes of materials used in upstream processing include:

1.3 Document organization

Section 5 Provides guidance for material selection of miscellaneous components.

Ref./17/ 20369.PIP.MEC.FUN 3.5% Ni Steel Piping Welding

1.4.2 International standard

1.5 Symbols and abbreviations

FEED Front End Engineering Design

2. MATERIAL SELECTION PROCESS

2.2 Oil and gas process and utility facilities

Most typical utility/service units include:

2.3 Material selection as part of the Corrosion Integrity Management

Material selection is strictly related to the corrosion assessment, which covers:

The Material Selection Report should be structured as follows:

2.4 Corrosion threats identification

The corrosion threats in upstream hydrocarbon processing facilities may include:

− Galvanic (or bimetallic) corrosion,

2.5 Corrosion control methods

2.6 Material selection philosophy

− local legislation aspects,

2.7 Material options

2.7.1 Carbon and low alloy steels

Welding of carbon steel piping systems is straightforward; ENI Company Standard

2.7.2 Corrosion resistant alloys

Most typical use in processing facilities:

2.7.2.2 High-alloy austenitic stainless steels

Most typical use in processing facilities:

2.7.2.3 Duplex stainless steels

Duplex stainless steels are classified into the following types:

Most typical applications of duplex stainless steels in processing facilities include:

2.7.2.4 Martensitic stainless steels

Most typical applications of martensitic stainless steels in processing facilities include:

2.7.2.5 Nickel alloys

Most typical applications of nickel alloys in processing facilities include:

2.7.3 Other materials

2.7.4 Metal cladding and lining, weld overlay, hard facing

Most typical applications in processing facilities:

2.7.5 Non-metallic materials

Because of these considerations use of plastics should be restricted to non-critical service/utility

2.7.5.1 Plastic lining and coatings

2.7.5.2 Fiber reinforced plastic / Glassfiber reinforced epoxy

FRP/GRE products are covered by several standards, including:

The advantages of these materials are:

Temperature limitation are shown in the below table.

The use of thermoplastics is more typical for drainage systems.

3. MATERIAL SELECTION FOR PROCESSING UNITS

3.2 Options evaluation and costs comparison

Capital costs include the following costs:

Operating costs include the following costs:

3.3 Material selection procedure

STEP 6 Mechanical requirements. Exclusion of material options based on mechanical

3.4 Identification of viable materials options

Table 3.12 to Table 3.15 cover the following process-support systems: