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Metallic Materials - Prevention of Brittle Fracture in New Assets
Metallic Materials - Prevention of Brittle Fracture in New Assets
DEP 30.10.02.31-Gen.
February 2013
ECCN EAR99
DEM1
This document contains information that is classified as EAR99 and, as a consequence, can neither be exported nor re-exported to any country which is under an
embargo of the U.S. government pursuant to Part 746 of the Export Administration Regulations (15 C.F R. Part 746) nor can be made available to any national of such
country. In addition, the information in this document cannot be exported nor re-exported to an end-user or for an end-use that is prohibited by Part 744 of the Export
Administration Regulations (15 C.F.R. Part 744).
PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
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regional, national and industry standards.
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TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................ 4
1.1 SCOPE........................................................................................................................ 4
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 4
1.3 DEFINITIONS ............................................................................................................. 5
1.4 CROSS-REFERENCES ............................................................................................. 6
1.5 SUMMARY OF MAIN CHANGES ............................................................................... 6
1.6 COMMENTS ON THIS DEP ....................................................................................... 6
1.7 DUAL UNITS ............................................................................................................... 6
2. BRITTLE FRACTURE ................................................................................................ 7
3. DESIGN CODES ........................................................................................................ 7
4. DETERMINATION OF THE MINIMUM METAL TEMPERATURE AND LOWER
DESIGN TEMPERATURE .......................................................................................... 8
4.1 MINIMUM METAL TEMPERATURE (MMT) ............................................................... 8
4.2 LOWER DESIGN TEMPERATURE ............................................................................ 8
4.3 SPECIFIC CONSIDERATIONS FOR LIQUEFIED GAS ............................................ 9
4.4 SPECIFIC CONDITIONS FOR SUBSEA EQUIPMENT ........................................... 10
5. TOUGHNESS REQUIREMENTS ............................................................................. 10
5.1 GENERAL ................................................................................................................. 10
5.2 CARBON AND LOW ALLOY STEELS WITH LESS THAN 2 % NICKEL ................ 10
5.3 NICKEL-ALLOYED STEELS .................................................................................... 11
5.4 STAINLESS STEELS ............................................................................................... 12
6. MATERIALS SELECTION FOR PRESSURE EQUIPMENT ................................... 13
6.1 PRESSURE VESSELS DESIGNED AND CONSTRUCTED IN ACCORDANCE
WITH PD 5500 AND DEP 31.22.00.31-Gen............................................................. 13
6.2 PRESSURE VESSELS DESIGNED AND CONSTRUCTED IN ACCORDANCE
WITH ASME SECTION VIII DIVISION 1 OR 2 AND DEP 31.22.00.31-Gen. .......... 13
6.3 PRESSURE VESSELS DESIGNED AND CONSTRUCTED IN ACCORDANCE
WITH EN 13445 AND DEP 31.22.00.31-Gen........................................................... 13
6.4 HEAT EXCHANGERS .............................................................................................. 14
6.5 ROTATING EQUIPMENT ......................................................................................... 14
6.6 PROCESS PIPING ................................................................................................... 15
7. REFERENCES ......................................................................................................... 16
1. INTRODUCTION
1.1 SCOPE
This DEP specifies requirements and gives recommendations for the selection and
application of steels in order to prevent brittle fracture at low temperature, and is applicable
to new assets. This DEP applies irrespective of the contained fluids and covers low
temperatures caused both by climate and by the process operating envelope. In addition,
specific requirements are given for equipment containing liquefied gas.
Guidelines are given for steel selection on the basis of the Lower Design Temperature for:
• unfired pressure vessels;
• piping, piping components and valves (including control valves);
• rotating equipment;
• subsea equipment subjected to Joule Thompson cooling.
This DEP shall only be used within the context of the relevant design and construction
codes and the corresponding DEPs. See (3).
This DEP is not applicable to:
• fired heaters;
• transmission pipelines;
• vertical atmospheric storage tanks;
• steel structures.
This DEP contains mandatory requirements to mitigate process safety risks in accordance
with Design Engineering Manual DEM 1 – Application of Technical Standards.
This is a revision of the DEP of the number dated February 2011; see (1.5) regarding the
changes.
1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The capitalised term SHALL [PS] indicates a process safety requirement.
The word should indicates a recommendation.
1.3.2 Specific definitions
Term Definition
Adiabatic Flash The lowest temperature a liquid reaches, when a given quantity of a
Temperature mixture is adiabatically depressurised to atmospheric pressure.
(AFT)
Atmospheric The temperature at which the vapour pressure throughout the bulk of the
Boiling Point liquid exceeds the atmospheric pressure.
(ABP)
Equipment In the context of this DEP, any unfired vessel, column, reactor, heat
exchanger, pump, compressor, piping or part thereof under internal or
external pressure. Fired heaters, vertical atmospheric storage tanks,
steel structures and transmission pipelines are excluded from this
definition.
General The tensile component of the general primary stress resulting from
Membrane sustained loadings, such as internal and external pressures, static head,
Stress own weight and wind loading. The general membrane stress is averaged
over the thickness of the structure and it determines the elastic stored
energy in the wall of the equipment. In design or assessment of piping
systems, stresses due to thermal constraints contribute to the general
membrane stress.
Liquefied Gas A product which is gaseous at ambient temperature and atmospheric
pressure, but is maintained in a liquid state by means of pressure or
refrigeration, or a combination of the two.
Lowest Ambient The lowest one day mean ambient temperature on the basis of
Temperature meteorological data of hourly measurements over the last 20 years, or
(LAT) longer. The LAT shall not be warmer than the lowest ambient
temperature to be used for design under the local regulations.
Lower Design The lowest temperature at which equipment may be subjected to its
Temperature design pressure; LDT is further described in (4.2).
(LDT)
Minimum Metal The lowest temperature that equipment may possibly attain; MMT is
Temperature further described in (4.1).
(MMT)
1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets. Other documents referenced by this DEP are listed in (7).
Section Change
3 updated reference to design codes and pressure vessel DEPs
4.4 added new section “Specific conditions for subsea equipment”
Feedback that has been registered in the DEP Feedback System by using one of the above
options will be reviewed by the DEP Custodian for potential improvements to the DEP.
2. BRITTLE FRACTURE
Prevention of brittle fracture of steel equipment is largely a matter of design. The design
codes which are covered specifically by this DEP are PD 5500, ASME Section VIII
Division 1 or 2 and EN 13445 for pressure vessels, and ASME B31.3 for piping.
PD 5500 and EN 13445-2 Annex B allow the application of a fracture mechanics analysis
as an alternative method to assess the required fracture toughness. Such analyses are not
covered by this DEP. However, the rules for the assessment of the Lower Design
Temperature in this DEP remain valid and designs based on fracture mechanics analysis
shall be approved by the Principal.
Possibilities for embrittlement of materials during service are generally not addressed
directly by the design codes. Nevertheless, material qualification and fabrication practices
shall follow appropriate industry standards to ensure that the potential effects of
embrittlement in service are taken into account in design.
If equipment or piping is susceptible to crack growth in service, for example where
significant cyclic loading applies, the appropriate procedures of the design code shall be
applied in addition to the requirements of this DEP.
3. DESIGN CODES
For pressure vessels, including heat exchangers, the design codes are:
• PD 5500;
• ASME Section VIII Divisions 1 and 2;
• EN 13445
In combination with DEP 31.22.00.31-Gen.
For piping systems, the design code is ASME B31.3, plus DEP 31.38.01.11-Gen.
For rotating equipment, the following DEPs and the associated ISO or API standards refer
to the above pressure vessel design codes for the design of the pressure retaining casings,
and the requirements of this DEP apply thereto.
a) DEP 31.29.02.30-Gen.
b) DEP 31.29.06.30-Gen.
c) DEP 31.29.12.30-Gen.
d) DEP 31.29.40.30-Gen.
e) DEP 31.29.40.31-Gen.
f) DEP 31.29.40.32-Gen.
For equipment governed by standards and design codes other than those defined above,
the Contractor shall develop supplementary specifications to arrive at equivalent prevention
of brittle fracture. This specification shall be subject to the approval of the Principal.
allowed if the General Membrane Stress for temperatures colder than the LDT is below
2
50 N/mm (7250 psi).
The reductions in lower design temperature allowed on the basis of reduced design
stresses relative to the maximum code allowable stress shall only be used when approved
by the Principal. In addition, such reductions in LDT shall be limited to a maximum
temperature credit of 50 °C (90 °F) unless a greater temperature reduction established in
accordance with the code is justified on the basis of a fracture mechanics analysis using
internationally recognized guidances/practices and approved by the Principal.
Any design with a LDT warmer than the MMT shall have a process whereby the pressure in
2
the system is physically limited such that the general membrane stress is below 50 N/mm
(7250 psi) at all temperatures colder than LDT. Any such design shall have homogeneous
processes and equipment temperatures. Any possibility for re-pressurisation or
pressurisation from connected systems, whilst the equipment is colder than the LDT,
SHALL [PS] be excluded.
Instrumented protective systems which disable re-pressurisation by forced opening of the
depressuring valve or forced closure of valves separating connected systems, during the
time the equipment is colder than the LDT, shall be considered.
The LDT shall be explicitly recorded on materials selection diagrams and on equipment
data sheets. If the MMT is colder than the LDT both temperatures shall be recorded.
If the LDT is above the LAT, then no strength pressure test is allowed when the equipment
temperature is lower than the LDT. Minimum hydrotest temperatures shall be specifically
reviewed when LDT is above LAT and shall not be colder than 7 °C (45 °F) unless allowed
by the design code and approved by the Principal.
Embrittlement of low-alloy steels in service above 370 °C (698 °F) may increase the lowest
temperature at which equipment can be subjected to its design pressure. Preventive
measures given in DEP 31.22.00.31-Gen. Appendix 4shall be applied in the design and
fabrication of all susceptible equipment and piping.
5. TOUGHNESS REQUIREMENTS
5.1 GENERAL
Steels shall be impact tested at the lowest temperature for which the standard specification
specifies the toughness. Where the standard specification specifies a range of absorbed
energy values at different temperatures - such as in European EN standard specifications -,
impact tests can be conducted at a higher temperature corresponding to the impact energy
required by the design code. In all cases, the impact test temperature in the specification
should be minus 20 °C (-4 °F) or colder unless otherwise specified by the Principal.
If a standard specification, which specifies the required toughness, is not available, the
Principal shall approve the use of steel produced with a prior guarantee by the steel maker
to meet the required toughness. Qualified welding procedure specifications shall be
available to prove that the impact toughness of the weld and heat affected zone of the
non-standard steel meet the specific impact toughness requirement.
The possibilities offered by the design codes for a lesser impact toughness for the steel and
the welds at the Lower Design Temperature, when the design stress is reduced relative to
the maximum design stress allowed by the code, shall only be used when approved by the
Principal. The hydrostatic test pressure in these cases shall be equal to the hydrostatic test
pressure required by the code on the basis of the maximum allowable design stress.
Particular cases for rotating equipment and for flare lines are discussed in (6.5) and (6.6).
5.2 CARBON AND LOW ALLOY STEELS WITH LESS THAN 2 % NICKEL
Applications at Lower Design Temperatures for which the design code requires an impact
test temperature colder than minus 60 °C (-76 °F) for thicknesses up to 50 mm (2 in) and
minus 50 °C (-58 °F) for larger thicknesses, require experimental verification on the basis of
fracture mechanics and shall be approved by the Principal.
Where post-weld heat-treatment is applied to enable the use of steels for lower
temperatures than allowed in as-welded condition, the temperature of the post-weld heat-
treatment shall be higher than 580 °C (1076 °F). Thermo-mechanically processed steels
with a lean chemical composition may lose their strength at a high post-weld heat-treatment
temperature and the steelmaker may not support heat treatment at 580 °C (1076 °F).
A minimum heat-treatment temperature colder than 580 °C (1076 °F) is only allowed if the
Manufacturer demonstrates that welding residual stresses after PWHT are sufficiently low
or that the integrity of the component is not adversely affected by the higher welding
residual stress levels that could result from the lower PWHT temperature. This justification
shall be approved by the Principal.
The impact toughness of carbon steels, high-strength or low-alloy steels in quenched and
tempered or in thermo-mechanically treated condition can be affected by forming and heat
treatment during fabrication of the equipment, as properties like strength and hardness can
be affected. Steels shall be ordered from the steelmaker with additional specified
requirements to ensure that the required impact toughness is maintained for the full range
of forming and heat treatment procedures during fabrication, except for:
• steels with a normalised microstructure and a minimum specified tensile strength
2
below 500 N/mm (72,500 psi); or
• steels which are tempered at the mill at a temperature which is 30 °C (54 °F) or more
above the maximum of the range of heat-treatment needed during fabrication.
For the steels which require the above additional specification, the allowed heat treatment
conditions during fabrication shall be stated in the steel certificate. Welding procedures
shall be qualified accordingly.
Typical bolting materials are listed in DEP 30.10.02.11-Gen. Bolting materials, other than
the austenitic stainless steel materials in (5.4) which are applied for equipment with a Lower
Design Temperature colder than –30 °C (-22 °F), shall have been manufactured in
accordance with a specification which requires impact testing at a temperature not warmer
than the Lower Design Temperature.
Impact tested steels shall be used for all equipment designed to contain liquefied gas and
excludes any exemption curve or low stress arguments unless agreed by the Principal.
The steel toughness shall meet the requirements of the design code for the given Lower
Design Temperature, but the impact test temperature of the steel shall not be warmer than
–20 °C (-4 °F).
procedure qualification for nickel-base weld metals in Ni alloyed steels shall include impact
testing of the centre of the weld metal at -196 °C (-321 °F) to prove that the absorbed
energy is greater than 65 J (48 ft-lb). Special care must be taken to demonstrate the use of
appropriate inspection techniques, owing to the inherent difficulties posed for defect
detection by high strength steels.
Non-impact tested carbon steels shall not be used below -48 °C (-54 °F) unless approved
by the Principal.
The reductions in lower design temperature allowed in EN 13445-2 on the basis of reduced
design stresses relative to the maximum code allowable stress shall only be used when
approved by the Principal. (Refer to Table B.2-12, EN13445:2009.)
piping will be mainly absorbed by the piping and not by the rotating equipment. This is
feasible if the minimum load bearing thickness of the relevant parts of the rotating
equipment is designed sufficiently greater than the wall thickness of the piping connected
to it.
7. REFERENCES
In this DEP, reference is made to the following publications:
NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.
SHELL STANDARDS
DEP feedback form DEP 00.00.05.80-Gen.
Metallic materials – Selected standards DEP 30.10.02.11-Gen.
Metallic materials - prevention of brittle fracture in existing assets DEP 30.10.02.50-Gen.
Unfired pressure vessels DEP 31.22.00.31-Gen.
Axial, centrifugal and expander pumps (amendments/supplements DEP 31.29.02.30-Gen.
to ISO 13709:2009)
Centrifugal submerged motor pumps and electro submersible DEP 31.29.06.30-Gen.
hydraulic turbines
Reciprocating positive displacement pumps and metering pumps DEP 31.29.12.30-Gen.
(amendments/supplements to API 674 and API 675)
Axial, centrifugal, and expander compressors DEP 31.29.40.30-Gen.
(amendments/supplements to API Std 617)
Reciprocating compressors (amendments/supplements to DEP 31.29.40.31-Gen.
API Std 618)
Rotary-type positive displacement compressors DEP 31.29.40.32-Gen.
(amendments/supplements to API 619)
Piping – General requirements DEP 31.38.01.11-Gen.
Selection of materials for lifecycle performance (Upstream DEP 39.01.10.11-Gen
Facilities) Materials selection process
Design Engineering Manual DEM 1 – Application of Technical DEM 1
Standards http://sww.manuals.shell.com/HSSE/
AMERICAN STANDARDS
Process piping ASME B31.3
ASME Boiler and Pressure Vessel Code:
Section II: Materials – Part C: Specifications for welding rods,
electrodes and filler metals:
- Specification for nickel and nickel alloy welding for shielded ASME Section II
metal arc welding C-SFA 5.11
- Specification for nickel and nickel-alloy bare welding ASME Section II
electrodes and rods C-SFA 5.14
Section VIII Div. 1: Rules for construction of pressure vessels ASME Section VIII, Div. 1
Section VIII Div. 2: Alternative rules for construction of pressure ASME Section VIII, Div. 2
vessels
BRITISH STANDARDS
Specification for unfired fusion-welded pressure vessels PD 5500:2009
EUROPEAN STANDARDS
Unfired pressure vessels EN 13445
Unfired pressure vessels, Part 2: Materials EN 13445-2:2009
Metallic Industrial Piping Part 2 EN 13480-2
INTERNATIONAL STANDARDS
Centrifugal pumps for petroleum, petrochemical and natural gas ISO 13709:2009
industries
Welding consumables – Covered electrodes for manual metal arc ISO 14172
welding of nickel and nickel alloys – Classification
Welding consumables – Solid wire electrodes, solid strip ISO 18274
electrodes, solid wires and solid rods for fusion welding of nickel
and nickel alloys — Classification - Second Edition