Professional Documents
Culture Documents
SP-2041
Document Type
Specification
Security
Unrestricted
Discipline
Owner
Issue Date
Version
20 February 2014
4.0
Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any
part of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in
any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written
consent of the owner.
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CP-117
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TABLE OF CONTENTS
i
Document Authorisation................................................................................................................... 3
ii
iii
iv
Introduction ...................................................................................................................................... 7
1.1
Scope ............................................................................................................................................... 7
2.1
2.2
2.3
2.4
3.2
Definitions .................................................................................................................................. 9
4.2
4.3
4.4
4.4.1
4.4.2
4.4.3
Examinations .......................................................................................................... 11
4.4.4
4.4.5
Manufacturing Process........................................................................................... 12
4.4.6
4.5
5
Purpose ...................................................................................................................................... 7
5.2
Retesting .................................................................................................................................. 13
5.3
5.4
The following minimum acceptance criteria for HIC for sour service vessels shall apply. ................ 13
5.5
5.6
Acceptance criteria:.................................................................................................................. 14
6.2
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10
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Introduction
1.1 Purpose
The purpose of this specification is to define additional requirements to other company
specifications (SPs), Shell DEPs and MESC SPEs, and International Standards for materials in
SOUR service environments. This specification also addresses some of the roles and
responsibilities of projects, function, designers, contractors and vendors to ensure materials are
designed, manufactured, procured and constructed to meet Company specified technical
requirements within agreed delivery period.
This Specification is intended for use by Petroleum Development Oman LLC (PDO), its
Contactors/Subcontractors and Design Consultants and vendors for all PDO equipment and
facilities, some of the equipments are covered below:
a)
b)
c)
d)
e)
f)
g)
h)
Scope
This specification shall be applied in addition to other Company, Shell and international technical
specifications for all materials used in sour service environment as defined in DEP 30.10.02.15Gen and ISO 15156.
This specification shall be read in conjunction with other Company, Shell and International
Technical Specifications such as DEP 39.01.10.11-Gen, 39.01.10.12-Gen, DEP 31.22.00.31Gen, DEP 31.40.20.37-Gen, DEP 30.10.02.15-Gen, DEP 30.10.02.16-Gen, NACE TM0284;
NACE TM0177 and ISO 15156-1/2/3.
This specification is intended to cover H2S related environmental cracking mechanisms
SSC,SOHIC,SWC/HIC, CSCC, and not intended to cover other threats caused by H2S
environments such as pitting, crevice or general corrosion.
In case of any conflict between this specification and other standards the most stringent
requirements shall apply.
2.2
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2.4
Effective period
The requirements of this specification shall remain in force indefinitely unless superseded by an
authorized revision.
3.1
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Abbreviated terms
CRA
CS
Carbon Steel
CLR
CSR
CTR
DEP
EFC
ERW
GHSC
HIC
H2S
Hydrogen Sulfide
HFI
ILAC
ISO
ITP
MESC SPE
NACE
SSC
SWC
Stepwise Cracking
SZC
SOHIC
SP
Specification
SCC
TA
Technical Authority
UKAS
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Definitions
Company
Shall
Should
SHALL [PS]
Material requirements
The definition of sour service shall be as stated in 3.19 of ISO 15156-1 as indicated by DEP
Specification 30.10.02.15-Gen.
Therefore the requirements of this specification, and DEP Specification 30.10.02.15-Gen, shall
be applied when design estimates, or measured operating conditions, identify any level of H 2S
above detectable limits. Unless explicitly specified, the permitted exclusions of Table 1 in ISO
15156-2 and ISO 15156-3 shall not be applied.
HIC testing shall apply to all product forms of carbon steel system components when specified
in the applicable manufacturing or supply standard. Where HIC testing is left optional (not
specified in the product specification), supplementary HIC testing shall be carried out when a
risk assessment results in a medium or high risk ranking within the PDO risk assessment matrix
as per the following criteria:
-
For carbon steel equipment operating continuously above 65C HIC testing is not required.
Design documents shall identify the service conditions as Sour or Non Sour. Sour Service
shall be specified in the Purchase requisition/ ITP, Manufacturing procedure.
Carbon steel shall be designed and manufactured from the melting, casting and mechanical
working stage to meet the sour service and HIC requirements by controlling the chemistry and
microstructure. Original materials (Mill) MTC shall indicate materials compliance with sour
service and HIC testing.
Clause A.2 of ISO 15156-2 shall apply to all carbon steel items designated as being in Sour
Service. SSC Regions of ISO 15156-2 shall not be applied.
4.1
4.2
Chemical composition
Carbon steel materials used in sour service shall not have Sulphur content more than 0.002%
mass fraction for flat rolled products, 0.01% mass fraction for seamless products, 0.025% mass
fraction for forged components and there is no limit on castings.
Sulphur content in pipeline flanges shall be in line with ISO 15590-3.
Specific equipments shall comply with relevant DEPs or MESC SPEs or International Standards
if they are more stringent.
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Line pipe
Carbon steel line pipe materials which are not listed in ISO15156-2 Table A.2 shall not be used
in sour service. Qualification of un-listed materials by testing is not acceptable.
CS - ERW/HFI line pipe
For severe sour service (SSC Region 3 as defined in section 7.2.1.2 of ISO15156-2), ERW/HFI
line pipe shall be limited to material grades not higher than Gr. L360 (API 5L Gr. X52).
ERW/HFI pipe shall not be permitted for use as on plot piping in sour service.
4.4
4.4.1
Chemical Composition
Chemical composition (product analysis) of the plates for vessels/ heat exchangers in sour
service shall be in accordance with Table 1 below, except where the standard material
specification or the appropriate limit specified in Table 1 of ASME SA-20 whichever is more
restrictive. Other components such as nozzles, pipes, flanges, fittings etc shall meet applicable
MESC SPEs requirements.
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MAXIMUM %
Carbon
0.20
Manganese (Mn)
1.30
Phosphorous (P)
0.010
Sulphur (S)
0.0020
Silicon (Si)
0.40
Copper (Cu)
0.40
Nickel (Ni)
0.40
Chromium (Cr)
0.30
Molybdenum (Mo)
0.12
Vanadium (V)
0.020
Niobium (Nb)
0.020
Titanium (Ti)
0.020
Boron (B)
0.0010
MULTIPLE ELEMENTS:
Cr + Mo
0.30
Ni + Cu + Cr + Mo
0.80
V+Nb
0.03
0.43
0.45
0.48
NOTES:
4.4.2
1.
2.
The micro-alloying elements boron (B), titanium (Ti), niobium (Nb) and vanadium (V)
shall not be intentionally added to the steel, unless the Principal has given prior
approval. Chemical analysis results and carbon equivalent shall be reported in a
material test report (MTR).
Mechanical Properties
All plates shall have a tensile strength of less than 585 MPa (85,000 psi)
4.4.3
Examinations
All plate shall be subjected to an ultrasonic lamination check in accordance with EN 10160,
quality classes S2 (plate) E3 (Edge), or ASME SA-578, acceptance Level A, (ASME SA-578
Supplementary requirement S1 shall be applied) or JB 4730, whichever specification is applied.
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4.4.5
Manufacturing Process
The steel shall be vacuum-treated, fully deoxidised, desulphurised and dephosphorised. The
manufacturing/rolling process shall be such that a homogeneous microstructure is obtained.
Calcium treatment shall be applied for inclusion shape control, except that it need not be
applied to plate with very low sulphur levels (below 0.001%). The calcium content should not
exceed 3 times the sulphur content. Alternative methods of inclusion shape control shall be
subject to the approval of Company .
4.4.6
Heat Treatment
Normalised, Normalised & Tempered, NACT (Normalised accelerated cooling and tempered)
and Quenched & Tempered shall be the only acceptable heat treatment processes for vessel
plates.
4.5
Clad/weld overlay
Clad/weld overlay shall not be considered as an SSC barrier. The base carbon steel material
shall meet sour service requirements as stated in this specification with the exception of HIC
testing.
5.1
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5.2
For each purchase order only one test laboratory shall be used for testing.
Retesting
Retesting of the failed heat shall not be permitted. The failed heat shall be rejected.
For line pipe manufacturing, when a heat has failed HIC test as part of quality control program,
testing of two additional heats (one before and one after the failed heat) shall be carried out.
Both of these heats shall pass the HIC test. If one or both of these tests fail the previous ten
heats shall be tested and only passed tests shall be accepted.
5.3
5.4
Pressure vessels
The following minimum acceptance criteria for HIC for sour service vessels shall apply.
Table 2: Acceptance criteria sour service shall be as follows:
% maximum)
CLR
CTR
CSR
15
The maximum individual crack length on any section shall not exceed 5 mm.
If any specimen fails to meet any of the above acceptance criteria, the heat of steel
represented by the test shall be rejected.
For vessels operating with H2S in the gas above 5 %, the following acceptable criteria shall be
considered.
Table 3: Acceptance criteria wet conditions, >5 % of H2S in gas phase.
% maximum)
CLR
CTR
CSR
10
Single
12
1.5
The maximum individual crack length on any section shall not exceed 5 mm.
If any specimen fails to meet any of the above acceptance criteria, the heat of steel represented
by the test shall be rejected.
5.5
Pipeline steel
Acceptance criteria shall be in accordance with DEP 31.40.20.37-Gen.
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Acceptance criteria shall be in accordance with the relevant MESC SPEs and requirements of DEP
30.10.02.16-Gen.
Test
Method
Applied tensile
stress
or
FPB
H2 S
partial
pressure
(Constant load)
UT
All SSC regions
of figure 1 of
ISO 15156-2:09
Environment
90%AYS
or
CR
NACE TM0177-05
Environment
A
(5% mass fraction
NaCl + 0.5% mass
fraction
CH3COOH)
Welded sections shall be tested by FPB except longitudinal welds in pipes with 6 ND where CR
tests are applicable.
Test Temperature: The temperature shall be maintained at ambient (24 deg C 3 deg C) as this
is the worst case expected in service for the occurrence of SSC in carbon and low alloy steels.
UT : Uniaxial Tensile test in accordance with NACE TM0177-05, Method A
FPB: Four Point Bend test is in accordance with EFC Publication 16, Appendix 2
CR : C-ring test in accordance with NACE TM0177-05, Method C
AYS : Actual Yield Stress
ND: Nominal Diameter
6.1
Acceptance criteria:
No cracks are acceptable
6.2
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Scope of work for SSC/SCC testing shall be reviewed and approved by function Company
Materials & Corrosion Engineer CFDH prior to placement of the order.
Quality Management
All equipment / components intended for sour service shall be manufactured and constructed to
meet the requirements of ISO 29001. ITP requirements shall be stated in the purchase
specification. For Sour Service, ITP shall be in place and the company/ TPI interventions
(witness/ review and monitoring stages) as per the equipment criticality rating.
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Contractor/Manufacturer
Ensure that the inspector (TPI) deployed is competent to perform the required activities
and conversant with testing standards / inspection test procedure.
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TPI to review the laboratory certification approval covers the testing scope.
TPI Shall not deviate from the Company approved Inspection & Test Plans (ITP) without
formal written approval from Company Function/Quality Assurance CFDH.
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10 Appendix 2: References
In this specification, reference is made to the following publications:
PDO Standards
Technical Authorities System
SP 2061
SP-1171
DEP 31.22.00.31-Gen
DEP 64.51.01.31-Gen
International Standards
Standard Test Method: Evaluation of Pipeline and Pressure Vessel
Steels for Resistance to Hydrogen-Induced Cracking
NACE TM 0284
NACE TM0103
NACE TM0177
NACE TM0103
ISO 15156-part 1, 2
and 3
ISO 3183
ISO 15590-3
ISO 10474
EFC16
EFC17
ISO 29001
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DNV-RP-G101
Heading Number:
Figure Number:
Comments:
Suggestions:
Ref.
Signature:
Date:
Ind.:
Phone:
Document Control Section Actions
Comment
Date:
CFDH
Number:
Ref. Ind.:
Recd.:
To CFDH:
CFDH Actions
Recd.
Decision:
Date:
Reject:
Accept, revise at next issue:
Accept, issue temporary amendment
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Inits.:
Ref.
Date:
Ind.:
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Originator
Date:
Advised:
Inits.:
Document
Control
Date:
Inits.:
Section
Advised:
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