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Project / Initiative name ZOHR DEVELOPMENT PROJECT

ADDITIONAL MATERIAL AND FABRICATION REQUIREMENTS FOR SEVERE
Document Title SERVICES
This document deals with material and fabrication requirements for metallic material in sour, amine and
caustic services.
ABSTRACT

Document Verification
Prepared by Signature Date
Quattrocchi, Mara 17-12-2015

Checked by Signature Date

Contractor

Paci, Giulio 17-12-2015

Approved by Signature Date

Paci, Giulio 17-12-2015

Verified by Unit Signature Date

Interdisciplinary
Company

Review

Verified by Unit Signature Date

Verified by Unit Signature Date

Checked by Unit Signature Date

Company
Checked

Checked by Unit Signature Date

Approved by Unit Signature Date

Approved
Company

Endorsed by Unit Signature Date

This document is property of Eni S.p.A.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
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REVISION LIST
00 Issued for Information
01 Final Issue

HOLD RECORD

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It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
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TABLE OF CONTENTS

1.0 SCOPE OF THE DOCUMENT .......................................................................................................................... 5

2.0 APPLICABLE DOCUMENTS ............................................................................................................................ 6
3.0 ABBREVIATIONS AND DEFINITIONS .......................................................................................................... 7
3.1 ABBREVIATIONS ................................................................................................................................................ 7
3.2 DEFINITIONS ...................................................................................................................................................... 7
4.0 ADDITIONAL REQUIREMENTS FOR MATERIALS IN SOUR SERVICE .............................................. 8
4.1 GENERAL ........................................................................................................................................................... 8
4.2 DEFINITIONS ...................................................................................................................................................... 8
4.3 CARBON STEEL PLATES ..................................................................................................................................... 8
4.4 CARBON STEEL FORGING ................................................................................................................................... 9
4.5 CARBON STEEL SEAMLESS PIPE ......................................................................................................................... 9
4.6 CARBON STEEL SEAMLESS FITTING ................................................................................................................. 10
4.7 CARBON STEEL WELDED PIPES AND FITTINGS (FOR PIPING SYSTEM COMPONENTS ONLY) ............................... 10
4.8 TUBES .............................................................................................................................................................. 10
4.9 BOLTS AND NUTS ............................................................................................................................................. 10
4.10 CARBON STEEL CASTING ................................................................................................................................. 10
4.11 FABRICATION AND WELDING REQUIREMENTS .................................................................................................. 10
5.0 ADDITIONAL REQUIREMENTS FOR AMINE SERVICE ........................................................................ 12
5.1 AMINE SERVICE ............................................................................................................................................... 12
6.0 ADDITIONAL REQUIREMENTS FOR CAUSTIC SERVICE .................................................................... 12
6.1 CAUSTIC SERVICE ............................................................................................................................................ 12

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1.0 SCOPE OF THE DOCUMENT

This document descibes the additional material and fabrication requirements for metallic materials operating
in severe service for ZOHR Onshore Plant. It applies to, but it is not limited, to the following:
• Static Equipment;

• Plant piping and valves.

Rotating machinery are excluded in the scope of this document. Manufacturers shall comply with
requirements included in the applicable international standard and will include proposed materials as well as
all relevant information about H2S resistance in its proposal for contractor’s review and acceptance.
Process datasheet shall clearly outline the amount of H2S that may be present including traces, as well as
species which may promote stress corrosion cracking.
This document is also not applicable for items included inside the packages with excemption of MEG
Regeneration.

This document is property of Eni S.p.A.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
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2.0 APPLICABLE DOCUMENTS

• ANSI/NACE MR0175/ISO 15156 (Latest Edition) – Petroleum and Natural gas industries – Material
for use in H2S – containing environments in oil and gas production;

• NACE TM0284 – Standard Test Method – Evaluation of Pipeline and Pressure Vessel Steels for
Resistance to Hydrogen - Induced Cracking.

• API 945 Recommended Practice – “Avoiding Environmental Cracking in Amine Unit” third Edition,
June 2003 Reaffirmed April 2008;

• NACE SP0403-2008 Approved 2003-11-14 Reaffirmed 2008-02-11 - Avoid Caustic Stress Corrosion
Cracking.

The above Recommended Practices and Standard Practices shall be considered applicable for the
purpose of this project, prescriptions clearly stated in the following pages shall be considered as
mandatory.

This document is property of Eni S.p.A.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
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3.0 ABBREVIATIONS AND DEFINITIONS

3.1 Abbreviations
The following abbreviations may be used in this document.

ANSI American National Standard Institute

API American Petroleum Istitute
ASME American Association Mechanical Engineers
ASTM American Society Testing and Material
CE Carbon Equivalent
CLR Cracking Length Ratio
CRA Corrosion Resistant Alloy
CSR Cracking Sensitivity Ratio
CTR Cracking Transverse Ratio
HIC Hydrogen Induced cracking
HRC Hardness Rockwell C
H2S Hydrogen Sulphide
NACE National Association Corrosion Engineers
PWHT Post Weld Heat Treatment
ISO International Standard Organization
SSC Sulphide Stress Craking
WPS Welding Procedure Qualification

3.2 Definitions
The following definition may be used in this document.

Company: ENI SPA – E&P Division

Contractor: SAIPEM SPA

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4.0 ADDITIONAL REQUIREMENTS FOR MATERIALS IN SOUR SERVICE

4.1 General
All materials shall be in compliance with chemistry, mechanical properties and heat treatment requirements
of ANSI/NACE MR0175/ISO 15156 all parts last edition and as modified in this chapter.

4.2 Definitions
Sour Service: Exposure to oilfield environments that contains H2S and can cause cracking of materials.
HIC (Hydrogen Induced Cracking): Planar cracking that occurs in carbon steel and low alloy steels when
atomic hydrogen diffuses into the steel forming molecular hydrogen in trapped points.
SSC (Sulphide Stress Cracking): Metal cracking involving anodic processes of localized corrosion and
tensile stress (residual and/or applied) in the presence of water and H2S.

4.3 Carbon Steel Plates

Material grade: ASME SA-516 gr 60 and 65 and shall be manufactured by the basic oxygen or electric arc
furnace.
Chemical analysis (product analysis) shall be in accordance with the applicable product standard and
addition shall be the following limitations:
• Carbon ≤ 0.23%;

• Sulphur ≤ 0.003%;

• Phosphorous ≤ 0.020%;

• Nickel ≤ 1%;

• Ti+Ni+V ≤ 0.3%;

• CE ≤ 0.43%;

where:
%𝑀𝑀𝑀𝑀 %𝐶𝐶𝐶𝐶 + %𝑀𝑀𝑀𝑀 + %𝑉𝑉 %𝑁𝑁𝑁𝑁 + %𝐶𝐶𝐶𝐶
𝐶𝐶𝐶𝐶 = %𝐶𝐶 + + +
6 5 15
The micro-alloying elements (B, Ti, Nb, V) shall not be intentionally added to the steel.
All materials shall be fully killed and fine grained. The steel shall be vacuum degassed and shall be supplied
in the normalized condition as a minimum requirement. The steel shall be calcium treated for inclusions
shape control, except for very low (≤ 0.001%) sulphur steel.
The minimum rolling reduction ratio of the plates shall be at least 4:1.
Plates material shall be inspected by ultrasonic examination for internal defects in accordance with ASTM
A578 – level A, including supplementary requirements S1 (100%) scanning.
HIC resistant requirements are mandatory for bare carbon steel operating in sour service.
HIC testing shall be performed following the NACE TM0284 by using solution A.
For plate material, one plate shall be tested for each plate thickness produced from each heat.
Acceptable criteria for HIC test are as follows (ANSI/NACE MR0175/ISO 15156):
• CLR ≤ 10%;
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• CTR ≤ 3%;

• CSR ≤ 1%;.
Carbon steel backing material of cladded or overlayed plates shall comply with the material requirements
reported above for bare carbon steel with the exception of the HIC testing.
Hardness requirements shall be as per ANSI/NACE MR0175/ISO 15156.
Whenever one of the above requirements are not satisfactory, plates are not acceptable. Supplier is fully
responsible for the test results.

4.4 Carbon Steel Forging

Material grade: ASME SA-105 or ASME SA-350 grade LF1/LF2 or ASME SA-266 class 1 or ASME SA-765.
Material shall be in the normalized condition as minimum requirement.
Chemical analysis (product analysis) shall be in accordance with the applicable product standard and
addition shall be the following limitations:
• Carbon ≤ 0.25%;

• Sulphur ≤ 0.025%;

• Nickel ≤ 1%;

• CE ≤ 0.43%;

where:
%𝑀𝑀𝑀𝑀 %𝐶𝐶𝐶𝐶 + %𝑀𝑀𝑀𝑀 + %𝑉𝑉 %𝑁𝑁𝑁𝑁 + %𝐶𝐶𝐶𝐶
𝐶𝐶𝐶𝐶 = %𝐶𝐶 + + +
6 5 15
No HIC test is required for carbon steel forgings.
Hardness requirements shall be as per ANSI/NACE MR0175/ISO 15156.

4.5 Carbon Steel Seamless Pipe

Material grade: ASME SA-106 grade B or ASME SA-333 grade 1 or 6.
Material shall be in the normalized condition as minimum requirement.
Chemical analysis (product analysis) shall be in accordance with the applicable product standard and
addition shall be the following limitations:
• Carbon ≤ 0.23%;

• Sulphur ≤ 0.01%;

• Nickel ≤ 1%;

• CE ≤ 0.43%;

where:
%𝑀𝑀𝑀𝑀 %𝐶𝐶𝐶𝐶 + %𝑀𝑀𝑀𝑀 + %𝑉𝑉 %𝑁𝑁𝑁𝑁 + %𝐶𝐶𝐶𝐶
𝐶𝐶𝐶𝐶 = %𝐶𝐶 + + +
6 5 15
No HIC test is required for carbon steel seamless pipes.
Hardness requirements shall be as per ANSI/NACE MR0175/ISO 15156.

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4.6 Carbon Steel seamless Fitting

Material grade: ASME SA-234 grade WPB or WPC or ASME SA-420 grade WPL6.
Fittings manufactured from plate or forging, shall be in accordance with paragraphs § 5.3 or § 5.4.
Hardness requirements shall be as per ANSI/NACE MR0175/ISO 15156.

4.7 Carbon Steel Welded Pipes and fittings (for piping system components only)
Welded pipe shall be in accordance with API 5L PSL2 or ASTM ASME SA-671 or SA-672 Gr. C65 or C60
Class 22.
Carbon steel material for welded pipes and fittings shall be in compliance with para. § 5.3 for plates. The
adoption of TMCP plates is not allowed.
Longitudinal welds shall be examined on their full length by ultrasonic examination or radiographic
examination in accordance with above applicable pipe material standard specification.
HIC testing is required for welded pipes and fittings made from plate.
Hardness requirements shall be as per ANSI/NACE MR0175/ISO 15156.

4.8 Tubes
Tubes material shall be in normalized condition and ASME SA-179 material is not permitted.

4.9 Bolts and Nuts

Bolts and Nuts will be as follows:

a) Material grade of Bolts: ASME SA-193 grade B7M or ASME SA-320 grade L7M;

b) Material grade of Nuts: ASME SA-194 grade 2HM or ASME SA-194 grade 7M;

Bolts shall be specified with hardness 22HRC maximum.

4.10 Carbon Steel Casting

Material grade: ASTM A216 grade WCB or grade WCC or ASTM A352 grade LCB or grade LCC.
Casting material shall be fully killed, fine grained and supplied in the normalized heat treatment condition as
minimum requirement.
Chemical analysis (product analysis) shall be in accordance with the applicable product standard and
addition shall be the following limitations:
• Carbon ≤ 0.23%;

• CE ≤ 0.43%;

where:
%𝑀𝑀𝑀𝑀 %𝐶𝐶𝐶𝐶 + %𝑀𝑀𝑀𝑀 + %𝑉𝑉 %𝑁𝑁𝑁𝑁 + %𝐶𝐶𝑢𝑢
𝐶𝐶𝐶𝐶 = %𝐶𝐶 + + +
6 5 15

No HIC test is required for castings.

4.11 Fabrication and welding requirements

Weldments shall be qualified and tested in accordance with ISO 15156.
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Dissimilar metal welds between any CRA and carbon or low alloy steels are not allowed for pressure-
containing welds.
Socket welds are not allowed.
PWHT for service is not required for cladded or overlayed plates for static equipment (unless required by the
design code).
PWHT for service is not required for piping system (but it may be required by design code).
Carbon steel material for static equipment, without corrosion resistant alloys shall be subject to PWHT at
minimum 620°C minimum for 1 hour/25,4mm (with a minimum soaking time of 1 hour). Using a lower
temperature for a longer period of time is not permitted; if lower PWHT temperatures or shorter times are
considered necessary by the manufacturer or fabricator, because of concerns with strength or impact
toughness, this shall be reviewed and agreed with Contractor.
All welding procedure qualifications shall be performed on coupons from base material exhibiting highest
carbon equivalent range.
Welding consumables containing more than 1% nickel are not acceptable.
Production hardness tests on pressure equipment or piping system welded joints shall be carried out after
the final heat treatment using portable hardness equipment on all carbon steel welds subject to pressure.
Portable Hardness equipment(s) shall comply with one of the following standard:
• Portable Brinell type hardness testing shall be performed in accordance with ASTM A833 and the
equipment manufacturer’s recommendations.
• Portable dynamic or rebound type hardness testing shall be performed in accordance with ASTM
A956 and the equipment manufacturer’s recommendations.
• Portable Ultrasonic Contact Impedance (UCI) Vickers hardness testing shall be performed in
accordance with ASTM A 1038 and the equipment manufacturer’s recommendations.
An adequate number of hardness tests shall be carried out both in the weld zone and in the heat affected
zone, whenever possible on the side contacted by the process.
The hardness value of 22 HRC shall not be exceeded.
The average of several readings may be taken into account for every homogeneous zone examined; every
zone shall be suitably levelled.
If the above values are exceeded, heat treatment will be repeated.
Hardness test (average of three (3) indentations) shall be done at least according to the following Table.
TEST LOCATION ALONG
EXTENTION
WELD JOINT
Static Equipment: each three (3) meter length and
(1) one (1) hardness test
Category “A” or “B” applicable WPS
one (1) hardness test on
joints representing all
nozzles up to OD ≤ 4” and
applicable WPS
Static Equipment:
three (3) hardness test on
Category “C” and “D” (except
joints representing all
tubesheet to shell/channel joints) 0° - 120° - 240°
(1) nozzles having 4” < OD ≤
12” and applicable WPS
four (4) hardness test on
joints representing all 0° - 90° - 180° - 270°
nozzles having OD >12” and
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applicable WPS
Static Equipment: at least four (4) hardness
Tubesheet to shell/channel joints test along each
(1)
circumferential weld joints
≤ 4” two (2) locations welding start/stop location and
(2)
Piping system 6” – 10” four (4) locations at a location 180° away from the
> 10” eight (8) locations start/stop locations.
Note:
(1) Weld joints category as per ASME VIII Div.I (para. UW-3 and Fig. UW-3) or ASME VIII Div.II
(Table 4.2.1 and Fig. 4.2.1).

(2) Weekly % of piping system welded joints to be tested shall be the following:
- 100% (as welded condition);
- 10% (Furnace PWHTed at the same time);
- 100% (Local PWHTed).

5.0 ADDITIONAL REQUIREMENTS FOR AMINE SERVICE

5.1 Amine Service

Carbon steel materials, including welding repairs, in contact with the amine solution shall be post weld heat
treated irrespective of the service temperature.
Material requirements and PWHT parameters shall be according to API 945 (latest Edition).

6.0 ADDITIONAL REQUIREMENTS FOR CAUSTIC SERVICE

6.1 Caustic Service

Carbon steel materials, including welding repairs, in caustic service shall be post weld heat treated and cold
formed parts shall be stress relieved, irrespective of the service temperature or concentration of caustic
solution.
PWHT/ stress relieving parameters shall be as per NACE STD SP0403-2008.

This document is property of Eni S.p.A.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.