Refining & Chemicals

GENERAL SPECIFICATION

Welding - Materials

GS RC WAM 011

Additional Requirements for pressure equipments

in Wet H2S Services

00 08/2012 Original issue

Rev. Date Subject of revision

This document is the property of DGRC. It must not be stored, reproduced or disclosed to others without written authorisation from DGRC.

This document is the translation of the official French version

 General Specification Date : 08/2012

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Contents

Foreword ........................................................................................................................ 3

1. Subject ..................................................................................................................... 3

2. Reference documents ............................................................................................. 3

2.1 Priority rules .................................................................................................................... 5
2.2 Deviations ....................................................................................................................... 5

3. Applicability ............................................................................................................. 5

4. General ..................................................................................................................... 6

5. Moderate wet H2S Service...................................................................................... 6

5.1 Carbon Steel Plate .......................................................................................................... 6
5.2 Carbon steel forgings, pipes, tubes and fittings ............................................................... 7

6. Severe wet H2S service .......................................................................................... 7

6.1 Carbon Steel Plate .......................................................................................................... 7
6.2 Carbon Steel forgings, pipes, tubes and fittings .............................................................. 8

7. Additional requirements for moderate and severe wet H2S services ................ 9
7.1 Welding ........................................................................................................................... 9
7.2 Post Weld Heat Treatment (PWHT) .............................................................................. 10
7.3 Production Weld Test Coupons ..................................................................................... 10
7.4 Non Destructive Examination ........................................................................................ 10
7.5 Tests on Raw Material .................................................................................................. 11
7.6 Bolting Material ............................................................................................................. 13

8. Hydrogen induced crack (HIC) testing ................................................................ 13

8.1 General ......................................................................................................................... 13
8.2 Acceptance criteria ....................................................................................................... 13
8.3 Reporting ...................................................................................................................... 14

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Foreword
Engineering Companies and Design Offices that are contractually bound to TOTAL, are obliged
to always check that the applicable regulations, in particular regarding SAFETY, QUALITY and
protection of the ENVIRONMENT, do not impose more restrictive measures. If they do,
alternative solutions in accordance with the regulations must be submitted in writing to TOTAL.
Except for when it is used internally, the application of this specification is systematically
covered by a contract.
Caution, for new equipment, this specification supersedes the following specifications:
• GS RM PVE 011 Rev 00 dated 01/2012,
• GS TP WAM 001 Appendix 1 Rev 00 dated 12/2008.

1. Subject
This General Specification defines the additional requirements for Carbon Steel material grade
to be used on unfired metallic pressure equipments (pressure vessels and heat exchangers) in
Wet H2S Service.

2. Reference documents
The reference documents listed below form an integral part of this General Specification. Unless
otherwise stipulated, the applicable version of these documents, including relevant appendices
and supplements, is the latest revision published at the EFFECTIVE DATE of the CONTRACT.
Standards
Reference Title
EN ISO 17638 Non destructive examination of welds - Magnetic particle examination of
welds
EN 10028-3 Flat products made of steels for pressure purposes - Part 3 : weldable fine
grain steels, normalized
EN 10160 Ultrasonic testing of steel flat product of thickness equal or greater than 6 mm
EN 10164 Steel products with improved deformation properties perpendicular to the
surface of the product
EN 10204 Metallic products, Types of Inspection Documents
EN 10222-2 Steel forgings for pressure purposes - Part 2 : ferritic and martensitic
steels with specified elevated temperature properties
EN 10222-4 Steel forgings for pressure purposes. Part 4 : weldable fine grain steels
with high proof strength
ISO 3690 Welding and allied processes - Determination of hydrogen content in arc
weld metal
ASME Specification for carbon steel forgings for piping applications
SA-105/SA-105M
ASME Specification for alloy-steel and stainless steel bolting materials for high-
SA-193/SA-193M temperature or high pressure service and other special purpose applications

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Reference Title
ASME Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure
SA-194/SA-194M or High Temperature Service, or Both
ASME Specification for Alloy Steel and Stainless Steel Bolting Materials for Low-
SA-320/SA-320M Temperature Service
ASME Specification for carbon and low-alloy steel forgings, requiring notch
SA-350/SA-350M toughness testing for piping components
ASME Specification for carbon and low-alloy steel forgings, requiring notch
SA-516/SA-516M toughness testing for piping components
ASME standard specification for straight-beam ultrasonic examination of rolled
SA-578/SA-578M steel plates for special applications
ASME Specification for through thickness tension testing of steel plates for
SA-770/SA-770M special applications

Professional documents
Reference Title
AWS A4.3 Standard methods for determination of the diffusible hydrogen content of
martensitic, bainitic, and ferritic steel weld metal produced by arc welding
NACE Standard Materials resistant to sulfide stress cracking in corrosive petroleum
MR 0103 refining environments
NACE Standard Standard test methods, evaluation of pipeline and pressure vessel steels
TM0284 for resistance to hydrogen-induced cracking
NACE International Materials and fabrication practices for new pressure vessels used in wet
Publication 8X194 H2S refinery service
EEMUA Working guide for carbon steel equipment in wet H2S service
Publication N°179

Regulations
Reference Title
Not applicable

Codes
Reference Title
Not applicable

TOTAL General Specifications

Reference Title
DS RC GEN 002 Formal Deviation Form

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Reference Title
GS RC WAM 001 Welding and material of pressure equipments

Other documents

Reference Title
Not applicable

2.1 Priority rules

The subject of this specification shall satisfy, in descending order of priority, the requirements of:
• the local regulations, when applicable,
• the project’s Job specification, when existing,
• this specification,
• other codes, specifications and standards to which this specification refers.
In the event of conflicting requirements between the selected construction code and these other
codes, specifications and standards (if they are stipulated by a particular contract), the most
restrictive requirement shall apply.

2.2 Deviations
Any deviation from the requirements of this specification may be suggested by the General
contractor, Engineering company, Manufacturer or Contractor, if he considers such deviation
beneficial for reducing the cost and/or completion time, provided that it does not compromise
the safety of personnel or the regulatory requirements (when such regulations apply).
Deviations must be submitted to TOTAL, as a variant with the necessary justifications, and must
receive the written approval of TOTAL.
The deviation request shall be issued using the TOTAL form DS RC GEN 002.

3. Applicability
This specification is applicable to all new and existing unfired pressure equipments (pressure
vessels and heat exchangers) installed in refineries or petrochemical plants operated by TOTAL.
The severity categories according to the NACE International Publication 8X194 Ed.2006,
“Moderate Wet H2S Service (Category 2 service)” and “Severe Wet H2S Service (Category 3
service)” are covered in this specification.
The applicable severity category shall be indicated in the Equipment Data Sheets and shall be
specified by the Engineering Company or by TOTAL.
This specification (including the Post Weld Heat Treatment requirement) is not applicable when
cladded or weld-overlaid carbon steel materials (on the H2S fluid exposed side) are used.

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4. General
• All carbon steel materials shall be delivered fully killed and normalized.
The steel plate shall be fabricated from unalloyed carbon steels produced by electric arc
furnace or oxygen furnace process. The steel shall be vacuum degassed, deoxidized and
produced to a fine grain structure, with low sulfur and phosphorus process.
The supplier shall exercise special care in the selection and supervision of the fabrication
conditions and normalizing heat treatment conditions, in order to eliminate heterogeneous
structures, such as pearlite structures in very pronounced bands and aggregates of
bainite and unannealed martensite.
Chemical analysis shall be in accordance with material norm/specification requirements
and shall include all elements required in this specification.
• All base materials (plate, formed head, forging, fitting…) shall have a hardness value less
than 200HB (or 210HV10) (through thickness test).
• Irrespective of the wet H2S service category (severe or moderate), the carbon steel internal
parts (non removable parts) welded to pressure retaining components shall fulfill the
chemical composition of the Carbon, Sulfur, Manganese and Phosphorus elements in
moderate wet H2S service. The Carbon equivalent value of the moderate wet H2S service
shall be also met.
• The requirements of this specification are not mandatory for other internal parts
(removable) or for external parts welded to pressure retaining components.

5. Moderate wet H2S Service

5.1 Carbon Steel Plate
The following requirements shall be applied to the plates and to all components made from
plates (formed head, caps…).
5.1.1 Chemical composition
The chemical composition of carbon steel plates (heat analysis) shall be restricted as follows,
except when the material norm/specification is more restrictive:
Single Elements Maximum wt. %
Carbon (C) 0.20
Sulfur (S) 0.015
Manganese (Mn) 1.30
Phosphorus (P) 0.020
Multiple Elements Maximum wt. %
Vanadium (V) + Nobium (Nb) 0.03
Nb + V + Titanium (Ti) 0.12
Carbon Equivalent (Note 1) 0.43

Note 1: Carbon Equivalent (CE) shall be calculated using the following formula:
Mn ( Ni + Cu ) (Cr + Mo + V )
CE = C + + +
6 15 5

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5.1.2 Through-thickness tensile test

Through-thickness tensile test is required for plates having a thickness greater than 15mm.
The minimum value of the reduction of area on through thickness tension test specimens shall
conform to Z35 quality class according to EN 10164, or 35% according to ASME SA-770/SA-770M,
supplementary requirement S3.

5.2 Carbon steel forgings, pipes, tubes and fittings

Only seamless components (pipes, tubes, fittings…) are allowed.
5.2.1 Chemical composition
The chemical composition (heat analysis) shall be restricted as follows, except when the
material norm/specification is more restrictive:
Single Elements Maximum wt. %
Carbon (C) 0.21 / 0.20 (Note 2)
Sulfur (S) 0.025 / 0.020 (Note 2)
Manganese (Mn) 1.15
Phosphorus (P) 0.030
Multiple Elements Maximum wt. %
Vanadium (V) + Nobium (Nb) 0.03
Nb + V + Titanium (Ti) 0.12
Carbon Equivalent (Note 1) 0.42 / 0.37 (Note 2)
Note 1: Carbon Equivalent (CE) shall be calculated using the following formula:
Mn
CE = C +
6
Note 2: The higher limits are applicable to forgings and the lower ones are applicable to pipes,
tubes and fittings.
The requirements on multiple elements (V+Nb and Nb+V+Ti) are not mandatory for heat
exchanger tubes (shell & tube heat exchanger, air-cooler…).

6. Severe wet H2S service

6.1 Carbon Steel Plate
The following requirements shall be applied to the plates and to all components made from
plates (formed head, caps…).
6.1.1 General
Plate material shall be HIC-tested in accordance with section 8 of this specification.
Materials with a minimum specified tensile strength value according to the material
norm/specification greater than 451 MPa are not allowed (Material grade allowed:
ASME SA-516 Gr.60/65 – EN 10028-3 P275NH/NL1/NL2).
Steel shall be produced with thorough desulphurization, dephosphurization and deoxidizing
treatments. Calcium treatment shall be applied for inclusion shape control; it doesn’t need to be
applied to steel with very low sulfur levels (below 0.002 %).
The calcium content shall not exceed 3 times the sulfur content.

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6.1.2 Chemical composition

The chemical composition of carbon steel plates (heat analysis) shall be restricted as follows,
except when the material norm/specification is more restrictive:
Single Elements Maximum wt. %
Carbon (C) 0.20
Manganese (Mn) 1.20
Phosphorus (P) 0.010
Sulfur (S) 0.003
Silicon (Si) 0.40
Copper (Cu) 0.20
Nickel (Ni) 0.40
Chromium (Cr) 0.30
Molybdenum (Mo) 0.12
Vanadium (V) 0.020
Niobium (Nb) 0.020
Titanium (Ti) 0.02
Boron (B) 0.0010
Multiple Elements Maximum wt. %
Cr + Mo 0.30
Ni + Cu + Cr + Mo 0.70
V + Nb 0.030
Carbon Equivalent (Note 1) 0.42 (0.43 for thk>100mm)

Note 1: Carbon Equivalent (CE) shall be calculated using the following formula:
Mn ( Ni + Cu ) (Cr + Mo + V )
CE = C + + +
6 15 5

6.1.3 Lamination check

A scanning (100% ultrasonic lamination check) of the plate surface shall be performed in
accordance with EN 10160 Class S2 or ASME SA-578/SA-578M, level C, supplementary
requirement S1.

6.2 Carbon Steel forgings, pipes, tubes and fittings

Only seamless components (pipes, tubes, fittings…) are allowed.

6.2.1 Mechanical properties

Materials with a minimum specified tensile strength value according to the material
norm/specification greater than 491MPa are not allowed (Material grade allowed for forgings:
ASME SA-350 gr.LF2 – ASME SA-105N – EN 10222-4 P285NH – EN 10222-2 P305GH-N/NT).

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6.2.2 Chemical composition

The chemical composition (heat analysis) shall be restricted as follows, except when the
material norm/specification is more restrictive:
Single Elements Maximum wt. %
Carbon (C) 0.21 / 0.20 (Note 2)
Manganese (Mn) 1.05 (Note 3)
Sulfur (S) 0.020 / 0.010 (Note 2 – Note 3)
Phosphorus (P) 0.025 (Note 3)
Multiple Elements Maximum wt. %
Vanadium (V) + Niobium (Nb) 0.03
Nb + V + Titanium (Ti) 0.12
Carbon Equivalent (Note 1) 0.43 / 0.40 (Note 2 – Note 3)

Note 1: Carbon Equivalent (CE) shall be calculated using the following formula:
Mn ( Ni + Cu ) (Cr + Mo + V )
CE = C + + +
6 15 5
Note 2: the higher limits are applicable to forgings and the lower ones are applicable to pipes,
tubes and fittings.
Note 3: for forgings: Mn = 1.35% max providing P ≤ 0.015% and S ≤ 0.010%.
The tubes to be used for heat exchanger bundle (shell & tube heat exchanger, air-cooler…)
shall meet the chemical composition of the moderate wet H2S service tube requirements.

7. Additional requirements for moderate and severe wet H2S services

7.1 Welding
In addition to the TOTAL specification GS RC WAM 001 requirements, the following shall be met.

7.1.1 Filler products

The following supplementary requirement shall be applied:
• nickel content of the welding consumables shall not exceed 1%,
• pressure retaining welds shall be made with low hydrogen consumables,
• low hydrogen electrodes shall exhibit a very low diffusible hydrogen (less than 5 cm3 H2
per 100gr of metal deposit) in accordance with ISO 3690 , AWS A 4.3 or equivalent
standard.
• Mn content shall not exceed 1.5% weight in filler metal or 1.6% weight in weld metal
deposit.

7.1.2 Shielding gas

The shielding gases shall not contain hydrogen. Their dew point shall be less or equal to -40°C.

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7.2 Post Weld Heat Treatment (PWHT)

All pressure equipments in wet H2S Service shall be Post Weld Heat Treated in accordance with
the design code requirements, TOTAL specifications and the Project Specifications (in any),
considering 1 hour minimum holding time per 25 mm of thickness (with a minimum holding time of
1 hour). The Post Weld Heat Treatment temperature shall be chosen in the 600-625°C temperature
range; the acceptable tolerance on this PWHT temperature during the PWHT is ±10°C.

7.3 Production Weld Test Coupons

Production weld test coupons are mandatory and shall be performed according to the TOTAL
specification GS RC WAM 001 considering the following additional requirements.
Irrespective of the coupon thickness, mechanical tests (at least hardness test, impact test and
transverse tensile test) shall be performed for equipments under severe wet H2S service.
The plates and the welding consumables of the order (used for pressure retaining component
manufacturing) shall be used for production test coupon execution.

7.4 Non Destructive Examination

A detailed procedure including all the tests, extent… shall be issued and submitted to the
Engineering Company and/or TOTAL for approval.
The non destructive testing shall be performed according to the TOTAL specification
GS RC WAM 001 with the following additional requirements:
7.4.1 Magnetic particle testing
All accessible wetted welds (exposed directly to the wet H2S environments) of pressure retaining
components and all wetted welds of parts welded to a pressure retaining component shall be
100% inspected by Wet Fluorescent Magnetic Particle Test (WFMT) after PWHT. The test shall
be performed in accordance with EN ISO 17638 or ASME V and the chosen design code.
All other weld surfaces of pressure retaining components and all other welds of parts welded to a
pressure retaining component shall be 100% inspected by Magnetic Particle Test (MT) after PWHT.
Dye penetrant testing shall be performed for welds that cannot be examined by magnetic
particle methods.
7.4.2 Volumetric non destructive examination
The volumetric tests shall be performed in accordance with the chosen design Code and, as a
minimum, shall comply with the following:
Moderate wet H2S Service Before PWHT After PWHT
100% RT
Butt weld OR Not required
100% UT
Corner weld joint (nozzle attachment...) 100% UT Not required

Severe wet H2S service

Before PWHT After PWHT
Thickness < 40mm
100% RT (10% + cross welds) RT
Butt weld AND OR
100% UT (10% + cross welds) UT
Corner weld joint (nozzle attachment...) 100% UT 10% UT

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Severe wet H2S service

Before PWHT After PWHT
Thickness ≥ 40mm
100% RT
Butt weld AND 100% UT
100% UT
Corner weld joint (nozzle attachment...) 100% UT 100% UT

Use of Time of Flight Diffraction (TOFD) shall conform to GS RC WAM 001 restrictions and
requirements.
7.4.3 Hardness testing
For each equipment, hardness measurements of the side of each weld seam in contact with the
fluid shall be performed after PWHT. Hardness measurements shall be also performed after
PWHT on the side of each pressure retaining butt weld seam not in contact with the fluid. The
hardness measurement tester shall be identical (the same) to the one used for the production
test coupon checking.
A hardness test shall be performed each 3 meters maximum with at least one per weld seam.
The hardness value at one test location shall be considered as the average of 3 measurements
(minimum 3 values and depending of the hardness tester method used) and this average value
shall be less than 210HV10 (or 200HB). The hardness test shall be performed on the base
metal and the weld metal.
When a tube to tubesheet weld is required, a mock-up (test coupon) shall be performed and the
hardness test of welds shall be checked. A detailed specification shall be issued and submitted
to the Engineering Company and/or TOTAL for approval.
Additional requirements according to TOTAL specification GS RC WAM 001 shall be also
followed.

7.5 Tests on Raw Material

7.5.1 Mechanical tests
The mechanical tests and the hardness test shall be performed after 1 cycle of post weld heat
treatment (named initial PWHT cycle) which is identical to the post weld heat treatment to be
done to the equipment.
Manufacturer shall consider all heat treatment cycles performed during fabrication and shall
consider all components (raw materials) to determine the simulated heat treatment cycles to be
applied to each component, some examples of combinations:
• The mechanical tests and the hardness test of formed components (head …) shall be
performed after 1 cycle of heat treatment (identical to the final post weld heat treatment to
be done to the equipment) plus 1 cycle of heat treatment corresponding to the heat
treatment done after forming (if required). The sum is considered as 1 heat treatment
cycle (named initial PWHT cycle).
• For the components heat treated several times during the equipment fabrication (for
example partial heat treatment followed by a local post weld heat treatment), the holding
time of the simulated heat treatment to be considered for those components is equal to
the sum of all heat treatment durations done to the component. The sum is considered as
1 heat treatment cycle (named initial PWHT cycle).

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The maximum simulated heat treatment holding time is the sum of the initial PWHT cycle
holding time plus 2 times the post weld heat treatment holding time to be done to the equipment
(the PWHT done to the main pressure shell shall be considered).
The simulated heat treatment condition shall reflect exactly, component per component, the
heat treatments done to each component. Tests conducted at different holding times shall be
performed when different heat treatment cycles are required.
The tests shall be performed in accordance with the following table:
Raw material Wet H2S Thickness range Minimum simulated PWHT = Maximum
type Service 1 initial PWHT cycle with 1 hour simulated PWHT
minimum holding time
Plate Moderate All thicknesses Sy, Su, Kv, Hv
Severe Thk < 40mm Sy, Su, Kv, Hv
Severe Thk ≥ 40mm Su, Sy, Kv, Hv Su, Sy
Forging, pipe Moderate All thicknesses Sy, Su, Kv, Hv (Note 1)
& fitting
Severe Thk < 40 Sy, Su, Kv, Hv (Note 1)
Severe Thk ≥ 40 Su, Sy, Kv, Hv Su, Sy

With:
• Sy: Specified minimum yield strength at room temperature
• Su: Specified tensile strength at room temperature
• Kv: Charpy V-notch impact test at low temperature (at least the Minimum Design Metal
Temperature)
• Hv: Hardness
Note 1: The standardized components (according to a dimensional norm/standard) taken from
stock (with material test certificate as specified hereafter and without any testing in
simulated PWHT condition) can be used as it is if the mechanical properties of the
component (Sy and Su) are 30MPa greater concerning Sy and 25MPa greater
concerning Su than the minimum values specified in the applicable material
norm/standard of this component. The hardness of the component shall be in any case
checked and reported.
Mechanical tests in simulated PWHT condition are not required for heat exchanger tubes.
When mechanical tests in simulated heat treatment condition are not performed by the mill or by
the component Manufacturer, they shall be witnessed by a Third Party.
When tests are required in a maximum simulated PWHT condition, the tests in minimum
simulated PWHT condition shall be also performed as specified in the table just above.
The raw material purchase technical specifications (including at least the data defining the
simulated heat treatment conditions, the different tests to be performed…) shall be issued by
the pressure vessel Manufacturer and shall be submitted to the Engineering Company and
TOTAL for approval.

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7.5.2 Material test certificate

Unless otherwise specified or required by the design code, the material certificate shall be in
accordance with EN 10204 type 3.1 as a minimum, including but not limited to:
• Chemistry on all required elements,
• mechanical properties (including tests after simulated heat treatment),
• heat treatment condition/data and reports,
• hardness test results and location,
• through thickness tensile test results (if required),
• ultrasonic examination results and report (if required),
• HIC testing results (if required).

7.6 Bolting Material

The material grade to be used for bolting exposed to the wet H2S environment shall be in
accordance with the NACE MR0103 requirements.
The following material norms and grades shall be used:
Component Type Norm / Grade
Bolt, stud, screw… ASME SA-193 grade B7M
ASME SA-193 grade B8MA, class 1A
ASME SA-320 grade L7M
Nut ASME SA-194 grade 2HM
ASME SA-194 grade 7M
ASME SA-194 grade 8MA

8. Hydrogen induced crack (HIC) testing

8.1 General
The HIC test is required for plates with a thickness above 15mm.
The HIC test and crack evaluation shall be in accordance with NACE Standard TM0284. The
test is performed using the solution A.
The test shall be performed by the plate manufacturer (mill) per heat on the thickest plate in a
simulated heat treatment condition (initial PWHT cycle).

8.2 Acceptance criteria

The following acceptance criteria shall be met:
% (maximum)
CLR CTR (*) CSR (*)
Average 5 1.5 0.5
Single 10 3 0.7
(*): Not required for plate thickness below 20mm

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The maximum individual crack length on any section shall not exceed 5 mm.
The average value is the arithmetical mean of the value obtained on the total number of the
sections examined.
The single value is the arithmetical mean of the value obtained on the 3 examined sections for
each specimen.

8.3 Reporting
The HIC test report shall include:
• Full Chemical analysis (including analysis of micro-alloy elements) and mechanical
properties results of material tested.
• Crack evaluation, maximum crack length and width, single and average values of CLR,
CTR and CSR.
• pH of the test solution at the beginning and at the end of the test and the H2S content.
• Location and dimensions of specimens.
• Photographs of specimens showing any blisters.

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