RNP DCU Plant Project

CB&I s.r.o. Brno, NIS a.d., Novi Sad,

Czech Republic Serbia

Document Title: Service Definition Philosophy

Unit Code: General for all units

Document No: 172784-00-PR-PH-00002

CB&I Contract No: 172784 and 222121

Issued for Construction 2 15-Dec-17 KOV MHR MHR

Issued for Design 1 06-Dec-16 MUrsu JLAS MHR
Issued for Design 0 25-Nov-16 MUrsu JLAS MHR
Revision Descriptions Rev Date Originator Checker Approver

Page 1 of 8

"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE
SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
 RNP DCU Plant Project (WP1)
Document Title: Document No. Rev:
Service Definition Philosophy 172784-00-PR-PH-00002 2

Table of Contents
Contents Page

1.0 INTRODUCTION ....................................................................................................................................... 3

2.0 LIST OF ABREVIATIONS ........................................................................................................................ 3
3.0 SERVICES DEFINITION ........................................................................................................................... 4
3.1 Amine Service ............................................................................................................................... 4
3.2 Caustic Service (1) ........................................................................................................................ 4
3.2.1 Caustic Stress Corrosion Cracking (Caustic SCC) ................................................... 4
3.3 Corrosive Service ......................................................................................................................... 5
3.4 Corrosive Service due to Wet H2S/ Sour service ....................................................................... 5
3.4.1 Sour / Sulphide Stress Cracking (SSC) service ......................................................... 5
3.4.2 HIC Service .................................................................................................................... 6
3.5 Erosive Service ............................................................................................................................. 6
3.6 Flammable Liquids ....................................................................................................................... 6
3.7 High Temperature Service ........................................................................................................... 6
3.7.1 Corrosive Service due to Sulphur Compounds (in the absence of hydrogen) ...... 7
3.7.2 Corrosive Service due to Sulphur Compounds (in the presence of hydrogen) ..... 7
3.7.3 Corrosive Service due to High Temperature Hydrogen Attack ................................ 7
3.7.4 Corrosive Service due to Naphthenic Acid Corrosion .............................................. 7
3.8 Hydrogen Service ......................................................................................................................... 7
3.9 Light Hydrocarbons ...................................................................................................................... 7
3.10 Oxygen service ............................................................................................................................. 8
3.11 PWHT / Stress Relief..................................................................................................................... 8
3.12 Toxic Service ................................................................................................................................. 8
3.13 Very Toxic Service ........................................................................................................................ 8
4.0 REFERENCES .......................................................................................................................................... 8

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 RNP DCU Plant Project (WP1)
Document Title: Document No. Rev:
Service Definition Philosophy 172784-00-PR-PH-00002 2

1.0 INTRODUCTION

The purpose of this document is to present the basic terminology and service definition philosophy in
system (piping or equipment). Document gives general recommendations only.

More insights in the discussed corrosion phenomena or project specific parameters may lead to some
small deviations or some additional requirements than those as specified in this document.

2.0 LIST OF ABREVIATIONS

Definitions and abbreviations used in this document as shown below:

API - American Petroleum Institute

DEA - Di Ethanol Amine
DGA - Di Glycol Amine
DIPA - Di Iso Propanol Amine
HAZ - Heat-affected Zone
HIC - Hydrogen Induced Cracking
HTHA - High Temperature Hydrogen Attack
MDEA - Methyl Di Ethanol Amine
MEA - Mono Ethanol Amine
NACE - National Association of Corrosion Engineers
ppmw - part per million weight
PWHT/SR - Post Weld Heat Treatment/ Stress Relief
OSHA - The Occupational Safety and Health Administration
SCC - Stress Corrosion Cracking
SSC - Sulphide Stress Cracking
Very Toxic - Acute - Single exposure via inhalation, skin or ingestion to this process stream can
cause serious adverse health effects/fatality
Very Toxic - Chronic - Repeated or long term exposure via inhalation to this process stream can
cause serious adverse health effects which may lead to fatality

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 RNP DCU Plant Project (WP1)
Document Title: Document No. Rev:
Service Definition Philosophy 172784-00-PR-PH-00002 2

3.0 SERVICES DEFINITION

3.1 Amine Service

System (piping or equipment) is considered as amine service when pure amine or amine solution is
present. Following compounds are amines:

DEA = Di Ethanol Amine

DGA = Di Glycol Amine
DIPA = Di Iso Propanol Amine
MDEA = Methyl Di Ethanol Amine
MEA = Mono Ethanol Amine

3.2 Caustic Service (1)

The practices detailed below are specifically intended for handling aqueous solutions containing sodium
hydroxide (NaOH). NACE SP0403 addresses applications that use “fresh” caustic. However, several
companies extend these practices to include aqueous solutions of other strong alkali compounds such
as potassium hydroxide (KOH) and lithium hydroxide (LiOH).

3.2.1 Caustic Stress Corrosion Cracking (Caustic SCC)

The majority of more recent industry cases of
caustic SCC in CS equipment and piping are
associated with non-stress relieved welds, typically
in the heat-affected zone (HAZ) and adjacent base
metal.

The level of tensile stress required to produce

cracking is a function of metal temperature and
caustic concentration. CS welds, cold-formed
piping bends and heat exchanger tube “U” bends in
services that fall within are “B” and area “C” of the
Caustic Service Chart (Figure 1: Caustic Service
Chart, NACE SP0403) shall be thermally stress
relieved.

In some services that involve contaminated caustic,

SCC has been observed at conditions within are
“A” of the Caustic Service Chart. The need for
thermal stress relief should be considered when the
service contains contaminated caustic.

For Caustic SCC susceptibility of austenitic

stainless steel (SS) see Figure 2: Caustic Service
chart for 300 Series Austenitic SS, NACE SP0403
(1).
Figure 1 Caustic Service Chart

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 RNP DCU Plant Project (WP1)
Document Title: Document No. Rev:
Service Definition Philosophy 172784-00-PR-PH-00002 2

3.3 Corrosive Service

System is considered as corrosive service when physicochemical interaction between a metal and
system results in changes in the properties of the metal and which may often lead to impairment of the
function of the metal, the environment, or the technical system of which these form a part.

3.4 Corrosive Service due to Wet H2S/ Sour service

We define two corrosion processes due to Wet H2S service: Sulphide Stress Cracking (SSC) and
Hydrogen induced Cracking (HIC).
NACE MR-0103 is applicable. For further detail see document Wet Hydrogen Sulphide (H2S) Service
Specification (172784-00-PR-SP-00001).

3.4.1 Sour / Sulphide Stress Cracking (SSC) service

System (piping and equipment) is considered as Sour service when a liquid phase, with free water,
containing H2S can be present and operating temperature is between ambient and 150°C (302°F). Also
during upset conditions.
The NACE International Publication 8X194, 2006 Edition, indicates that risk for sulphide stress cracking
is only present between ambient and 150°C. Therefore, 150°C can be applied as a safe upper limit for
wet H2S corrosion. At higher temperatures, the formed corrosion product FeS is more adherent, more
protective, thus lowering the H2S activity.
When pH value is known it gives two service categories, one where the potential for SSC is low and one
where the potential for SSC is higher.
The low SSC potential service category is a process service, with a certain amount of H2S in water, with
average pH values, and no accelerating components, such as cyanides.
The high SSC potential service category can be a process service, with a (1):
 > 50 ppmw total sulfide content in the aqueous phase; or
 ≥ 1 ppmw total sulfide content in the aqueous phase and pH < 4; or
 ≥ 1 ppmw total sulfide content and ≥20 ppmw free cyanide in the aqueous phase and pH>7.6;
or
 >0.3kPa absolute partial pressure H2S in the gas phase associated with the aqueous phase
of a process.
Table 1 Severity of SSC as a function of H2S content of water

pH of Water Cyanide content Severity of SSC as a function of H2S content of water

ppmw ≥1ppmw >50ppmw

< 20 High High

<4
≥ 20 High High

< 20 Low High

4 to 7.6
≥ 20 Low High

< 20 Low High

>7.6
≥ 20 High High

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 RNP DCU Plant Project (WP1)
Document Title: Document No. Rev:
Service Definition Philosophy 172784-00-PR-PH-00002 2

3.4.2 HIC Service

System (piping or equipment) is considered as HIC service when the liquid phase, with free water is
continuously present and minimum 50 ppmw H2S is dissolved in liquid water.

When pH value is known it gives two service categories, one where the potential for HIC is low and one
where the potential for HIC is higher.

The high potential of promotion HIC is applicable for the following cases:
 H2S in water above 2000 ppm in combination with pH > 7.8
 H2S in water above 50 ppm in combination with pH < 5
 H2S above 50 ppm and HCN above 20 ppm.

Table 2 Severity of HIC as a function of H2S content of water

pH of Water Cyanide Severity of HIC as a function of H2S content of water

content

ppmw <50ppmw ≥50ppmw ≥2000ppmw

< 20 Low High High

<5
≥ 20 Low High High

< 20 Low Low Low

5 to 7.8
≥ 20 Low High High

< 20 Low Low High

>7.8
≥ 20 Low High High

3.5 Erosive Service

System (piping or equipment) is considered as erosive service when fluids are containing solid particles.

3.6 Flammable Liquids

Flammable liquid is defined as a liquid with a flashpoint below 37.8°C (100°F).

3.7 High Temperature Service

System (piping or equipment) is considered as high temperature service when the operating temperature
is above 230°C (446°F).

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 RNP DCU Plant Project (WP1)
Document Title: Document No. Rev:
Service Definition Philosophy 172784-00-PR-PH-00002 2

3.7.1 Corrosive Service due to Sulphur Compounds (in the absence of hydrogen)
Sulphur compounds originate with crude oils and may include poly-sulphides, mercaptans, aliphatic
sulphides, etc. At elevated temperatures above 260°C (500°F), these sulphur compounds react with
metal surfaces forming metal sulphides. Sulphur compounds may be corrosive themselves as well as
they are converted to hydrogen sulphide through thermal decomposition.
To predict the corrosion rates in high temperature sulfidic environments, the modified Mc Conomy curves
(API 571), which apply to liquid crude oil streams, can be applied.

3.7.2 Corrosive Service due to Sulphur Compounds (in the presence of hydrogen)
Corrosion by various Sulphur compounds is a common problem above about 230°C (500°F).
The presence of hydrogen, e.g. in case of hydrodesulfurising and hydrocracking operations, increases
the severity of high-temperature sulphur corrosion. Hydrogen converts organic sulphur to hydrogen
sulphide and corrosion becomes a function of the hydrogen sulphide concentration (or partial pressure).
To estimate the corrosion rate in H2/ H2S environments, the Couper – Gorman curves can be used
(API 571).

3.7.3 Corrosive Service due to High Temperature Hydrogen Attack

High temperature hydrogen attack (HTHA) only occurs in carbon and low-alloy steels exposed to a high
partial pressure of hydrogen at elevated temperatures above 230°C (446°F).
Atomic hydrogen reacts with the carbon in the steel to cause either surface decarburization or internal
decarburization and fissuring, and eventually cracking.
Nelson Curves in API 941 describe susceptible zones. Nelson curves are experience based.

3.7.4 Corrosive Service due to Naphthenic Acid Corrosion

Naphthenic acid corrosion is only experienced at temperatures above approximately 230°C (446°F).
The naphthenic acid content is expressed in terms of neutralization number, i.e. Total Acid Number
(TAN). At any given temperature the corrosion rate is proportional to the TAN (a TAN value of 0.5 is
normally taken as threshold value below which no special material selection requirements are
applicable). High corrosion rates can occur in carbon steel piping and equipment between 230°C (446°F)
and 400°C (752°F), since the formed iron naphthenics are soluble in the hydrocarbons, and thus non-
protective. Especially high velocities and turbulence will increase the corrosion attack. Above 400°C
(752°F), the naphthenic acids will either break down or distill into the vapor phase.

3.8 Hydrogen Service

System (piping or equipment) is considered as hydrogen service when the H 2 partial pressure is higher
than 3.5 bar a, regardless of temperature.

3.9 Light Hydrocarbons

Light hydrocarbons are defined as hydrocarbon fluids consisting of C4 material and lighter.

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 RNP DCU Plant Project (WP1)
Document Title: Document No. Rev:
Service Definition Philosophy 172784-00-PR-PH-00002 2

3.10 Oxygen service

Oxygen-enriched mixtures or atmospheres defined as those containing more than 23.5% oxygen by
volume. In oxygen-enriched atmospheres, the reactivity of oxygen significantly increases the risk of
ignition and fire. Materials that may not burn in normal air may burn vigorously in an oxygen-rich
environment.
In oxygen-enriched environment materials, become easier to ignite, because their flammable ranges
start to expand and their autoignition temperatures begin to drop. This includes the materials of
construction used in oxidizer systems, such as metals.
In addition, contamination in a system can initiate a system fire. It must be stressed that systems must
not only be cleaned to oxidizer service requirements on initial construction but must be maintained in that
condition cleanliness.

3.11 PWHT / Stress Relief

Post weld heat treatment (PWHT) and stress relief (SR) are synonyms. These terms can be
interchangeably used. The purpose is to reduce stresses induced during welding.
The temperature used during the stress relieving on the weld joints have to be below the critical
transformation temperature.
The necessity for PWHT/ SR depends on the material and the service requirements.

3.12 Toxic Service

System is considered as toxic service when the fluid contains one or more substances listed in the OSHA
1910 Regulation Table Z-1 or Z-2 at a concentration greater than the acceptable maximum peak
concentration.
This includes any stream with H2S concentration higher than 50 ppmw, regardless of presence of free
water.

3.13 Very Toxic Service

Process streams can be classified as Very toxic – Acute and Very toxic – Chronic when the following
concentrations will be exceeded:

Substance Vapor Liquid “Very toxic”

Benzene 1vol% 5wt% Chronic

Carbon Monoxide 1vol% N/A Chronic

(CO)

Hydrogen Sulfide 0.1vol% 0.06wt% Acute

(H2S)

4.0 REFERENCES
(1) International, NACE. “Avoiging Caustic Stress Corrosion Cracking of Refinery Equipment and Piping.”
SP0403. 2015.
(2) International, NACE. “Materials Resistant to Supfide Stress Cracking in Corrosive Petroleum Refining
Environments.” MR0103. 2012.

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