DIVISION ENGINEERING

&
CONSTRUCTION

MATERIAL SELECTION
PHILOSOPHY
 CONTENTS

1. INTRODUCTION 3
1.1. Foreword 3
1.2. Objectives 3
1.3. Scope 3

2. APPLICABLE STANDARDS 4

3. FACTORS AFFECTING MATERIAL SELECTION 5

3.1. General 5
3.2. Corrosion Assessment 5
3.3. Internal Corrosion 6
3.4. External Corrosion Risks 7
3.5. Corrosion Under Insulation 8
3.6. Welding 9

4. MATERIAL SELECTION FOR SPECIFIC APPLICATION 10

4.1. Structural Materials 10
4.2. Processing Facilities 10
4.3. Pipeline Systems 12

5. DESIGN LIMITATIONS FOR CANDIDATE MATERIALS 13

5.1. General 13
5.2. Structural Materials 13
5.3. Materials For Pressure Retaining Equipment 13
5.4. Bending and Cold Forming of Pipes 13
5.5. Glass Reinforced Plastic 14
5.6. Polymeric Materials 14

6. CORROSION INHIBITION 16

7. CORROSION MONITORING 18
7.1. General 18
7.2. Internal Corrosion Monitoring – Piping 19
7.3. Data Acquisition and Processing 20

Appendices

Appendix 1 Material Selection Guideline for Surface Facilities

MATERIAL SELECTION PHILOSOPHY Page 2

1. INTRODUCTION

1.1. Foreword

This document represents the Sonatrach (SH) Operational Philosophy

on Material Selection for projects in Algeria.

1.2. Objectives

The primary objective of this document is to provide guidance to

discipline engineers in progressing a conceptual design through to
detailed design, based on operational requirements.

1.3. Scope

The philosophy requirements apply to all pipe work, instruments,

equipment and structural steel work.

MATERIAL SELECTION PHILOSOPHY Page 3

2. APPLICABLE STANDARDS

The following are key standards applicable to this philosophy. Any equipment
or systems installed shall also comply with other relevant Standards,
Specifications, Industry Codes, Algerian Laws and Sonatrach Standards.

NACE Sulphide Stress Cracking Resistant Metallic Materials for

MR0175 Oilfield Equipment

ASME B 31.3 Process Piping.

ASMEVIII Boiler and Pressure Vessel Code

PD 5500 Specification for unfired fusion welded pressure vessels.

EEMUA 153 EEMUA Supplement to ASME B31.3 – 1996 Edition. Process

Piping

EFC Corrosion Resistant Alloys for Oil and Gas Production.

Publication Guidelines on Materials Requirements for Carbon and Low
No.16 Alloy Steels for H2S containing environments in Oil and Gas
Production.

MATERIAL SELECTION PHILOSOPHY Page 4

3. FACTORS AFFECTING MATERIAL SELECTION

3.1. General

3.1.1 Material selection shall be optimised, considering investment and

operational/maintenance costs, such that overall costs are minimised
while providing acceptable safety and reliability. As a minimum, the
following shall be considered:

 Corrosivity, taking into account specified worst case operating

conditions including start up, shut-down and upset conditions.

 Erosion prediction

 Low temperature properties

 Elevated temperature properties

 Thermal and mechanical fatigue resistance

 Design life and system availability requirements.

 Failure probabilities, failure modes and failure consequences for

personnel health, environment, safety and material assets.

 Inspection and corrosion monitoring possibilities.

3.1.2 For the final materials selection the following additional factors shall be
included in the evaluation:

 Priority shall be given to materials commonly used in Algeria.

 Emphasis shall be given to materials with good market availability

and documented fabrication and service performance.

 The number of different materials shall be minimised considering

stock, costs, inter-changeability and availability of relevant spare
parts.

3.1.3 Deviations from materials selections specified in this philosophy may

be implemented if an overall cost, safety and reliability evaluation
shows the alternative to be more cost effective.

3.1.4 A material selection flow diagram shall be produced.

3.2. Corrosion Assessment

3.2.1 Corrosion calculations shall take into consideration the following where
applicable:

 Project life

 CO2-content

MATERIAL SELECTION PHILOSOPHY Page 5

  H2S-content.

 Water content.

 Salt content.

 Oxygen content and content of other oxidising agents.

 Operating temperature and pressure.

 Acidity, pH.

 Halide, metal ion and metal concentration.

 Velocity, flow regime

 Sand concentration (normal, peak and duration)

 Biological activity.

 Chloride content.

 Temperature (minimum and maximum) and pressure.

 Predicted production profile

3.2.2 A gas may be considered dry when the water dew point at the actual
pressure is at least 10°C lower than the actual operation temperature
for the system. Materials for stagnant gas containment needs particular
attention.

3.2.3 Galvanic corrosion between corrosion resistant alloy equipment and

the vessel wall in internally coated carbon steel vessels shall be
addressed in case of coating damages. As a minimum corrosion
resistant alloy support brackets shall be painted. Other protection
methods should be considered.

3.2.4 Risk for "sour" service conditions during the lifetime shall be evaluated
in accordance with NACE MR0175 and EFC Guideline No 16.

3.2.5 Drying or use of corrosion inhibitors shall not relax the requirement to
use "sour" service resistant materials if the conditions otherwise are
categorised as "sour".

3.2.6 Material selection shall consider minimum design temperatures to

ensure toughness at low temperatures and avoidance of brittle fracture.

3.3. Internal Corrosion

3.3.1 For carbon steel piping, a corrosion allowance of 3 mm shall be used,

unless higher corrosion allowances are required. Where a corrosion
allowance requirement greater than 6mm is predicted consideration
shall be given to use of an appropriate corrosion resistant alloy and the

MATERIAL SELECTION PHILOSOPHY Page 6

 increased cost shall be balanced against cost of replacement of carbon
steel during the life cycle.

3.3.2 Corrosion during installation and testing prior to start-up shall be

considered.

3.3.3 Galvanic Corrosion Protection

3.3.3.1 Wherever dissimilar metals are coupled together in piping systems, a

corrosivity evaluation shall be carried out. If galvanic corrosion is likely
to occur suitable mitigating measures shall be implemented, e.g.

 Apply electrical insulation of dissimilar metals. Possible electrical

connection via pipe supports, deck and earthing cables should be
considered.

 Install a distance spool between the dissimilar metals so that they

will be separated by at least 10 pipe diameters from each other in
addition to fully isolating the junction. The distance spool may be
either of a solid electrically non-conducting material, e.g. GRP, or
of a metal that is coated internally with an electrically non-
conducting material, e.g. rubber for saltwater systems or epoxy
resin for hydrocarbon systems. The metal in the distance spool
should be the most noble of the dissimilar metals.

 Apply a non-conducting coating on the most noble of the

dissimilar metals in addition to fully isolating the junction. Coating
to extend at least 10 pipe diameters into the most noble pipe
material and terminating at a positive location such as a flange.

 Apply greater corrosion allowance on the less noble metal, e.g. in

hydrocarbon systems.

 Install internal sacrificial anodes through access fittings near the

interface. e.g. resistor controlled cathodic protection. This works
only when the system is filled up with a conductive liquid, and
special precautions during commissioning and shut-in are
required.

 Install insulation kits.

3.3.3.2 In hydrocarbon systems, isolating spools shall be avoided where

possible and transitions shall normally be made in dry, inhibited or
other areas with low corrosivity.

3.4. External Corrosion Risks

3.4.1 Material selection and surface protection shall be such that general
corrosion is cost effectively prevented and, pitting and crevice
corrosion are prevented.

MATERIAL SELECTION PHILOSOPHY Page 7

 3.4.2 Material selection and protection shall also take into consideration
erosion caused by sand, exposure to direct sunlight and high ambient
temperatures.

3.4.3 Carbon steel shall always have surface protection to the external
environment. Additional corrosion allowance or other means of
protection are required for installations normally exposed to water and
equipment resting or passing under grade.

3.4.4 Corrosion resistant alloys should not be coated, except under

insulation or pipe clamps or where a materials has been selected that
will operate in a temperature range where it will be prone to another
failure mechanism, such as pitting corrosion or chloride stress
corrosion cracking.

3.4.5 Coating system selections for pipelines, structures and equipment shall
make due consideration to structural design, operating conditions and
conditions during storage and installation.

3.4.6 The following areas/conditions shall be subject to special evaluation:

 Coatings for areas normally exposed to water.

 Use of thermally sprayed aluminium coating for elimination of

maintenance coating.

 Coatings for passive fire protection.

 Coatings for bolts and nuts, flanges, machined surfaces of valves,

etc. For such applications wax coatings should be considered.

 Coating and/or insulation when connecting aluminium, stainless

steel, carbon steel and other materials where galvanic corrosion
may occur.

 Designs where a “crevice” is produced resulting in trapped water

for long periods (e.g. vertically mounted compression fittings,
clamps).

3.5. Corrosion Under Insulation

3.5.1 Thermal insulation shall be avoided to the extent possible, and only be
used if required for safety or processing reasons.

3.5.2 Piping and equipment which have to be insulated shall be coated

appropriately to prevent corrosion under insulation. The insulation
design and installation shall prevent water ingress.

3.5.3 The requirement for coating under insulation also includes corrosion
resistant alloys. Titanium alloys need not be coated even if insulated.

MATERIAL SELECTION PHILOSOPHY Page 8

 3.5.4 The design of insulation for structures and piping systems shall ensure
drainage, and access in areas where maintenance and inspection are
required.

3.5.5 Heat tracing shall to the extent possible be avoided in conjunction with
stainless steel materials in particular.

3.6. Welding

3.6.1 Welds in pipeline systems for corrosive hydrocarbons shall be qualified

by corrosion testing under simulated operating conditions with and
without corrosion inhibitors as a part of weld procedure qualifications,
unless relevant documentation exist.

3.6.2 The chemical composition, by check analysis of steels to be welded

shall be restricted as follows:

 Carbon 0.23% maximum (pipe), 0.25% max (forgings and

castings)

 Carbon Equivalent (C.E.) 0.45% maximum, where

C.E. = C +(Mn/6)+[(Cr+Mo+V)/5]+[(Cu+Ni)/15]

C Carbon
Mn Manganese
Cr Chromium
Mo Molybdenum
V Vanadium
Cu Copper
Ni Nickel

MATERIAL SELECTION PHILOSOPHY Page 9

4. MATERIAL SELECTION FOR SPECIFIC APPLICATION

4.1. Structural Materials

4.1.1 The number of steel grades used shall be minimised in order to benefit
from standardisation.

4.1.2 Passive fireproofing materials for protection of structural steel or for

area segregation should be of spray applied types. A corrosion
protection coating system shall be applied to the steel. The passive fire
protection materials shall be sprayed to required minimum thickness.

4.1.3 For outdoor applications, or where the passive fireproofing is subjected

to wear, impact or other mechanical damages, an epoxy based coating
system shall be used. For other applications, cement type materials
with a diffusion open top-coat can be used for steel structures.

4.2. Processing Facilities

4.2.1 General

4.2.1.1 Carbon steel can be used in processing systems where the

predicted cumulative corrosion loss over the lifetime is less than the
corrosion allowance or where several material replacements are
permitted during the lifetime as part of the maintenance philosophy.

4.2.1.2 The piping materials shall be standardised on the following material

types as far as practical:

 Carbon steel ASTM A106/ API 5L GrB/ A105/ A234WPB, A333 Gr

6/ A350LF2/ A420 WPL6 and API 5LX60/ ASTM A694 F60

 Stainless steel Type 316 ASTM A312 TP316L/ A182 F316L/ A403
WP316L.

 Stainless steel Type, Type 22Cr (ASTM A790 S31803/ A182 F51/
A815 WP S31803) and 25Cr super duplex (ASTM A790 S32760/
32750/ A182 F53/F55)

 Super austenitic stainless steel Type 6Mo (ASTM A312 S31254)

 Titanium (ASTM B337 Gr 1/2/ SB381 Gr F1/F2/ SB363 WPT1/

WPT2)

 Copper nickel alloy (ASTM B466 C70600/ B151 C70600)

 Nickel alloy (ASTM B423 UNS N08825/ B425 UNS N08825/ B366
CRNICMC)

 GRP.

4.2.1.3 Other materials shall only be considered after their performance and
availability have been considered.

MATERIAL SELECTION PHILOSOPHY Page 10

 4.2.1.4 General guidelines for material selections for processing facilities are
given in Appendix 1 with amendments as given below. A premise for
the selections in the table has been limitation of number of grades and
types for each application. For each project a detailed review shall be
carried out and more specific selection criteria shall be applied.

4.2.2 Oil and Gas Processing

4.2.2.1 Pressure rating, maximum and minimum design temperature, and

size shall be taken into account when selecting materials. This
includes soft goods such as valve seats, stem seals and ‘o’ rings. For
minimum design temperature, all depressurisation cases shall be taken
into account

4.2.2.2 All components which may contact oil well streams shall be resistant
against well treating, well stimulating chemicals and other additives.

4.2.3 Water Injection

4.2.3.1 In injection water systems where alternating deaerated

seawater, produced water, aquifer water and/or gas could flow through
the systems, the material selection shall take this into account. All
components which may contact injection water or back-flowing fluids,
shall be resistant against well treating chemicals or well stimulating
chemicals in case of back-flow situations.

4.2.4 Bolting Materials

4.2.4.1 The general bolting material for bolt diameters above 10 mm in

piping systems and equipment shall be low alloy steel selected in
accordance with ASTM Standards A193/ A320/ A194 as appropriate.

4.2.4.2 Bolts with a diameter < 10 mm shall be stainless steel Type 316
for metal temperatures below 50 °C for topside applications based
upon maximum operating temperature.

4.2.4.3 Bolting materials for structural applications shall be low alloy

steel.

4.2.4.4 Bolts with a diameter above 25 mm shall be impact tested to the

same requirements as for the steels to be bolted, except where the bolt
material specification demands higher properties.

4.2.4.5 If other bolting materials are required due to corrosion

resistance or other reasons, the material shall be selected in
accordance with the general requirements of this document.

4.2.4.6 Bolts screwed into component bodies shall be of a material that

is compatible with the body with respect to galling and ability to
disassemble the component for maintenance, if relevant. Risk for
galvanic corrosion and the effect of cathodic protection, shall be
considered.

MATERIAL SELECTION PHILOSOPHY Page 11

 4.2.4.7 Low alloy bolting material shall be hot dip galvanized and
centrifuged or have similar corrosion protection.

4.3. Pipeline Systems

4.3.1 For pipeline systems for processed oil and gas and for injection water,
carbon steel according to API 5L, grade X65 or lower shall be used.

4.3.2 The line pipe material shall be specified and tested to verify acceptable
weldability under field welding conditions.

4.3.3 Pipeline systems containing gas shall be designed for a minimum

design temperature that takes into account possible blow down
situations.

4.3.4 Pipelines for unprocessed or partially processed oil and gas shall follow
the material selection requirements in Appendix 1.

MATERIAL SELECTION PHILOSOPHY Page 12

5. DESIGN LIMITATIONS FOR CANDIDATE MATERIALS

5.1. General

5.1.1 For carbon and low alloy steels, the yield to tensile strength ratio
(actual values) shall not exceed 0.9.

5.1.2 In cases where the minimum design temperature is a limiting factor for
a material, also temperature exposures during intermediate stages
(such as manufacturing, storage, testing, commissioning, transport,
installation) shall be considered when specifying the minimum design
temperature and handling procedures.

5.2. Structural Materials

5.2.1 Aluminium may be used for all relevant ambient temperatures.

Aluminium alloys shall not be used for elevated temperatures. In
particular, AlMg-alloys with Mg-content above 3.0 % shall not be used
when the design temperature is above 60 °C. Special consideration
shall be given to loss of strength above approximately +200 °C.

5.2.2 Hardened aluminium alloys suffer from a reduction in strength in the

heat affected zone after welding. Consideration shall be given to
providing post weld heat treatment to maintain material properties at
the levels of the base material. The actual reduction factors to be used
for as-welded structures shall comply with applicable design code but
shall be evaluated and verified by welding and appropriate mechanical
testing. The weld metal strength shall be included in this evaluation and
minimum yield and tensile strength requirements shall also be defined.
Necessary precautions shall be taken to ensure homogeneous material
properties in extruded sections and in particular across extrusion
welds.

5.2.3 For GRP used in applications such as panels, gratings and other
secondary applications, special emphasis must be put on risk
assessment and evaluation of fire performance and degradation where
exposed to ultraviolet sunshine.

5.3. Materials For Pressure Retaining Equipment

5.3.1 Titanium base alloys shall not be used for hydrofluoric acid or pure
methanol (> 95 %) or exposure to mercury or mercury based
chemicals.

5.3.2 Copper base alloys shall not be exposed to mercury or mercury based
chemicals, ammonia and amine compounds.

5.3.3 Aluminium base alloys shall not be exposed to mercury or mercury

containing chemicals.

5.4. Bending and Cold Forming of Pipes

MATERIAL SELECTION PHILOSOPHY Page 13

 5.4.1 It shall be documented that the material after bending complies with the
requirements to mechanical properties and corrosion resistance as per
the relevant material data sheet.

5.5. Glass Reinforced Plastic

5.5.1 The need for fire and impact protection shall be evaluated whenever
GRP is used.

5.5.2 The use of GRP for piping systems on process facilities is limited as
follows:

 No use in hydrocarbon and methanol systems.

 Max. internal design pressure 40 bar g.

 Design temperature range from -40 up to 95 °C for epoxy and up

to 80 °C for vinyl ester.

 The possible hazard for static electricity build-up shall be

accounted for.

5.5.3 For GRP tanks and vessels the following limitations apply:

 Design pressure in bar times internal volume in litres shall not

exceed 75000 and a design temperature of maximum 75 °C.

 The potential hazard for static electricity build-up shall be

accounted for.

 The use for systems containing hydrocarbons shall be based on

risk assessment.

5.5.4 For systems where GRP can be applied, epoxy and vinylester resins
shall be evaluated as alternatives for piping components and tanks.
Polyester resin can be used in tanks for water and open drain services.

5.5.5 For systems handling hypochlorite, GRP with vinylester resin and PVC
lining or titanium shall be used. For sulphuric acid, only GRP with
vinylester resin and PVC lining shall be used. For other strong acids,
GRP with C glass or ECR glass combined with resin rich internal
barrier, or CRA of applicable grade, shall be used.

5.5.6 If GRP is considered used as rigid pipe for downhole produced water
and seawater injection tubing, material properties shall be documented
in accordance with relevant API standards.

5.6. Polymeric Materials

5.6.1 The selection of polymeric materials, herein included elastomeric

materials, shall be based on a thorough evaluation of the functional
requirements for the specific application. Dependent upon application,
properties to be documented and included in the evaluation are:

MATERIAL SELECTION PHILOSOPHY Page 14

  Thermal stability and ageing resistance at specified service
temperature and environment.

 Physical and mechanical properties.

 Thermal expansion.

 Swelling and shrinking by gas and by liquid absorption.

 Gas and liquid diffusion.

 Decompression resistance in high pressure oil/gas systems.

 Chemical resistance.

 Maximum and minimum design temperatures.

 Control of manufacturing process.

5.6.2 Necessary documentation for all important properties relevant for the
design, area/type of application and design life shall be provided. The
documentation shall include results from relevant and independently
verified tests, and/or confirmed successful experience in similar design,
operational and environmental situations.

MATERIAL SELECTION PHILOSOPHY Page 15

6. CORROSION INHIBITION

6.1 Corrosion inhibitors, scale inhibitors, oxygen scavenger or other

chemicals can be used to reduce corrosion. The efficiency in the
specified service shall be proven by laboratory trials and this shall be
followed by field trials using sidestreams with fast-acting probes in
process streams and documented as well as the compatibility with
other chemicals to be used. Performance of inhibitors in process
systems shall be monitored in service using appropriate fast acting
probes intrusively mounted in main streams. These shall also be used
to optimise inhibitor dosage. Performance of chemicals in all systems
shall also be monitored by production chemistry checks in addition to
wall thickness surveys.

6.2 Biocides should be used in process, injection water systems etc. to

prevent bacterial growth and possible microbiologically induced
corrosion problems.

6.3 The primary means for corrosion protection shall be correct material
and corrosion allowance. Corrosion inhibitors should only be
considered if there is a significant life cycle cost saving versus use of
exotic materials and/or additional corrosion allowance.

6.4 Use of corrosion inhibitors in process systems requires careful

consideration because the ability to coat all walls can not be
guaranteed under certain flow regimes, principally very high and low
velocities, and to reduce chemical handling and injection requirement.

6.5 When assessing corrosion inhibitors for process systems the inhibitor in
each process stream shall satisfy the inhibitor supplier’s minimum
recommended concentration. In the design an inhibitor efficiency of
maximum 80% in relation to the calculated corrosion rate in the
prediction model, should be used and an inhibitor availability of 95%
should be assumed.

6.6 For pipelines, an inhibitor efficiency of up to 95 % % and an availability

of 95% can be used. The inhibitor efficiency includes the effect of
glycol and/or methanol injection and shall be related to the corrosion
rate calculated. The corrosion rate in the inhibited fluid shall be
documented by corrosion tests unless relevant field or test data are
available and continuously monitored by fast acting probes.

6.7 In pipeline systems carrying hydrocarbons with condensed water, the

corrosivity may be reduced by application of inhibitors in combination
with pH stabilisers as an alternative to inhibitors alone. The combined
effect of inhibitors and pH stabilisers shall be qualified and documented
by corrosion tests unless relevant documentation exists and shall be
continuously monitored by fast acting probes.

6.8 Vessel materials for oil separation and gas treating systems shall be
selected based on the same corrosivity criteria as for hydrocarbon
piping systems. Vessels manufactured in suitable solid corrosion
resistant alloy, internally corrosion resistant alloy clad or weld
MATERIAL SELECTION PHILOSOPHY Page 16
 overlayed, should not need additional internal corrosion protection
systems.

6.9 Exceptions to above that may require additional lining if exposed to

water are as follows:

 Three phase separators to maximum water level.

 Tanks to water draw off.

 Instrument bridles

 valves

MATERIAL SELECTION PHILOSOPHY Page 17

7. CORROSION MONITORING

7.1. General

7.1.1 A comprehensive review of the process plant materials, corrosion

allowances and operating conditions should be carried out to identify all
areas which could be susceptible to significant corrosion within the
projected lifespan of the plant. An assessment of the consequences of
a corrosion failure occurring will be an integral part of the review. The
identification of the specific corrosion processes likely to occur is
essential to the selection of particular on-line corrosion monitoring
devices to be used. The review should also identify those parameters
which are instrumental in causing corrosion and which are likely to
influence the corrosion rate. The results of the review should be used
to develop a corrosion monitoring strategy encompassing the
following:-

 Identification and location of monitoring devices and their location.

 Prescribed monitoring frequencies.

 Agreed monitoring procedures.

 The interrogation, storage and retrieval of the information

recorded.

 The presentation of detailed reports at the required frequency.

7.1.2 The corrosion monitoring requirements shall be established during the

early development of the design.

7.1.3 The following established and industrially proven methods shall be

considered:

 Weight loss coupons

 Corrosion probes (Electrical Resistance, Linear Polarisation

Resistance, Electrochemical Noise etc.)

 Solid particle impingement probes

 Hydrogen probes and monitors

 Acoustic emission probes

 Galvanic probes

 Bacterial probes

 Non-intrusive sand measurement probes

 Potential measurement

 Ultrasonic thickness measurements

MATERIAL SELECTION PHILOSOPHY Page 18
  Radiography

 Intelligent pigs

 Chemical analysis

7.1.4 Corrosion monitoring techniques involving the use of coupons and

probes provide a measure of the corrosivity of a process fluid.

Corrosion rates measured by these techniques are not necessarily

those that will be experienced by the pipe or vessel walls which contain
the fluid.

These techniques should be supported by non-destructive testing and

visual inspection methods, which should be routinely used to determine
plant condition.

7.1.5 Where corrosion inhibitors or other performance chemicals are used to

control corrosion, the chemical supplier may be appointed to undertake
the required corrosion monitoring to determine the effectiveness of the
product(s) in service. In this case the chemical supplier shall have a
proven track record of carrying out such duties. The chemical supplier
shall submit detailed corrosion monitoring procedures for approval.

7.2. Internal Corrosion Monitoring – Piping

7.2.1 The objective of internal corrosion monitoring is to monitor corrosivity

trends in carbon steel systems and to verify or adjust means for
preventing corrosion.

7.2.2 The selection of the specific on-line corrosion monitoring devices

should be determined by the known or perceived corrosion processes
taking place.

7.2.3 Individual corrosion monitoring devices provide only a limited amount

of information. A minimum of two techniques should be used to
monitor corrosion in order to provide complementary data. In addition
the information provided by the corrosion monitoring devices should be
supplemented by detailed operational data covering the monitoring
period, chemical analysis of process fluids and equipment inspection
records.

7.2.4 On-line internal corrosion monitoring should be undertaken using

proprietary access fittings which permit the installation and removal of
probes and coupons without the need for plant shutdown. The design
and mechanical properties of such fittings must meet the requirements
of the appropriate Standard(s) and Code(s) used for the design and
construction of the plant being monitored.

7.2.5 The selection of monitoring method and location of monitoring points

shall take into consideration system criticality, expected corrosivity,
water content and salinity, pigging facilities, maintenance and shall be
in accordance with requirements described below.
MATERIAL SELECTION PHILOSOPHY Page 19
 7.2.6 The probes/coupons shall be located at representative locations where
there is a high likelihood of corrosion taking place e.g. bottom of line
location in stratified flow where water is likely to accumulate.

7.2.7 Where intrusive monitoring devices are used for the measurement of
fluid corrosivity in high velocity process streams vortex shedding could
result in fatigue of the probe or coupon holder. The length of the probe
or coupon holder should be kept as short as possible, particularly in
large diameter lines.

7.2.8 A retrieval tool is required to install and to retrieve the coupons/probes

from equipment under pressure. Sufficient space for the tool shall be
allowed for in the piping layout and when selecting the sensor
locations. Adequate working space and safe access to the fitting by
service personnel shall be established.

7.2.9 Based on process parameters and selected material, an evaluation of

process lines to be monitored shall be done. Guidelines are given
below (for carbon steel only). This shall as a minimum include:

 All ingoing and outgoing pipelines lines from CPF, downstream

and upstream from the injection point for corrosion inhibitor (if
any).

 Each oil flowline downstream and upstream the injection point for
corrosion inhibitor (if any).

 The inlet of 1st stage oil separator and test separator.

 The water outlet pipe from each oil separator.

 In gas outlets from each oil separator.

 In a selected number of produced water lines from gas scrubbers.

 In fuel gas downstream gas scrubber.

 Downstream deaerator in water injection systems.

 Downstream injection pumps in water injection systems close to

the injection manifold.

 In main closed water systems with corrosion inhibitors, e.g.

cooling water system.

7.2.10 A piping system which is designed in corrosion resistant materials will

not need corrosion monitoring equipment. However, 2" access fittings
(with blind flanges) should be considered installed in flowlines
upstream manifolds to allow for future installation of sand probes for
erosion monitoring.

7.3. Data Acquisition and Processing

MATERIAL SELECTION PHILOSOPHY Page 20

 7.3.1 On-line data acquisition using a central corrosion monitoring computer
system should be employed where carbon steel is used.

7.3.2 A PC-based program shall be included for evaluation of relevant

corrosion data.

7.3.3 The PC-based database shall include data of the following categories:

 Cathodic protection monitoring.

 Corrosion rate measurements from different types of corrosion

sensors.

7.3.4 In selecting computer software consideration should be given to the

inclusion of plant process data and plant inspection results.

7.3.5 Statistical techniques for evaluating the data and the data quality shall
be supplied with the data processing unit.

MATERIAL SELECTION PHILOSOPHY Page 21

 APPENDIX 1

Material Selection Guidelines for Surface Facilities

The following guidelines maybe used to standardise materials across the facility to
minimise life cycle costs. The guidelines shall not be used as an alternative to
proper material selection and corrosion/erosion analysis.

Application Materials Note

Oil and gas production and
processing
Piping Carbon steel, 22Cr duplex, 25Cr duplex, 6Mo,
316L.
Thin wall vessels <= 1 inch Carbon steel, stainless steel 316L/ 22%Cr duplex/
25%Cr super duplex/ 6%Mo/ nickel alloy 625/ 825
Thick wall vessels > 1 inch Carbon steel with, Alloy 625, Alloy 825 or 904L
clad or weld overlay or epoxy coating.
Piping, vessels for produced 316 and 22Cr duplex
water
Produced water and aquifer Carbon steel, 316, 22Cr duplex, 6Mo, Titanium
water injection
Deaerated water injection Carbon steel, 25%Cr super duplex steel
Fresh and potable water Hot dip galvanized carbon steel, GRP, 2
Polypropylene, 316L, Copper base alloys.
Drains
Open drain Concrete, GRP, carbon steel.
Closed drain without oxygen 316, carbon steel.
Closed drain with oxygen 22Cr duplex, 25Cr duplex, 6Mo, Titanium, GRP.
Flare systems
Relief system 316, 6Mo, low temperature carbon steel.
Burner components Alloy 800, Alloy 800HT, Alloy 625; For
temperatures below 650 °C: 310.
Flare boom Structural steel with thermally sprayed aluminium.
Dry fuel gas and diesel
Piping Carbon steel.
Tanks Carbon steel, GRP.
Lubrication and seal oil 316, 22Cr duplex, 6Mo. 3
Hydraulic fluid 316, carbon steel upstream filters.
Instrument air 316, carbon steel upstream filters.
Inert gas/plant air piping Carbon steel, 316.
Instrumentation
Tubing 316, nickel alloy 825, Monel 400, Titanium.
Junction boxes/cabinets GRP, 316.
Cable trays 316; Hot dip galvanized carbon steel in fully HVAC
controlled areas.
HVAC ducts and units
Ventilation/air intake ducts 316, Hot dip galvanized steel. 4
MATERIAL SELECTION PHILOSOPHY Page 22
Application Materials Note
Air handling units 316.
Active fire fighting systems
Dry CO2 systems Carbon steel.
Freshwater/plant air/nitrogen 316.
Glycol Carbon steel, 316.
Methanol Carbon steel, 316.
Heating/cooling media Carbon steel. CRA in heat exchanger tubes.
Miscellaneous chemical GRP, 316, 6Mo, Titanium. 5
systems
Bolting materials Low alloy steel hot dip galvanised and centrifuged.
Internal: as per material specification for vessel/
piping system.
NOTES
1. Large diameter piping and tanks can be made in internally coated carbon steel.
Tanks not intended for potable water, shall in addition be cathodically protected.
GRP, polypropylene and coating used for potable water shall be accepted by the
national health authorities.
2. Tanks in carbon steel shall have 3 mm corrosion allowance at the bottom section.
In addition the bottom and roof shall be coated. Cathodic protection shall only be
used if corrosion products from the sacrificial anodes do not cause damage to the
turbines. No corrosion allowance is required for cathodically protected surfaces.
3. For uninsulated stainless Type 316 instrument piping downstream a shut-off
valve, normally no extra precautions are required, provided process medium
temperature is below 85 °C and there is no flow in the instrument piping.
4. Hot dip galvanized steel can be used in living quarter and domestic areas.
5. The combination of chemical and material has to be considered in each case.
Titanium or GRP shall be used for hypochlorite systems.

MATERIAL SELECTION PHILOSOPHY Page 23