STANDARDS PUBLICATION

QP GUIDELINE FOR MATERIAL SELECTION

(SPECIAL APPLICATIONS - NON-SOUR SERVICE)

DOC NO: QP- GDL- R- 007

REVISION 1

CORPORATE QUALITY & MANAGEMENT SYSTEMS DEPARTMENT

 QP GUIDELINE FOR MATERIAL SELECTION
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DOC. No. QP-GDL-R-007 Rev. 1

TABLE OF CONTENT

FOREWORD Page No.

1.0 INTRODUCTION…………………………………………………………………...... 5

2.0 SCOPE ……………………………………………………………………………..... 5

3.0 APPLICATION …………………………………………………………………….... 5

4.0 TERMINOLOGY …………………………………………………………………….. 6

4.1 DEFINITIONS ……………………………………………………………………...... 6
4.2 ABBREVIATIONS …………………………………………………………………... 6

5.0 REFERENCE DOCUMENTS............................................................................. 7

6.0 MATERIALS SELECTION PHILOSOPHY........................................................ 8

7.0 GENERAL REQUIREMENTS............................................................................ 8

8.0 SPECIFIC REQUIREMENTS............................................................................. 9

8.1 SEA-WATER APPLICATIONS.......................................................................... 9
8.1.1 Composition of Sea water................................................................................. 9
8.1.2 Factors Affecting Corrosion of Materials in Sea Water..................................... 10
8.1.3 Material Requirements...................................................................................... 11
8.1.4 Materials........................................................................................................... 12
8.1.5 Water Injection.................................................................................................. 12
8.2 FIRE-WATER APPLICATIONS......................................................................... 13
8.3 REFINERY & PETROCHEMICAL APPLICATIONS........................................ 13
8.3.1 Factors in Materials Selection for Petrochemical Refineries............................. 14
8.3.2 Material Selection Based on Temperatures....................................................... 14
8.4 Materials Selection Guide for Rotating Equipment……………….....………….. 16
8.5 NON- METALLIC MATERIALS APPLICATION................................................ 16
8.5.1 Thermo-plastics Includes................................................................................... 16
8.5.2 Glass Fibre Reinforced Thermosets Includes.................................................... 16
8.5.3 Glass Fiber Reinforced Plastic (GRP)............................................................... 17
8.6 POLYMERIC MATERIALS............................................................................... 17
8.7 ASBESTOS...................................................................................................... 18
8.8 SWEET SERVICE ENVIRONMENT (CO2 CORROSION)............................. 18
8.8.1 CO2 Corrosion Mechanisms.............................................................................. 18
8.8.2 Main factors affecting severity of CO2 Corrosion Rate (CR)........................... 18
8.8.3 Preventions / Mitigations.................................................................................... 19

9.0 QUALIFICATION OF MATERIALS AND MANUFACTURERS...................... 19

9.1 MATERIAL QUALIFICATION........................................................................... 19
9.1.1 General............................................................................................................. 19
9.1.2 Qualification by past experience........................................................................ 20

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DOC. No. QP-GDL-R-007 Rev. 1

9.1.3 Qualification by general test data...................................................................... 20

9.1.4 Qualification by specific test programme.......................................................... 20
9.2 MANUFACTURER QUALIFICATION............................................................... 20

10.0 QUALITY REQUIREMENTS........................................................................... 21

11.0 APPENDICES
11.1 APPENDIX-I: TABLE 4 - Sea Water Materials Comparison.............................. 22
11.2 APPENDIX-II: TABLE 5 - Materials for Process & Utility Use........................... 24
11.3 APPENDIX-III: TABLE 6 - Materials for Construction Of Grp Systems............. 27
11.4 APPENDIX-IV: TABLE 7: Materials for Handling Inhibitors & Other Chemicals 28
REVISION HISTORY LOG ……………………………………………………….. 29

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DOC. No. QP-GDL-R-007 Rev. 1

FOREWORD

This document has been developed by QA/STI–Pipeline Engineering Division , reviewed

by Working Group Four-Task Force Five (WG4-TF5) and User Departments before
endorsed by QP Management for use as QP Technical Standard-Guideline.

This document is published for QP Departments/ Contractors/ Consultants utilisation. It shall

be emphasised that the document is to be used for QP operations wherever applicable and
appropriate.

The document in all its parts reflects as far as possible the current QP requirements, taking
into account the known available industry practices and the applicable latest national and
international codes and standards.

All parts will guide QP and its contractors in the selection of materials for special applications
considered non-sour.

This document is subjected to periodical review to re-affirm its adequacy or to conform to

any changes in the corporate requirements or to include new developments on its subject.

It is recognised that there will be cases where addenda or other clarifications need to be
attached to the standard to suit a specific application or service environment. As such, the
content of the document shall not be changed or re-edited by any user, but any addenda or
clarifications entailing major changes shall be brought to the attention of the Custodian
Department.

The custodian of this document is Corporate Quality and Management Systems

Department. Therefore, all technical comments, views, recommendations, etc, on this
document shall be forwarded to Manager, Corporate Quality & Management Systems
Department (QA).

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1.0 INTRODUCTION

Various national and international standards and guidelines exist for the selection of
engineering materials for sour service environment which is considered peculiar due to
its catastrophic nature on production facilities. However, there exists several other
service environments encountered in oil & gas operation outside of the sour service.
Several equipment failures have also been encountered in these environments
necessitating caution in the selection of materials to be used.
In practice, material selection for many applications is a mixture of two logical
approaches resulting in the high initial costs of one and the high maintenance costs of
the other. For example, a plant which has experienced costly replacement to
galvanized steel piping may replace it with copper alloy piping leaving valves fittings,
etc., in carbon steel and cast iron. The resulting galvanic corrosion effects result in
reduced life for these parts. Thus, higher initial costs have resulted in reduced reliability
and high maintenance costs.
It is essential therefore in selecting materials for ‘special applications’ to treat the
system as a whole.
This guideline provides a framework for the selection of materials for use in ‘special
applications’ in QP operations other than Sour service.
Note: All sour service related applications shall follow the requirements of QP
Standard for Materials for Sour Service (QP-STD-R001).

2.0 SCOPE

This document covers the various engineering materials used in special applications in
QP operation other than Sour service
It specifies the service limits/requirement for these materials in terms of:
 Service conditions such as minimum & maximum operating temperatures,
 Design requirements such as load limits, lifetime, installation & operational
constraints.
3.0 APPLICATIONS

This guideline should be used in the selection of materials for the following areas
considered as Special Applications:-
a. Sea Water Environment
b. Fire Water Applications
c. Refinery & Petrochemical Applications
 High Temperature Applications including Refractory Applications
 Low Temperature (Cryogenic) Applications
d. Non-Metallic Applications
e. Super-Alloys, Cast-Alloys, etc

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4.0 TERMINOLOGY

4.1 DEFINITIONS

C-glass - Special fibre type that is used for its chemical stability in corrosive
environments
Corrosion - alloy which in a given environment shows negligible weight loss
resistant alloy corrosion and no significant localized corrosion nor cracking
(CRA) problems
E-glass - general purpose fibre that is most used in reinforced Plastics
ECR-glass - modified E-glass fibre type with improved corrosion resistance
against acids
Glass fibre - composite material made of thermosetting resin and reinforced
reinforced with glass fibres as defined in ISO 14692-1
plastic (GRP)
High - Applications at regions above the recrystalization temperature of
Temperature the material, or equal to or more than two-third the melting point of
Applications the material, capable of altering the materials property.

Low - Applications at environment far below the normal ambient

Temperature temperature, or near to or below 0 degrees C or subzero.
Applications
Maximum - maximum temperature predicted including deviations from normal
operating operations, like start-up/shutdown, process flexibility, control
temperature requirements and process upsets

Operating - temperature in the equipment when the plant operates at steady

temperature state condition, subject to normal variation in operating parameters
Oxygen mg/m3 oxygen + 0,3 mg/m3 free chlorine
equivalent
pH - Increase in bulk pH to reduce corrosion in condensing water
stabilization systems
Sour Service - An environment that contains H2S in significant proportion and right
conditions capable of causing hydrogen cracking
Special - Applications in environment other than sour service environment
Applications

4.2 ABBREVIATIONS

ABS - Acrylonitrile-butadene-styrene
CAB - Cellulose Acetate Butyrate
CAPEX/OPEX - Capital Expenditure / Operating Expenditure
CPVC - Chlorinated Polyvinylchloride
GRP - Glass fibre reinforced plastic
NDT - Non Destructive Test

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PE - Polyethylene
PVC - Polyvinylchloride
TDS - Total Dissolved Solid

5.0 REFERENCE STANDARDS AND CODES

5.1 INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 4427 - Plastic Piping Systems: PE Pipes and Fittings for Water Supply
ISO 13705 - Fired Heaters for General Refinery Service
ISO 10441 - Flexible Coupling for Mechanical Power Transmission-Special
Purpose Application
ISO 13702 - Requirements & guidelines for Offshore Production Installation,
Control & Mitigation of Fires and Explosion
ISO 13705 - Requirements & Guidelines for Fired Heaters for General Refinery
Service
5.2 AMERICAN PETROLEUM INSTITUTE (API)
API Spec 5 LC - Specification for CRA Line Pipe
API Spec 5LD - Specification for CRA Clad or Lined Steel Pipe
API Spec 15 HR - Specification for High Pressure Fiberglass Line Pipe
API Spec 15 LR - Specification for Low Pressure Fiberglass Line Pipe
API Spec 17J - Specification for Unbonded Flexible Pipe

5.3 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B 31.3 - Process Piping

5.4 AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A153 - Standard Specification for Zinc Coating (Hot Dip) on Iron and Steel
Hardware
ASTM A 193 - Specification for Alloy - Steel and Stainless Steel Bolting Materials
for high temperature Service
ASTM A 194 - Specification for Carbon and Alloy Steel Nuts for Bolts for high
Pressure and high temperature Service
ASTM A 320 - Specification for Alloy Steel Bolting Materials for Low temperature
Service
ASTM D 2992 - Practice for Obtaining Hydrostatic or Pressure Design Basis for
Fiberglass Pipe and Fittings
5.5 BRITISH STANDARDS INSTITUTE (BSI)
BS EN 10204 - Metallic products – types of inspection documents

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5.6 DNV SOCIETY

DNV RP B201 - Metallic Materials in Drilling, Production and Process Systems
DNV OS C501 - Composite Components
DNV OS F101 - Submarine Pipeline Systems

5.7 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 13 - Standard for the Installation of Sprinkler Systems

NFPA 15 - Standard for the Inspection, Testing & Maintenance of Water-

Based Fire Protection Systems
5.8 SHELL - DESIGN AND ENGINEERING PRACTICE(SHELL DEP)
DEP 39.01.10.12-Gen - Selection of materials for life cycle performance (upstream
facilities) – Equipment
DEP 31.38.01.12-Gen - Piping Classes - Refining and Chemicals
DEP 31.38.01.15-Gen - Piping classes - Exploration and Production

6.0 MATERIALS SELECTION PHILOSOPHY

The materials selection process should reflect the overall philosophy regarding design
life time, cost profile (CAPEX/OPEX), inspection and maintenance philosophy, safety
and environmental profile, failure risk evaluations and other specific project
requirements.

7.0 GENERAL REQUIREMENTS

Materials selection should be optimized and provide acceptable safety and reliability.
As a minimum, the following should be considered:
 Corrosively, taking into account specified operating conditions including start-up and
shut-down conditions
 Design life and system availability requirements
 Failure probabilities, failure modes and failure consequences for human health,
environment, safety and material assets
 Resistance to brittle fracture
 Inspection and corrosion monitoring
 Access for maintenance and repair
 Flow regime
 Effect of possible atmospheric emission from close-by surrounding plants area
 Specific plant field air quality heat / Meteorological data
For the final materials selection the following additional factors should be included in
the evaluation:

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a) Priority should be given to materials with good market availability and

documented fabrication and service performance
b) The number of different materials should be minimized considering stock, costs,
interchangeability and availability of relevant spare parts.
Deviations from materials selections specified in this guideline may be implemented if
an overall cost, safety and reliability evaluation shows the alternative to be more
beneficial.
The type of service and its peculiar characteristics should dictate the choice of the
material to be used. Such requirements should include the operating conditions such as
temperature regime, pressure, design limits. The selected material should satisfy the
specifications stated in the design philosophy. In other words, materials should be
selected based on their ability to meet service requirement as dictated by the operating
environment.

8.0 SPECIFIC REQUIREMENTS

8.1 SEA-WATER APPLICATIONS

The main applications to be considered are seawater intakes and distribution systems
for:-
a. Sea-going and coastal vessels of all types
b. Offshore oil and gas platform installations
c. Displacement fluids during drilling & cementation
d. Water Injection
e. Desalination plants producing fresh water from seawater
f. Coastal petroleum and petrochemical processing plants
g. Fire fighting
h. Coastal electricity generating stations
8.1.1 Composition of Sea water
Sea water principally contains water and dissolved salts. The total dissolved solid
(TDS) in sea water determines its corrosivity and varies from place and to place. The
higher the TDS, the more corrosive the sea water becomes. In the bay areas of the
Arabian Gulf, the TDS is higher than other areas due to the evaporation by tropical heat
in the desert air. Typical composition of Sea Water and Arabian Gulf are given in
Tables 1 and Table 2.

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Table 1: Composition of Sea Water

Dissolved Salt Concentration (mg/l) % of Total Salt
-
Chloride (Cl ) 18,980 55.04
Sodium (Na+) 10,556 30.61
2-
Sulphate (SO4 ) 2,649 7.68
Magnesium (Mg2+) 1,272 3.69
3-
Bicarbonate (HCO ) 140 0.41
Boric acid 26 0.07
Bromide (Br-) 65 0.19
Calcium (Ca2+) 400 1.16
Strontium (Sr2-) 13 0.04
+
Potassium (K ) 380 1.10
Fluoride (F-) 1 0.00
Total Dissolved Solid (TDS) 34,482 99.99
Source: The Hendrix Group Reporter – A Corrosion & Materials Technology Site

Table 2: TDS Composition of Arabian Gulf

Dissolved Salt (Ions) Concentration mg/L % of Total Salt
-
Chloride (Cl ) 23,000 51.11
Sodium (Na+) 15,850 35.22
2-
Sulfate (SO4 ) 3,200 7.11
2+
Magnesium (Mg ) 1.765 0.00
2+
Calcium (Ca ) 500 1.10
+
Potassium (K ) 460 1.02
-
Bicarbonate(HCO3 ) 142 0.32
Strontium (Sr2+) 17 0.38
-
Bromide (Br ) 80 1.78
-
Fluoride (F ) 1 0.00
2-
Silicate (SiO3 ) 1,5 0.00
pH 8.2
Total dissolved solids 98.04
45,000
(TDS)
Source: Magazine - Water Condition & purification

8.1.2 Factors Affecting Corrosion of Materials in Sea Water

a) Velocity
Corrosion of carbon steel in seawater is controlled by the availability of oxygen to
the metal surface. Under static conditions, carbon steel corrodes at between 0.1
and 0.2 mm/yr, reflecting the oxygen level and temperature variations in different
locations. Pitting also occurs.
As velocity causes a mass flow of oxygen to the surface, corrosion is very
dependent on flow rate and can increase by a factor of 100 in moving from static
(zero velocity) to high velocity (40 m/s) conditions.

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Galvanizing confers only limited benefit under flow conditions, as corrosion of zinc
also increases with velocity. For the thicknesses normally used in seawater piping, it
will extend the life of the pipe for about six months.
The copper base alloys are velocity limited as impingement attack occurs when the
hydrodynamic effect caused by seawater flow across the surface of such alloys
exceeds the value at which protective films are removed and erosion-corrosion
occurs. Thus, these alloys, if they are to exhibit high corrosion resistance should be
used at design velocities below this limiting value.
Stainless steels are not subject to impingement attack, but are prone to pitting and
crevice corrosion under low velocity conditions and this should be taken into
consideration when these alloys are used in seawater.
Nickel base alloys such as Inconel Alloy 625, Hastelloys C-276 and C-22 and
titanium are not subject to pitting or crevice corrosion in low velocity seawater, nor
do they suffer impingement attack at high velocity. However, price limits their use to
special applications in seawater systems.
b) Temperature
Although oxygen solubility tends to fall with rise in temperature, higher temperature
tends to increase reaction rate. Corrosion of steel is increased with temperature.
For copper alloys, increase in temperature accelerates film formation; this takes
about 1 day at 15°C, whereas, it may take a week or more at 2°C. It is important to
continue initial circulation of clean seawater long enough for initial film formation for
all copper alloys. More time is needed for winter than for summer start-ups.
For stainless steels and other alloys prone to pitting and crevice corrosion, increase
of temperature tends to facilitate initiation of these types of attack. However, data on
propagation rate suggest that this declines with rise in temperature. The net effect
of these conflicting tendencies is not always predictable. Temperature also
influences biological activity which may, in turn, influence corrosion
c) Environmental and Atmospheric Conditions
Changes in the environment especially in view of the on-going climatic change
could also affect deterioration of materials in given service environment. It is
therefore necessary to factor these potential changes when considering a material
for a particular use.
8.1.3 Material Requirements
a. The factors that are relevant in selecting the material for seawater applications are:
 Resistance to corrosion by seawater over a wide range of operating conditions.
 Resistance to corrosion by the external environment
 Resistance to marine biofouling
 Permissible water velocities
 The physical and mechanical properties of the material
 Ability to cut, machine, bend and perform other fabricating operations
 Availability of suitable jointing techniques and of NDT methods to confirm the
quality and serviceability of joints.

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 Availability of comprehensive ranges of components to enable complete systems

to be assembled, including compatible pumps, valves, heat exchangers, etc.
 Existence of adequate and reliable supplies of pipes and components and free
availability of raw materials for their fabrication.
 Initial cost of pipe and components and costs of fabricating and installing
systems.
 Life expectancy and the value of scrap when the system is dismantled.
 Demonstrable reliability based on adequate service experience.
 Ability to withstand hazards during construction and service, e.g. mechanical
damage and fire.
b. In considering behaviour in seawater, account has to be taken of many factors
including:
 Rate of general and/or localized corrosion under steady state flow conditions.
 Possibility of crevice corrosion and of deposit attack or pitting, particularly
under stagnant or slowly moving conditions.
 Resistance to stress corrosion cracking.
 Effect of variations in composition of seawater including salinity, oxygen
content, suspended material, pollutants, etc.
 Effect of chlorination of seawater, if practiced.
 Velocity limitations.
 Effect of variation of temperature, possible spheres of operation being
anywhere from arctic to tropical regions; in some applications hot brine has to
be handled.
 Possible galvanic effects between different materials.
 Biological corrosion and special attention to SRB presence.
In the marine environment, external corrosion of piping systems can be a hazard,
e.g. occurrence of crevice corrosion due to ingress of chloride beneath sheathings,
laggings, brackets, etc.
8.1.4 Materials
The main types of material considered for seawater piping systems are:
a) Copper alloys, particularly the copper-nickel series
b) Carbon steel internally coated or lined (e.g. with epoxy, bitumen, rubber, cement,
mortar)
c) Stainless steels
d) Plastics or reinforced plastics
e) Titanium
A summary of the relevant properties of these materials in sea water environment is
given in Table 4 (Appendix:-I).
8.1.5 Water Injection
Water injection covers systems for injection of de-aerated sea water, raw untreated sea
water, produced water and combinations and mixing of different waters.

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Corrosivity evaluations and materials selection for de-aerated seawater injection

systems should be based on residual oxygen and chlorine levels. A typical residual
oxygen concentration for un-chlorinated sea water is 20 mg/m3 for normal operation,
but may be higher during upset conditions and during chemical treatments.
For chlorinated sea water the following oxygen equivalent levels is recommended:
• 50 mg/m3 for 90 % of operation time;
• 200 mg/m3 for 10 % of operation time, non continuous.

In addition bacteria control and flow velocities should be considered.

Even if the specification for the de-aeration equipment gives more strict requirements,
the above should be basis for the materials selection. If the specified oxygen equivalent
or temperature is above 50 mg/m3 or 30°C respectively for normal operation, the basis
for materials selection should be subject to special evaluation.
For carbon steel submarine injection Flowlines the corrosion allowance should be
minimum 3 mm.
In injection water systems where alternating de-aerated sea water, produced water,
aquifer water, any kind of process water, and/or gas could flow through the systems,
the materials selection should take this into account. Such systems may contain many
corrosive species, e.g. CO2, H2S from bacteria activity, oxygen from blanketing gases,
elemental sulfur. All components which may contact injection water or back-flowing
fluids should be resistant against well treating chemicals or well stimulating chemicals
in case of back-flow situations. For carbon steel piping maximum flow velocity should
be 6 m/s. Carbon steel should only be considered if the system can be kept clean and
corrosion inhibition and biocide treatment is applied. Internal organic lining should be
considered for water injection Flowlines.
For subsea applications such as produced water disposal, raw water intake and brine
water discharge, due consideration should be given to use of HDPE.
8.2 FIRE- WATER APPLICATIONS
Materials for fire-water applications should, as a rule be non-combustible. If it is
justified from a safety point of view to make use of materials that do not meet the
requirements to non-combustibility, such materials shall have limited flame spread
properties, low smoke development and heat generation.
The material shall also be resistance to corrosion attack from the water being used.
Where temperature is of essence in the vicinity of application, the material should be
resistant to the prevailing temperature. GRE/GRP are typical materials for fire-water
ring main, but has the limitation of poor resistance to high temperature. Therefore,
GRE/GRP materials should not be allowed for above ground fire-water ring main,
except for deluge systems with overhead sprinkler. Materials for fire-water applications
shall comply with the requirements of relevant sections of the National Fire Protection
Association (NFPA).
8.3 REFINERY & PETROCHEMICAL APPLICATION
Refinery and Petrochemical operations cut across different sphere of operating
conditions. Heat Exchangers, Boilers, Furnaces, Turbines, Storage Tanks, etc, used in

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refinery and petrochemical operations are often subjected to varying degree of

temperatures and pressure regimes, which make them vulnerable to failure. Therefore,
caution is required in the selection of materials for this application.
Generally, refinery and petrochemical materials are selected based on environmental
resistance, erosion, wear, mechanical behaviour and physical properties. In all these,
temperature and pressure are the controlling factors.
8.3.1 Factors in Materials Selection for Petrochemical Refineries
a. Type of Refinery
b. Type of crude to be processed
c. Service conditions in specific process unit/application like operating temperatures
and pressure, etc.
d. Type of Environment.
8.3.2 Material Selection Based on Temperatures
a. High Temperature Applications

Materials suitable for high temperature applications should have specific

requirements in order to function well. This includes, but not limited to:
 Adequate yield strength
 Creep Resistance
 High Thermal Conductivity
 Low Thermal Expansion Coefficient
 Oxidation Resistance
 Corrosion Resistance
 High Elastic Modulus
 Formability or Tensile Elongation
 Other properties, such as hydrogen embrittlement resistance, machinability,
etc.

Super-alloys have been developed for elevated temperature services where relatively
severe mechanical stresses are encountered and high surface stability is required.
Specifically, the Cr-Mo Steels, Fe-Ni-Cr steels and Co-Ni-Cr steels are preferred
materials for high temperature applications.

The following guidelines for Management of Change (MOC) for elevated stacks
and when refractory lining are used, should be adhered to:
 Materials shall withstand the high temperature of applications and be corrosion
resistant at such temperatures.
 Materials shall withstand the temperature and pressure stresses of the environment.
If refractory lining is damaged by cracking or spalling, corrosion of underlying steel
material can occur due to acid gas condensation if the dew point is reached within
the stack especially during wintery conditions. Therefore steps should be taken to
minimize the condensation risk, including gas purging and keeping metal
temperatures above the dew point
 The economics of application of such materials should be considered.

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The following guidelines are provided for Management of Change (MOC) for
boiler feed water pumps:
 Plastic should be avoided in the design and construction of pump heads as this
may be adversely affected by certain solvents and high temperatures.
 Abrasive resistant materials such as cast iron and stainless steel 316 or SS 304
are suitable materials for feed-water pumps.
 While deciding on material of construction in boiler systems, due consideration
should be given to presence of caustics and chlorides and possibility of Caustic
Embrittlement and Chloride Stress Corrosion should be checked before finalizing
the material of construction.
b. Materials for low temperature and cryogenic applications
Some other materials are used at low or sub-critical temperatures which also endanger
their material property. Cooling towers, refrigeration lines, liquid-knock-out lines, etc,
are some applications that require proper materials selection. Failure of any of these
could lead to production shutdown and subsequent revenue loss. For these
applications, such materials property as fracture toughness is a mandatory guiding
considerations. Operating facilities at temperatures below the ductile-to-brittle transition
temperature may be catastrophic, as this increases the yield strength and reduces
ductility. Thus, selection of special steels qualified by impact testing at the lowest
expected temperature is recommended. Carbon steels that require low temperature
properties or used in low temperature conditions should be impact tested according to
the governing code and meet the energy requirements stated for that particular low
temperature regime.
Ferritic and martensitic steels, including duplex steels should not be used for low
temperature/cryogenic applications as they tend to become brittle at such temperature
regime. Austenitic steels on the other hand are ‘tougher’ at low temperature/cryogenic
environments and are recommended.
Minimum temperature limits for piping material selection in QP should be as follows:-
Carbon Steel - Down to 0 degree C
Low Temperature Carbon Steel - Down to -10 degree C
Austenitic Stainless Steel - Down to -20 degree C

Low temperatures can also result from pressure reduction activities such as blow-down,
etc, especially in CO2 pipelines. The effect of this should be considered during material
selection and design of such pipelines.
The following guidelines are provided for Management of Change (MOC) for
liquid Nitrogen Storage Tanks:
 Use only tanks designed for extreme cold when handling liquid nitrogen
 Because liquid nitrogen freezes easily at room temperature, do not use rubber or
plastic tubing for liquid nitrogen transfer to prevent fracture.
 Use a double-walled tank for liquid nitrogen storage.
 Use flexible stainless steel transfer hose, insulated pipe, flexible or rigid vacuum-
jacketed pipes for liquid nitrogen transfer.

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8.4 MATERIALS SELECTION GUIDE FOR ROTATING EQUIPMENT

Rotating equipment by virtue of their function are in constant motion when in operation.
This subjects them to frictional forces, which leads to vibration, wear and tear, fatigue,
erosion and temperature rise. These rotating equipment sometimes are used in service
environments which also affect their functionality. Because rotating equipment consists
of different components in one unit, it is cautioned that extreme care should be taken
when selecting materials to ensure the various material parts are suitable to the
environment or function they play. All materials shall satisfy the requirement of the
relevant Standards and Specifications for Rotating Equipment.
8.5 NON- METALLIC MATERIALS APPLICATION
There has been an increased use of non-metallic materials in oil field operation,
because they do not corrode in the environment in which carbon steel readily corrodes.
They are light weight, suitable for rapid installation, and in most cases less expensive
than steel.
The three categories of non-metallic materials include:
 Thermoplastics,
 Glass Fibre reinforced,
 Cement-asbestos.
8.5.1 Thermo-plastics Includes:
 Polyvinylchloride (PVC)
 Chlorinated Polyvinylchloride (CPVC)
 Polyethylene (PE)
 Polyacetal
 Acrylonitrile-butadene-styrene (ABS)
 Cellulose Acetate Butyrate (CAB)
8.5.2 Glass Fibre Reinforced Thermosets Includes:
 Glass-Fibre Reinforced Epoxy
 Glass-Fibre Reinforced Polyester
Non-metallic materials of construction are widely used where temperatures, pressure,
and stresses are not limiting and in such media as aqueous chloride solution which
cause localized corrosion of metals and alloys. Examples are:-
a. Rubber-lined steel for water treatment ion exchange resin beds which should be
periodically regenerated with salt brine or dilute mineral acids or caustic solution.
b. Acid-proof brick and membrane line steel for higher temperature, and solid RTP
polyester and vinyl-ester construction for lower temperature, flue gas and chlorine
neutralization scrubbers.
Generally, proven non-metallic materials such as reinforced thermoplastic (RTP) are
often used as linings for low cost materials such as plain carbon steel or for solid
construction.

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However, some other non-metallic materials such as used for piping and some cases
as pipelines for water and hydrocarbon transport have their use restricted in some
areas and operating conditions. Such restrictions include pressure and temperature
limitations. At high operating pressures, they burst, and at low temperatures exhibit
brittle fracture characteristics. Therefore their selection should be properly advised
before use.
For services where aromatics may be present, UPVC materials shall not be used
unless pre-chlorination and clarification is applied to prevent or reduce organic fouling.
Besides UPVC, many of the other non-metals are generally available for various
internal packing such as EPDM, Neoprene, PTFE, etc.
8.5.3 Glass Fiber Reinforced Plastic (GRP)
Design of piping systems in GRP materials should in general be according to ISO
14692 (all parts) and ASME B 31.3. The need for fire and impact protection should be
evaluated whenever GRP is used.
a. The use of GRP for piping systems is limited by the following factors:
 Maximum internal design pressure of 40 barg;
 Design temperature range from -40°C up to 95°C for epoxy and up to 80°C for
vinyl-ester (according to qualifications);
 Possible hazard for static electricity build-up should be accounted for.
Recommended materials of construction for different fluids are listed in Table 5.
b. GRP tanks and vessels should be designed according to BS 4994 and with the
following limitations:
 Design pressure in barg times internal volume in liters should not exceed 75 000
and a design temperature of maximum 75 °C;
 The potential hazard for static electricity build-up should be accounted for;
 The use for systems containing hydrocarbons should be based on risk
assessment.
For systems where GRP can be applied, epoxy and vinyl-ester resins should be
evaluated as alternatives for vessels and tanks. Polyester resin can be used in tanks for
sea water and open drain services.
In corrosive environment internally or externally, GRP material can be used as tubing,
casing and line pipe.
The GRP material used should satisfy the requirements in API Spec 15 HR and API
Spec 15 LR depending on pressure.
If GRP is considered used as rigid pipe for downhole produced water and seawater
injection tubing, material properties should be documented in accordance with relevant
API standards and ASTM D 2992. GRP pipes can also be use as lining for downhole
steel tubing with temperature and environmental limitations dependent on
qualifications.
8.6 POLYMERIC MATERIALS
The selection of polymeric materials, including elastomeric materials, should be based
on a thorough evaluation of the functional requirements for the specific application. The

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materials should be qualified according to procedures described in applicable

material/design codes. Dependent upon application, properties to be documented and
included in the evaluation are:-
a. Thermal stability and ageing resistance at specified service temperature and
environment,
b. Physical and mechanical properties,
c. Thermal expansion,
d. Swelling and shrinking by gas and by liquid absorption,
e. Gas and liquid diffusion,
f. Decompression resistance in high pressure oil/gas systems,
g. Chemical resistance,
h. Control of manufacturing process.
8.7 ASBESTOS
Asbestos and asbestos-containing materials such as packing and gaskets shall not be
used in any QP facilities for health reasons.
8.8 SWEET SERVICE ENVIRONMENT (CO2 CORROSION)
8.8.1 CO2 Corrosion Mechanisms:
Carbon Dioxide gas (CO2) in oil/gas stream forms carbonic acid (H2CO3) when
dissolved in water (which is also contained in gas/crude oil reservoir/well).
Carbonic acid is corrosive to carbon steel or low alloy steel.
CO2 + H2O H2CO3 (Carbonic Acid)
Carbonic acid lowers the pH, and sufficient quantities may promote general corrosion
and/or pitting corrosion of carbon steel.

8.8.2 Main factors affecting severity of CO2 Corrosion Rate (CR):

a. CO2 partial pressure (ppC02): Higher (ppC02) leads to higher CO2 corrosion rate.
In sweet gas wells with a pH of 7 or less, CO2 corrosion can be predicted as
follows:
 CO2 partial pressure of 30 psi usually indicates corrosion,
 CO2 partial pressure of 7 - 30 psi may indicate corrosion,
 CO2 partial pressure of ≤ 7 psi is usually considered non-corrosive.
b. Temperature: Higher temperature leads to higher CO2 corrosion rate.
Increasing temperature leads to increase in CO2 vaporization which subsequently
increases the CO2 partial pressure and of course the corrosion rate.
c. pH: lower pH, higher CR
Increasing partial pressures of CO2 result in lower pH condensate and higher rates
of corrosion. Corrosion occurs in the liquid phase, often at locations where CO 2
condenses from the vapour phase.
d. Flow velocity: The higher the flow velocity, the higher the CO 2 corrosion rate.

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8.8.3 Preventions / Mitigations

The general rule of thumb for the mitigation of CO 2 corrosion is as following, which
depends on the level of CO2 partial pressure:
 ppCO2 <0.2 barg:
Corrosion rate generally low on carbon steel and low alloy steel. This does not
pose a threat, but use of material with appropriate corrosion allowance and other
corrosion preventive mechanisms are recommended.
 ppCO2 0.2 – 2.0 barg:
Corrosion rate mild. Use of carbon steel or alloy steel with appropriate corrosion
allowance is recommended. In addition it is recommended to use corrosion
inhibitors.
 ppCO2 > 2 barg:
Highly corrosive. Recommended to use corrosion resistant alloys e.g. 300, 400 or
duplex SS series.

Table 3: CO2 Corrosion Criteria

Controlling Factor Level CO2 Corrosion Indication
ppCO2 0 – 0.2 bar Non-Corrosive
0.2 – 2 bar Mild CO2 Corrosion
>2bar High CO2 Corrosion
pH Low High corrosion rate
High Low corrosion rate
Temperature High Higher corrosion rate
Low Lower corrosion rate
Flow Velocity High Higher corrosion rate
Low Lower corrosion rate

9.0 QUALIFICATION OF MATERIALS AND MANUFACTURERS

9.1 MATERIAL QUALIFICATION

9.1.1 General
The selection of materials for applications which may affect the operational safety and
reliability level should be made among the listed qualified materials.

The materials selected for special applications be regarded as qualified when used
within the design limitations specified. Other materials can be used if adequate
documentation is available and the objective of limiting number of material types and
grades is maintained. Qualified materials should fulfill the following requirements:
a. The material is listed by the relevant design code for use within the stated design
requirements;
b. The material is standardized by recognized national and international
c. standardization bodies;
d. The material is readily available in the market and stocked by relevant dealers;

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e. The material is readily weldable, if welding is relevant, and known by potential

fabricators;
f. The material has a past experience record for the applicable use, e.g. same type of
component and dimensional range.
9.1.2 Qualification by past experience
Where the same type of material is regularly supplied for the same application, the
qualification should be based on experience. This applies to most materials supplied
and used within the limitation of the design codes. The exception to this can be
manufacturing of special components outside the normal dimensional range.

9.1.3 Qualification by general test data

Where well known materials are used in "new" applications or "new" materials are to be
used, the qualification may be by reference to results from relevant laboratory or
production tests.
9.1.4 Qualification by specific test programme
When a material is proposed for a new application and the selection cannot be based
on the criteria in 9.1.1 to 9.1.3 above, a qualification programme should be initiated.
The objective of the programme should be clearly defined before starting any testing.
Such objectives may be qualitative or quantitative and aim at defining if the product is
acceptable or not for the design life of the system.

The qualification programme should consider both the effect of the manufacturing route
as well as fabrication on the properties obtained. Where possible, reference materials
with known performance (good, borderline or unacceptable) should be included for
comparison.
9.2 MANUFACTURER QUALIFICATION
Under certain conditions it may be necessary to apply additional requirements to the
potential or selected manufacturers to ensure their capabilities to supply the required
material. Such qualification should be evaluated when one of the following conditions
are present:-
a. The materials to be supplied include:
 22Cr and 25Cr duplex stainless steels: all grades, product forms and
dimensions;
 super-austenite and 6Mo stainless steels: all product forms and dimensions;
 nickel base alloys: castings;
 titanium and its alloys: castings.
b. The requested material dimensions and/or quality require special demands by being
outside the range of standardized products or outside the normal production range
of the potential manufacturer.
c. Non-metallic sealing materials for topside gas systems subjected to rapid de-
pressurization, well completion and critical permanent subsea equipment.

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10.0 QUALITY REQUIREMENTS

10.1 Contractor/Subcontractor should operate a quality system based on ISO 9000 series of
standards to satisfy the requirements of this document.
10.2 Contractor/Subcontractor should demonstrate compliance by providing a copy of the
accredited certificate or the contractor’s/subcontractor’s quality manual. Verification of the
contractor’s/subcontractor’s quality system is normally part of the pre-qualification
procedure, and is therefore not detailed in the core text of this document.

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11.0 APPENDICES

11.1 APPENDIX-I: TABLE 4: SEA WATER MATERIALS COMPARISON

Material General Deposit Crevice Impingement Behaviour Element of Marine Mechanical Fire Ease of
Corrosion Attack Corrosion Attack in the Chlorination Fouling Strength Resistance Fabrication
Presence &
of Component
Sulphide Availability
Pollution
90/10 Cu-Ni 2 2 2 1 1 2 2 1 2 2
CuNi10Fe1Mn
Carbon Steel 1 1 1 1 1 1 0 2 2 2
Austenitic 2 0 0 2 1 1 0 2 2 2
Stainless
Steel
Austenitic 2 1 1 2 1 1 0 2 2 1
Stainless
Steel*
Duplex 2 1 1 2 1 1 0 2 2 1
Stainless
Steel*
Ferritic 2 1 1 2 1 1 0 2 2 1
Stainless
Steel*
Plastics 2 2 2 2 2 2 0 1 0 1
Titanium 2 2 2 2 2 2 0 2 2 1

LEGEND:
0 – NOT RESISTANT
1 – POTENTIAL PROBLEMS, LIMITED LIFE, DESIGN RESERVATIONS
2 – SATISFACTORY
*HIGH MOLYBDENUM

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The 90/10Cu-Ni Alloy is the only material that provides the best requirement for
use in sea water applications.

Austenitic stainless steel is not recommended to be used in sea water

applications because of its vulnerability to pitting and crevice corrosion. Where
highly Molybdenum Austenitic or Duplex or Ferritic stainless steel is used,
threaded connections should not be allowed.

Graphite gaskets should not be used in sea water piping systems

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11.2 APPENDIX-II: TABLE 5 - MATERIALS FOR PROCESS AND UTILITY USE

PROCESS & UTILITY MATERIALS NOTES

OIL AND GAS PRODUCTION AND PROCESSING
Wellhead equipment/X-mas 13Cr4Ni, Low alloy steel with Alloy 625 weld overlay
trees 1
Piping and vessels 22Cr duplex, 25Cr duplex, 6Mo, 316, Super- 2
austenite.
Carbon steel with internal organic lining.
Thick wall vessels Carbon steel with SS316/309 overlay, Alloy 2
625, Alloy 825 or 904 clad or weld overlay.
Carbon steel with internal organic lining.

Piping and vessels in low Carbon steel.

corrosivity systems
Inlet side of compressorsCarbon steel. Carbon steel with CRA weld
overlay or solid CRA if required, based upon
corrosivity evaluations
Piping, vessels for SS316, 22Cr duplex, 25Cr duplex, 6Mo,
produced water Titanium or GRP.
SEAWATER SYSTEMS AND RAW SEAWATER INJECTION
Wellhead equipment/X-mas Carbon steel with weld overlay
trees
Vessels Titanium, GRP, carbon steel with internal
rubber lining or organic coating in combination
with cathodic protection
Piping materials 6Mo, 25 Cr duplex, Titanium, Cu-Ni 90-10, 3, 4
GRP.
Piping components 6Mo, 25Cr duplex, Titanium, Alloy 625, Alloy 3, 4, 5, 6
C276, Alloy C22, Cu-Ni 90-10, NiAl bronze.
Valves in GRP systems GRP, Carbon steel with polymeric lining, NiAl
bronze
Normally drained systems Copper base alloys, 6Mo, Titanium. Carbon 3
steel for short lifetimes, e.g. 5 years to 10
years
Pumps 25Cr duplex, 6Mo, Titanium 4, 7
DE-AERATED SEAWATER INJECTION
Wellhead equipment/Xmas Low alloy steel with Alloy 625 weld overlay in
trees sealing surfaces.
Piping Carbon steel, GRP
De-aeration tower Carbon steel with internal organic coating,
plus cathodic protection in bottom section
Pump and valve internals Provided carbon steel housing: 13Cr4Ni, 7
SS316, 22Cr duplex, 25Cr duplex.

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APPENDIX-II: TABLE 5 - MATERIALS FOR PROCESS & UTILITY USE (Cont’d)

PROCESS & UTILITY MATERIALS NOTES

PRODUCED WATER AND
AQUIFER WATER
INJECTION
Fresh and potable water
DRAINS AND SEWAGE
Open drain
Closed drain without
oxygen
Closed drain with oxygen
Sewage
FLARE SYSTEMS
Relief system
Burner components
Flare boom
Dry fuel gas and diesel
Piping
Tanks
Lubrication and seal oil
Hydraulic fluid
Instrument air
Inert gas/plant air piping
INSTRUMENTATION
Junction boxes/cabinets
Cable trays
HVAC DUCTS AND UNITS
Ventilation/air intake ducts
Air handling units
Seawater coils
ACTIVE FIRE FIGHTING SYSTEMS
Dry CO2 systems
Freshwater/plant air/nitrogen SS316.
Glycol
Methanol
Aqueous Film Forming
Foams (AFFF)
SS316, 22Cr duplex, 6Mo, Titanium, GRP.
Wellhead and X-mas trees as for de-aerated
seawater injection.
Hot dip galvanized carbon steel, GRP, 8
Polypropylene, SS316,
Copper base alloys.
GRP, carbon steel.
SS316, carbon steel
22Cr duplex, 25Cr duplex, 6Mo, Titanium, GRP.
GRP, polyethylene
SS316, 6Mo, low temperature carbon steel
Alloy 800H, Alloy 800HT, Alloy 625. For
temperatures below 650 °C: 310.
Structural steel with thermally sprayed aluminium
Carbon steel.
Carbon steel
Carbon steel, GRP. 9
SS316, 22Cr duplex, 6Mo. 10
SS316, carbon steel upstream filters 10
SS316, carbon steel upstream filters. 10
Carbon steel, SS316.
SS316, Alloy C276, 6Mo, 25 Cr duplex, Titanium 4,10, 11,14
GRP, 316.
SS316; Hot dip galvanised carbon steel in fully
HVAC controlled areas
316, Hot dip galvanised steel.
316.
Titanium.
Carbon steel 4
Carbon steel, SS316.
Carbon steel, SS316.
SS316, GRP

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APPENDIX-II: TABLE 5 - MATERIALS FOR PROCESS & UTILITY USE (Cont’d)

PROCESS & UTILITY MATERIALS NOTES

Heating/cooling media Carbon steel. CRA in heat exchanger tubes.
Miscellaneous chemical GRP, SS316, 6Mo, Titanium 13
systems
NOTES

1.0 Sealing surfaces of components in Type 13Cr4Ni should be overlay welded with Alloy 625. For wells with low
corrosivity and/or short lifetime, low alloy steel with Alloy 625 weld overlay in sealing surfaces only can be used.
2.0 Pressure vessels operating with low and moderate pressures can be made of carbon steel with internal lining.
Sacrificial anodes may be required. Regular inspection and coating repairs shall be accounted for.
3.0 Copper alloys shall not be used in combination with CRAs and titanium. Exception can be components in fire
water systems, provided galvanic corrosion can be avoided by proper isolation. If electrical isolation (15 000 ohm
in dry system) is ensured and verified after installation, mechanical connections between bronze/brass and noble
alloys such as Type 6Mo and titanium alloys are acceptable.
4.0 See design limitations.
5.0 Should also be used for process wetted parts of instrument systems.
6.0 See design limitations. Weld overlay can be applied to prevent crevice corrosion,
7.0 Ceramic filled epoxy coatings can be used for shorter lifetimes, e.g. 5 years to 10 years.
8.0 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.
9.0 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.
10.0 Type 316 is acceptable up to operating temperature 70 °C provided located indoor or in sheltered areas and not
insulated.
11.0 For un-insulated stainless Type SS316 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.
12.0 Hot dip galvanized steel can be used in living quarter and domestic areas.
13.0 The combination of chemical and material has to be considered in each case. Titanium or GRP shall be used for
hypochlorite systems.
14.0 There could be a high risk for crevice corrosion under clamps when using type SS316 tubing externally at
offshore conditions and at onshore plants close to sea. Alternative tubing material should be evaluated.

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11.3 APPENDIX-III: TABLE 6 - MATERIALS FOR CONSTRUCTION OF GRP SYSTEMS

Service Structural part Inner liner

Service water Bisphenol A epoxy resina Bisphenol A epoxy resin a

Process water reinforced with E-glass. reinforced with ECR-glass fibres
Cooling medium/water and with C-glass fibre or synthetic
Sewage fibre surface veil should be used.
Non-hazardous drain
Non-hazardous vent
Fire water main
Fire water deluge
Produced water
Ballast water
Potable water Bisphenol A epoxy resin a According to the national health or
reinforced with E-glass. certifying authorities in the country
of use.
Hydrochloric acid Bisphenol A epoxy resin a Bisphenol A epoxy resin a
reinforced with ECR-glass. reinforced with ECR-glass
Concentrated sodium Chemical resistant laminate Thermoplastic liner b
hypochlorite and sulphuric
acid
NOTES

a) Aromatic or cycloaliphatic curing agents should be used. An alternative is to use vinyl ester resin. In special cases
other resins may be used.
b) Requirements related to thermoplastic liner material and lined pipes shall be according to DIN 16965-2 and DIN
16966 (all parts), pipe type B.

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11.4 APPENDIX-IV: TABLE 7 - MATERIALS FOR HANDLING INHIBITORS

AND OTHER CHEMICALS

Fluid Material selection Temperature limits Piping

(°C) (1)
class
Corrosion inhibitor (neat or dissolved (2) –20 to +120 3410
AISI 316L
in solvent)
Scale inhibitor AISI 316L –20 to +120 3410
Wax inhibitor AISI 316L –20 to +120 3410
Coagulant/Anti-foam AISI 316L –20 to +120 3410
De-emulsifier (pure / diluted) AISI 316L –20 to +120 3410
Sodium hypochlorite (conc.) Titanium 0 to +50 6410X
Sodium hypochlorite (diluted.) C-PVC or GRP –10 to +50
Oxygen scavenger (conc.) AISI 316L –20 to +120 3410
Fire fighting foam (diluted) Galvanized carbon steel 0 to +60 8410
Fire fighting foam (pure) AISI 316L –20 to +120 3410
Biocide (3) –20 to +120 3410
AISI 316L
Odorant (ethyl mercaptan) Carbon steel (1 mm c.a.) 0 to +120 1410
Glycol (pure) Carbon steel (1 mm c.a.) 0 to +200 1450
Glycol (contaminated) See [3.2.9]
Methanol (pure) Carbon steel (1 mm c.a.) 0 to +120 1410
Ferrous sulphate dosing GRP/ABS/PVC 0 to +100
Drilling mud (dry/oil based) Carbon steel (1 mm c.a.) 0 to +120 1410
Drilling mud (water based) Carbon steel (3 mm c.a.) 0 to +120 1430
Drilling mud (0.0035 < H2S < 0.1 Carbon steel (1 mm c.a.) 0 to +120 1420
bar)
Drilling mud (0.0035 < H2S < 0.1 Carbon steel (3 mm c.a.) 0 to +120 1440
bar)
Ferric chloride Titanium –20 to +120
Notes: (1) Piping class numbers are included for guidance only
(2) Carbon steel can be used for concentrated corrosion inhibitor if the supplier recommends carbon steel for
use with his chemical. However, the corrosion inhibitor piping is normally small bore or instrument tubing,
and SS316L is selected for ease of installation and lower maintenance.
(3) AISI 316 grades shall not be used for DBNPA (2,2, Dibromo-3-Nitrilopropionamide) biocide.

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REVISION HISTORY LOG

Revision Number: 1 Date: 17/11/2011

Reason for Change/Amendment

Item Revised:
Changes/Amendment:
This guideline is developed to cover the corporate requirements for
Material Selection for Special Applications Non-sour Service.

Note:

The revision history log shall be updated with each revision of the document. It shall contain a
written audit trail of the reason(s) why the changes/amendments have occurred, what the
changes/amendments were and the date at which the changes/amendments were made.

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