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3210-8440-RP-0002
MATERIALS SELECTION REPORT FOR
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CONTENTS
1 INTRODUCTION ................................................................................................ 3
1.1 Scope ................................................................................................................. 3
1.2 Use of Document .............................................................................................. 3
2 REFERENCES ..................................................................................................... 3
2.1 Project Specifications........................................................................................ 3
2.2 International Standards ..................................................................................... 4
2.3 Materials Selection Diagrams ........................................................................... 6
2.4 Additional Reference documents...................................................................... 6
3 ABBREVIATIONS:.............................................................................................. 6
4 MATERIALS SELECTION................................................................................... 8
4.1 Introduction........................................................................................................ 8
4.2 Vacuum Distillation Unit ................................................................................. 14
5 FABRICATION AWARENESS.......................................................................... 17
APPENDIX A: MATERIALS OF CONSTRUCTION .................................................. 18
Appendix A1: Air Cooler ......................................................................................... 19
Appendix A2: Heat Exchangers ............................................................................... 20
Appendix A3: Pumps ............................................................................................... 23
Appendix A4: Vessels and Columns ...................................................................... 25
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1 INTRODUCTION
1.1 Scope
This document describes the Material of construction for the Atmospheric and
Vacuum Unit .
2 REFERENCES
The following documents are referred to within the text of this report. Latest
revisions have to be used:
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DSN 15857
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PARADIP REFINERY PROJECT
PROJECT SPECIFICATION
3210-8440-RP-0002
MATERIALS SELECTION REPORT FOR
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Environments
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3 ABBREVIATIONS:
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DSN 15857
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PARADIP REFINERY PROJECT
PROJECT SPECIFICATION
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MATERIALS SELECTION REPORT FOR
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4 MATERIALS SELECTION
4.1 Introduction
The objective of the CDU is to provide primarily separation of crudes to
produce straight run blend stocks of distillate products (after suitable
downstream treatment processes) and feedstock for other downstream
process units.
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DSN 15857
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The following steps are required to avoid problem with caustic injection.
• use of quill designed
• Put the crude on the tube side to avoid caustic concentration which would
possibly occur in the baffle plate.
• Avoid overfeeding i.e. using too strong caustic and poor mixing.
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HAGO circuits piping and the exchangers are in Cr-Mo steel (or CS for lower
temperature) with the corrosion allowance calculated according to the
modified Mc Conomy curves. Pumps are specified in 12 Cr (C6 API Class)
LAGO and Kerosene lateral draws are at a temperature below 260°C and
therefore high-temperature sulphidation corrosion is deemed not a risk for
these systems. No other corrosion mechanisms are foresee and for these
reasons carbon steel with a CA of 3mm is specified for piping and equipment
However LAGO pumps, operating above 200 °C are specified in API Class S-
6 material with carbon steel case and 12Cr impeller whereas Kerosene
pumps are with CS case and impeller (API Class S-5).
Corrosion allowance specified for CS piping is reduced to 1.5mm for all cold
hydrocarbon streams to storage
The top section down to tray D2 and the top PA circuit can be subject to wet
H2S conditions. For this reason this section is categorised in LSS.
Considering the size of the column and the fact that the bare carbon steel
section (from D1 to D2) can be subject to wet H2S conditions only during
upset condition, the requirement of PWHT can be waived for this section.
Cold reflux creates shock condensation in the top section down to tray D1.
The presence of traces of HCl and other contaminants such as NH3 and H2S
make the environment corrosive towards carbon and 300 series SS causing
generalised and/or localised corrosion. Also alloy 400 (Monel) has recently
suffered failure in this section, probably due to high levels of ammonia and
H2S. For these reasons a 6Mo superaustenitic SS (preferably UNS N08367)
is specified as clad material and for the trays; as alternative alloy 625 can be
used.
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Localized water condensation can occur before the Crude Column Overhead
Condenser (i.e. during upset or shut-down) thus, due to the expected
presence of hydrogen sulphide, the overhead system is assigned to LSS up
to wash water injection. The system is upgraded to HSS category
downstream the water injection.
When the overhead hot vapours containing ammonia (or amine compounds)
and HCl/H2S are cooled below 120 °C, Ammonium chloride and ammonium
bisulphide (NH4Cl / NH4HS) salt may be produced. Solid NH4Cl / NH4HS and
amine hydrochloride salts can deposit and collect on metal surfaces. This
causes
• under deposit corrosion, in particular in some areas such as cooler tubes.
These salt (in particular NH4Cl) can be corrosive towards almost all the
material including nickel alloy
• impede the flow of gases and liquids
• change the heat transfer characteristics of condensers and heat
exchangers by acting as insulation on the metal surface.
To overcome corrosion issues and meet the required lifetime the OVHD
condensed is specified in superduplex SS. Superduplex SS shall have a
PREN>40 and construction and materials shall fulfil the recommendations of
API 938C.
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OVHD receiver is specified with the bottom half clad with SS316L to protect
the item from the aggressive sour water.
A pH meter should be installed on the boot of Column Overhead Receiver to
regulate neutralizer injection to target value (i.e. pH 5.5 - 6.5 ± 0.2). In
addition, electric resistance corrosion monitoring probe and corrosion
coupons are specified in the overhead line where water condensation occurs
to asses the degree of corrosion and to optimize ammonia injection. An
additional set of monitoring probes (weight loss and LPR) is specified in the
sour water pipe.
The scheduled ultrasonic thickness survey will confirm the accuracy of the
corrosion monitors and the efficacy of neutraliser/inhibitor injection.
As more data become available from the monitors, the plant operators will be
in a better position to fine-tune the injection of the neutraliser/inhibitor and the
wash water.
Sour Water Pumps that handle sour water is specified with both casing and
impeller in duplex (API Class D1) as recommended by API 610.
Oil line from the receiver is assigned to LSS category because it can carry
over sour water. The OVHD liquid pump is specified according to API
recommendation.
The overhead vapours from receiver, after water washing, have had most of
the sour constituents (H2S and NH3) removed from it. However, the pressure
increase could create a similar corrosivity of the system and hence the same
selection philosophy has been followed for the recontactor section.
The cooler tubes are specified in duplex because a lower chloride
concentration is expected, compared with OVHD condenser. Duplex SS air
cooler construction and materials shall fulfil the recommendations of API
938C Furthermore a temperature reduction allows the use of SS 316L for the
trim cooler tubes and tube sheet.
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DSN 15857
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DSN 15857
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MATERIALS SELECTION REPORT FOR
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DSN 15857
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5 FABRICATION AWARENESS
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DSN 15857
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DSN 15857
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DSN 15857
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010-E-054 1ST STAGE A516 -70 + 3 mm ASTM A789 A266 Cl.2 + 3mm+ A516 -70 + 3mm LSS Y (a) tubeside
INTERCONDENSER S31803 3mm SS316L Clad (a) Shellside Shellside
010-E-055 2ND STAGE A516 -70 + 3 mm ASTM A789 A266 Cl.2 + 3mm+ A516 -70 + 3mm LSS Y (a) tubeside
INTERCONDENSER S31803 3mm SS316L Clad (a) Shellside Shellside
010-E-056 3RD STAGE A516 -70 + 3 mm ASTM A789 A266 Cl.2 + 3mm+ A516 -70 + 3mm LSS Y (a) tubeside
INTERCONDENSER S31803 3mm SS316L Clad (a) Shellside Shellside
010-E-102/202 WET CRUDE / VAC. A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
DIESEL EXCHANGER
010-E-103/203 WET CRUDE / AGO PROD. A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
EXCHANGER
010-E-104/204 WET CRUDE / TPA A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm LSS Y
EXCHANGER Shellside Shellside
010-E-106/206 WET CRUDE / KEROSENE A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
PA EXCHANGER
010-E-107/207 WET CRUDE / AGO A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
PROD.EXCHANGER
010-E-108/208 WET CRUDE / HOT VGO A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
PROD. EXCHANGER
010-E-113/213 DESALTING WATER FEED A516 -70 + 3 mm ASTM A789 A266 Cl.2 + 9mm A516 -70 + 3 mm LSS Y Water boxes
/ EFFLUENT EXCHANGER S31803 Shellside Shellside with Al anodes
sacrificial CP
010-E-116/216 DESALTING WATER FEED/ A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm LSS Y
KERO PA EXCHANGER Tubeside Tubeside
010-E-117/217 DESALTED CRUDE/VAC. A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
RESIDUE
PROD.EXCHANGER
010-E-118/218 DESALTED CRUDE/VGO A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
EXCHANGER
010-E-119/219 DESALTED CRUDE/LAGO A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
PA EXCHANGER
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010-E-124/224 FLASHED CRUDE / HVGO ASTM A516 Gr70 A269 TP304 A182 UNS S41000 + A516 Gr 70 + 3mm N N 12 Cr tubes (12
EXCHANGER + SS410S Clad 2mm clad 12Cr BWG) is an
acceptable
alternative
010-E-126/226 FLASHED CRUDE / A516 -70 + 6 mm A179 A266 Cl.2 + 9mm A516 -70 + 3mm N N
VAC.RESIDUE PRODUCT
EXCHANGER
010-E-127/227 FLASHED CRUDE / VAC. ASTM A516 Gr70 A269 TP304 A182 UNS S41000 + A516 Gr 70 + 3mm N N 12 Cr tubes (12
RESIDUE EXCHANGER + SS410S Clad 2mm clad 12Cr BWG) is an
acceptable
alternative
010-E-128/228 DESALTED CRUDE/AGO A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
PRODUCT EXCHANGER
010-E-129/229 FLASHED CRUDE / AGO A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
PRODUCT EXCHANGER
010-E-131/231 DESALTED CRUDE/KERO A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
PA EXCHANGER
010-E-132/232 FLASHED CRUDE / HAGO A516 -70 + 6 mm A179 A266 Cl.2 + 9mm A516 -70 + 3mm
PA EXCHANGER
010-E-149/249 HVGO/MP STEAM ASTM A516 Gr70 A268 TP410 A266 Cl.2 + 3mm 410S A516 -70 + 3mm N N (a) solid 5Cr +
GENERATOR + SS410S Clad Clad (a) 3mm CA (6mm
for tubesheet)is
an acceptable
alternative
010-E-151,251 HVGO PROD / LP STEAM A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm
GENERATOR
010-E-152/252 DESALTER EFFLUENT A516 -70 + 3 mm ASTM A789 A266 Cl.2 + 6mm A516 -70 + 3 mm
WATER TRIM COOLER S31803
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DSN 15857
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DSN 15857
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010-C-009 LOW PRESSURE SCRUBBER A516 - 70N +6mm SS 316L Y HSS Demister: SS 316L
010-C-010 AMINE ABSORBER A516 - 70N +6mm SS 316L Y HSS Demister: SS 316L
010-V-001 DESALTER WATER SURGE DRUM ASTM A 516-70N + 3mm 12 Cr Y LSS
010-V-102A 1 ST. STAGE CRUDE DESALTER CS + 6mm SS 316L - N
010-V-102B 2 ND STAGE CRUDE DESALTER CS + 6mm SS 316L - N
010-V-003 CRUDE FLASH DRUM ASTM A 516-70N +3 mm 12 Cr N N
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010-V-008 NAPHTHA STABILISER OVHD ASTM A 516-70N + 6mm SS 316L Y HSS Boot: 3mm clad SS 316L
RECEIVER
010-V-009 DE-ETHANISER OVHD RECEIVER ASTM A 516-70N + 3mm SS 316L Y LSS Boot: 6mm CA
MDMT= -46C
010-V-010 DEPROPANISER OVHD RECEIVER ASTM A 516-70N + 3mm 12 Cr N N MDMT= -43C
010-V-011 VENT GAS KO DRUM ASTM A 516-70N + 3mm 12 Cr N N
010-V-013 HOT WELL ASTM A 516-70N + 3mm SS 316L Y LSS Gunite internal lining
SS 316L clad is an acceptable
alternative
010-V-014 SOUR GAS SEAL DRUM ASTM A 516-70N + 3mm SS 316L Y HSS
010-V-015 HOT WELL OIL COALESCER ASTM A 516-70N + 3mm SS 316L Y LSS
010-V-016 OFF GAS KNOCKOUT DRUM ASTM A 516-70N + 3mm SS 304L Y LSS Demister: SS 304L
010-V-017 TREATED GAS KNOCK-OUT DRUM ASTM A 516-70N + 3mm SS 316L Y LSS Demister: SS 304L
010-V-018 AMINE BLOWDOWN DRUM ASTM A 516-70N + 3mm SS 316L Y LSS
DSN 15857