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PARADIP REFINERY PROJECT


PROJECT SPECIFICATION

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 .

1.2 Use of Document


This document is complemented with the referred documents listed in the
following section and shall be read in conjunction with these documents,
particularly, with the document 3210-8440-PH-0001 where the corrosion
mechanisms and the materials selection philosophy has been explained .
This document shall be considered as a “Live” document and requires
frequent updating until the materials of construction reaches “as built” stage.
Detailed Material of construction for this unit are listed in Appendix A

2 REFERENCES

The following documents are referred to within the text of this report. Latest
revisions have to be used:

2.1 Project Specifications

3210-8440-PH-0001 Materials Selection and Corrosion Control


Philosophy

3210-8440-SP-0002 Corrosion Monitoring Specification

3210-8440-SP-0003 Cathodic Protection Philosophy

3210-8440-SP-0006 Protective Paint And Coating

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3210-8440-SP-0007 Passive Fire Protection & External Fireproofing


of Equipment Support And Structure

3210-8440-SP-0008 Coating And Wrapping of Buried Pipework

3210-8440-SP-0018 General Requirement For Pipework Fabrication

3210-8440-SP-0019 Additional Requirement For Integrally Clad


Equipment
3210-8440-SP-0026 Materials For Sour Service

3210-8210-RP-0019 Pipelines Material Selection and Corrosion


Report
3210-8210-RP-0001 Pipelines Basic Engineering

3210-8440-SP-0004 Hot Insulation

3210-8440-SP-0005 Cold Insulation

3210-8440-SP-0009 Submission of Welding and Manufacturing


Procedure
3210-8440-SP-0010 General Requirement for Welding

3210-8440-SP-0012 Pre-commission Cleaning

3210-8440-SP-0014-16 Positive Materials Identification

3210-8440-SP-0018 General Requirements for Pipework Fabrication

3210-8210-RP-0017 Raw Water Pipeline Mechanical Design Report

3210-8440-SP-0019 Additional Requirement for Integrally Clad


equipment

2.2 International Standards

NACE MR0103 “Materials Resistant to Sulfide Stress Cracking in


Corrosive Petroleum Refining Environments”.

NACE RP0472 Methods and Controls to Prevent In-Service


Environmental Cracking of Carbon Steel
Weldments in Corrosive Petroleum Refining

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Environments

NACE RP0170 Recommended Practice on the Protection of


Austenitic Stainless Steels During Downtime.
NACE RP0198 The control of Corrosion Under Thermal
insulation and Fireproofing Materials
NACE RP0170 Protection of Austenitic Stainless Steel and other
Austenitic Alloys from Polythionic Acid Stress
Corrosion Cracking During Shutdown of Refinery
Equipment.
API 934 API Recommended Practice 934, First Edition,
December 2000,
“Materials and Fabrication Requirements for
2¼Cr-1Mo & 3Cr-1Mo Steel Heavy wall pressure
Vessels for High Temperature, High Pressure
Hydrogen Service”.

API 938 C Use of Duplex Stainless Steels in


the Oil Refining Industry

API 941 API Recommended Practice 941, Sixth Edition,


March 2004,
“Steels for Hydrogen Service at Elevated
Temperatures and Pressures in Petroleum
Refineries and Petrochemical Plants”.

API 945 API Recommended Practice 945, Third Edition,


June 2003,
“Avoiding Environmental Cracking in Amine
Units”.

API 581 API Publication 581, First Edition, May 2000,


Appendix G.
“Risk-Based Inspection Base Resource
Document”.

API 610 Centrifugal Pumps for Petroleum Heavy Duty


Chemical and Gas Industry Services.
API RP 571 Damage Mechanisms Affecting Fixed Equipment
in the Refining Industry-First Edition
ASME SECTION VIII Section VIII Division 1 Rules For Construction Of
Div 1&2 Pressure Vessels
Section VIII Division 2 Alternative Rules for
Construction of Pressure Vessels
API 530 Fired Heaters

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2.3 Materials Selection Diagrams

3210-8110-23-010-0001 MSD CRUDE PRE-HEAT SECTION


3210-8110-23-010-0002 MSD CRUDE DESALTING SECTION
3210-8110-23-010-0003 MSD CRUDE FLASHING SECTION
3210-8110-23-010-0004 MSD AVU CRUDE CHARGE HEATER SECTION
3210-8110-23-010-0005 MSD AVU CRUDE DISTILLATION SECTION
3210-8110-23-010-0006 MSD AVU CDU PRODUCTS SECTION
MSD AVU OFFGAS COMPRESSOR &
3210-8110-23-010-0007 RECONTACTOR SECTION
3210-8110-23-010-0008 MSD AVU NAPHTHA STABILISATION SECTION
MSD AVU DE-ETHANISER & DEPROPANISER
3210-8110-23-010-0009 SECTION
3210-8110-23-010-0010 MSD AVU VACUUM CHARGE HEATER SECTION
3210-8110-23-010-0011 MSD AVU VACUUM DISTILLATION SECTION
3210-8110-23-010-0012 MSD AVU UNIT VDU PRODUCTS SECTION
3210-8110-23-010-0013 MSD VDU VACUUM SECTION
3210-8110-23-010-0014 MSD AVU AMINE TREATING

2.4 Additional Reference documents


These documents are referred throughout the text where applicable by
referring to its correspondent number in [square bracket])

1. Materials Selection for Petroleum Refineries and Gathering Facilities,


NACE Publication, Rawhide
2. Corrosion Under Insulation Guideline, European Federation of
Corrosion (EFC) No. WP13 and WP 15
3. IOCL Reliability Report
4. Corrosion 98 Paper 578 on Assessment of Crude Oil Corrosivity.
5. Corrosion Control in The refining Industry, NACE Publication March
2004.

3 ABBREVIATIONS:

API: American Petroleum Institute


ARU: Amine Recovery Unit
AVU: Atmospheric and Vacuum Distillation Unit

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CA: Corrosion Allowance


CI: Cast Iron
ClSCC: Chloride Stress Corrosion Cracking
CMDI: Cement Mortar Ductile Iron
CP: Cathodic Protection
CS: Carbon Steel / Cast Steel
DSS: Duplex Stainless Steel
SDSS: Superduplex Stainless Steel
HAGO: Heavy Atmospheric Gas Oil
HC: Hydrocarbon
HHPS: Hot High Pressure Separator
HIC: Hydrogen Induced Cracking
HSS: High Severity Sour Service
HTHA: High Temperature Hydrogen Attack
IOCL: Indian Oil Corporation Ltd.
LME: Liquid Metal Embrittlement
LSS: Low Severity Sour Service
LTCS: Low Temperature Carbon Steel
MDMT: Minimum Design Metal Temperature
MOC: Materials of Construction
NAC: Naphthenic Acid Corrosion
NACE: National Association of Corrosion Engineers
PASCC: Polythionic Acid Stress Corrosion Cracking
PWHT: Post Weld Heat Treatment
SOHIC: Stress Oriented Hydrogen Induced Cracking
SCC: Stress Corrosion Cracking
SS: Stainless Steel
SSC: Sulphide Stress Cracking
SRU: Sulphur Recovery Unit
TAN: Total Acid Number
TSA: Thermal Spray Aluminum Coating
VDU: Vacuum Distillation Unit

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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.

4.1.1 Crude Oil Preheat Train


Material selection for this unit covers the crude and transfer lines, and pre-
heat crude exchangers.
The preheating section, up to crude flash drum, will handle sweet (without
hydrogen sulphide) hydrocarbon at a temperature below 220 °C, thus below
the threshold value where NAC and sulphidation can occur. For these
reasons, carbon steel is specified as material of construction. 1.5mm as
corrosion allowance is specified for piping whereas 3mm CA for equipment.
Material selection for the hot section of the crude heating train and transfer
lines is based on the sulphur compounds and on maximum operating
temperature. Corrosion rates for the different materials have been estimated
based on the Modified Mc Conomy Curves.
Carbon steel has been specified up to a maximum temperature of
approximately 270°C, with increased corrosion allowances for higher
temperatures. Above 270°C, Cr-Mo steel or SS is preferred to provide
increased corrosion resistance against sulphidation.
Due to the lack of availability of Cr-Mo tubes, 12Cr or SS304 has been
preferred for this service. For the same reason CS with 12Cr clad solution is
preferred over solid Cr-Mo steel for the equipment.
5Cr and 9Cr with corrosion allowance is specified for the piping and for the
transferline.
The material selection for this Crude Transfer Line from the Crude Heater to
the Crude Column is based on the predicted crude corrosion rate, but the
velocity in the line must be limited to reduce erosion corrosion.

4.1.2 Desalter and CDU Overheads


The initial corrosion control concern in crude unit is desalting system.
Desalters are installed in the preheat train of pipestills to reduce the BS&W
(bottom sediments and water) overhead corrosion and the salt content of the
crude.

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The main advantages gained by desalting are:


• Reduction of crude preheat exchanger fouling.
• Reduction of the HCI corrosion potential in overhead system.
• Reduction of the chemical neutralizer requirements.
• Reduction of the sodium contamination in fuel oils, FCCU feeds and
asphalts.
• Reduction of upsets due to water slugs in crude.
• Increased unit capacity by reducing entrained water and by reducing
fouling.

Desalting will have a very beneficial effect on control of overhead corrosion


since, with good operation, the salt content of the crude will be both low and
relatively constant, which makes the addition of chemicals easier.
The water content of the effluent crude should be less than 0.2% and desalter
efficiency should be about 90 to 95%.
Material selection of the Desalter is based on resistance from high salinity
aqueous corrosion in the bottom of the Desalter drum, and acid corrosion
from the salt removed from the crude. The Desalter is specified as carbon
steel with a high corrosion allowance, and this material selection follows
through to the Desalter effluent water transfer line.
The Desalter Effluent / Wash Water Exchanger has been specified as carbon
steel. The medium corrosion allowance on the shell, and the high corrosion
allowance on the channel side, are consistent with the corresponding piping.
However to increase the lifetime of the tube bundle of the exchanger, duplex
SS is selected for the tubes The tubes are 22% duplex steel and the tube
sheet is carbon steel with SS 316L clad. This selection will provide a longer
life than the 3-5 years that carbon steel tubes would in this acidic (salt)
service last. SS 316L is not expected to be subject to pitting because of the
fluid turbulence.
The material selection for the Desalter Effluent Cooler has been specified
using the same principal.
The circulating water pump, handling salted water is selected in duplex SS
(API Class D-1)
After the desalter caustic soda is injected. The technique of caustic injection
is used to minimize corrosion due to hydrogen chloride. The evolution of
hydrochloric acid is due to the hydrolytic decomposition of chloride salts,
principally calcium and magnesium chloride to form their hydroxides. Injection
of dilute caustic into the crude exiting the desalter, results in reaction with the
calcium and magnesium chloride salts still present in the crude. This reaction
limits the evolution of HCI, which will distill into the crude column overhead
vapour system. The chlorides are converted to sodium chloride, which is
harmless to the system, and will exit the column with the heavier streams.

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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.

4.1.3 Crude heater


The material selection of the crude heater is based on the crude corrosion
rate containing 2.9% S at the high temperatures involved (with a metal
temperature considerably higher than fluid temperature). The fluidodynamic
conditions such as turbulence and the two-phase flow affect total fluid
corrosivity. Moreover on the heater tubes (convection and radiant), external
corrosion occurs from the fuel. Nevertheless the heater will operate with fuel
gas and/or low sulphur fuel oil; therefore the corrosivity of the external side is
not expected to be severe.
Because of the high temperatures in the Crude and Vacuum Heaters, the
sulphur compounds are partially thermally decomposed. At these high
temperatures, the internal corrosion can be estimated using the Modified Mc
Conomy curves. The amount of evolved hydrogen sulphide, which can
increase the corrosion rate, have to be also taken into account. However it
has to be considered also that the heater tube can develop a protective layer
of coke on the internal surface.
Materials are selected to meet the API 530 lifetime requirement (100000 h).
The alloy 5Cr-1/2Mo with high CA is specified for the convection section
whereas 9Cr 1Mo is preferred for the radiant section.
The transferline is subject to highly turbulent two phase flow that can
exacerbate sulphidation attack. Therefore 9Cr 1Mo pipe with high CA is
selected.

4.1.4 Crude Column and Side strippers


The inlet crude from the transfer line is at 366°C and it contains 2.9% S. At
increased elevations in the Crude Column, the amount of sulphur in the
column, and hence in the product side streams and strippers, decreases from
4.4% to 2.5% sulphur and the temperature decreases from 356°C to 272°C
(HAGO lateral draw). Therefore atmospheric residue and HAGO are likely to
experience high-temperature sulphidation.
To protect the bottom section of the column and the HAGO stripper a 12Cr
clad is specified over the CS base. Trays and other internals follow the same
selection. The material selection for the Crude Column trays takes into
account the corrosion at both sides of the trays.

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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.

4.1.5 Overhead system


The Overhead System, (the top of the Column, the overhead piping,
Overhead Accumulator, and the condensers) is susceptible to severe
corrosion. The principal corrosive agents are hydrogen chloride, hydrogen
sulphide, ammonia, water and oxygen. These can cause wet H2S corrosion,
chloride stress corrosion cracking of austenitic stainless steels, and fouling
from salt deposits. Material selection for the overhead line to the Overhead
Accumulator is based on these corrosion problems. This is also the principal
for the material selection for the CDU Overhead Trim Condenser, and the
CDU Overhead Condenser.
Generalized corrosion on the overhead system is controlled in two ways:
• Injecting a neutralizer, such as ammonia or amine compounds, to
neutralize hydrochloric acid (and hydrogen sulphide) in the overhead line
• Injecting corrosion inhibitor.

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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.

The precipitation can occur in the overhead condenser and downstream


equipment and piping where the temperature is low, and neutralizer and
HCl/H2S are present. Wash water is provided to the overhead line before the
condenser, which dilutes the ammonium salts to keep them in solution and
dilute their corrosive effects. Washing will also prevent plugging and loss of
duty due to fouling on heat exchangers. Concentration of ammonium chloride
and ammonium bisulphide should be periodically measured on OVHD
accumulator and total salt concentration should be kept below 2% wt.
Care must be taken to circulate enough water to quench the overhead stream
below the steam dew point. If an insufficient amount of water is used,
ammonium salts or corrosion products in the water will deposit in the
exchangers and compound any problem that may have existed prior to water
recirculation. Therefore it is recommended to set the wash water injection rate
as 5% to 10% of the OVHD stream.
• As additional recommendation:
• the injection should be done through a spray nozzle
• design of the spray nozzle should avoid impingement corrosion of the
downstream piping
• the distribution system should ensure that the water flow is evenly divided
among the different bank of exchangers
• water must be kept oxygen free

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.

4.1.6 Naphtha Stabiliser


Material selection for this unit covers the Stabiliser Feed transfer line, the
Naphtha Stabiliser, the Stabilised Naphtha transfer line, the Naphtha
Stabiliser Overhead Drum, the LPG transfer line, and any connecting pumps,
heat exchangers and coolers.
The OVHD system of the naphtha experiences conditions similar to
recontactor section and hence the same philosophy has been followed.
However the trim cooler tube side is specified in CS with high corrosion
allowance, owing the estimated reduction of fluid corrosivity compared to the
recontactor section.
The top section of the Naphtha Stabilizer is subject to shock condensation
caused by the cold reflux. Therefore presence of water, combined with

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aggressive compounds such as NH3 and H2S, recommends the use of


SS316L to be used for clad and trays.
The rest of the column could experience wet H2S conditions during unit upset
/ shutdown; therefore is assigned to LSS service
In the bottom section up to the storage low temperature and absence of
corrodents compounds make adequate, as material of construction, carbon
steel with 1.5 mm CA for piping and plus 3mm CA for equipments.

4.1.7 De-ethaniser and De-propaniser


This section handles cold and non corrosive hydrocarbon and therefore
carbon steel with 1.5 mm CA for piping and plus 3mm CA for equipments is
selected as MOC. However the OVHD system of the De-ethaniser can
contain liquid water and H2S and hence it is specified for LSS service
including the top section of the De-ethaniser column. In addition the CA for
piping is increased to 3mm in this area. Weight loss corrosion coupon is
specified downstream of the condenser to asses the corrosion rate.
A higher corrosion allowance has been specified for the boot of the receiver
to provide resistance against the increased corrosion from the sour water
collecting in the boot, and hence reduce the likelihood for maintenance in the
life of the vessel.
This system can be subject to temperature lower than -29°C. Therefore,
according to Project philosophy, low temperature carbon steel is selected for
piping and equipment with a minimum design metal temperature (MDMT)
lower than -29°C.

4.2 Vacuum Distillation Unit


Corrosion concerns in the Vacuum unit are similar to those in the Crude Unit.
Main corrosion concerns in the VDU are associated with sulphur compounds
from the original crude plus any contaminants such as inorganic salts in the
reduced crude feed. There are significant differences though which modify the
corrosion behaviour in the VDU. The Vacuum unit processes reduced feed
from storage and from the CDU, which is a heavier hydrocarbon requiring
higher temperatures than in the CDU.

4.2.1 Vacuum Heater and Transferline


Material selection on this unit covers the atmospheric residue transfer line,
the Vacuum Heater , the Vacuum Column , the vacuum residue transfer line,
the HVGO transfer line, the VGO/diesel transfer line the overheads transfer
line, and any connecting pumps, heat exchangers and coolers.

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The material selection of the vacuum heater is based on the same


consideration expressed for crude heater. However corrosion rate is expected
to be slightly higher because of the higher temperature involved and the
higher sulphur content of the atmospheric residue (4.4%).
Therefore, to provide adequate resistance against sulphidation, 9 Cr 1Mo with
high CA is selected to meet the API 530 lifetime requirement.
The transferline is subject to highly turbulent two phase flow that can
exacerbate sulphidation attack. Considering the operating temperature of 401
°C and the sulphur % of the residue, the corrosion rate of the fluid is
estimated to be severe. Therefore the very high CA required for 9Cr 1Mo over
the plant lifetime make preferable the use of SS. Owing the size of the line
and the risk of PASCC a clad solution is preferred; as SS grade, either ferritic
or stabilized austenitic can be used

4.2.2 Vacuum Column


At the bottom of the column where the sulphur content is high (up to 5.5% for
the vacuum residue) and the temperatures are high corrosion is caused by
sulphidation. Stainless steels have been specified for increased resistance to
high temperature sulphidation and in particular 12 Cr is selected for trays and
as clad material. Above VGO lateral draw the temperature reduction make
negligible the risk of sulphidation attack and therefore CS with a CA of 3mm is
selected
HVGO and Vacuum residue 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. Hottest exchanger tubes are in
SS (see crude preheating section)
Pumps are specified in 12 Cr (C6 API Class)
VGO and Vacuum Diesel lateral draws are at a temperature below 260°C and
therefore high-temperature sulphidation corrosion is deemed not relevant for
these systems. No other corrosion mechanisms are envisaged and for these
reasons carbon steel with a CA of 3mm is specified for piping and equipment
However VGO pumps, operating above 200 °C are specified in API Class S-6
material with carbon steel case and 12Cr impeller whereas Vacuum Diesel
pumps are with CS case and impeller (API Class S-5).
Corrosion allowance specified for CS piping is reduced to 1.5mm for cold
streams to storage
The Vacuum Column is none-condensing so temperature at the top of the
tower is high enough for the H2S and other contaminants to be carried
overhead; hence, CRA clad is not necessary. The small length of lines after
strainers have been upgraded to SS to prevent any plugging in the column
distributors that can be caused by corrosion debris carry over.

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4.2.3 Vacuum Overhead System


The top section of vacuum column and the overhead system even if it
contains aggressive compounds such as H2S and traces of HCl and CO2, is
expected to be above water dew point (up to ejector system) and thus without
free water during normal operation. For this reason generalized corrosion is
not expected to be severe and thus CS plus 3mm CA is deemed adequate for
the unclad section of the column and for the pipe. Weight loss Corrosion
coupon is specified in the OVHD line to verify the corrosion rate.
Nevertheless, upset/short term condition can create the condition for wet H2S
service with the relevant issues. For this reason the top of the vacuum
Column and the OVHD line will be assigned a LSS Category. However,
considering the size of the column and the fact that the column can be subject
to wet H2S conditions only during upset condition, the requirement of PWHT
can be waived for this section.

4.2.4 Vacuum System


Vacuum system will contain corrosive water and, since condensing steam will
dissolve aggressive compounds (such as H2S), risk of both generalized and
localized corrosion have to be considered. Also oxygen presence, which
increases the severity of generalized corrosion, can not be generally excluded
in the vacuum system.
Generalized corrosion on the vacuum system will be controlled in injecting
ammonia to neutralize the acid compounds in the overhead line from Vacuum
Column
On the carbon steel pipe which carries the corrosive sour water, a pH meter
should be installed on the water phase of Vacuum Hotwell to monitor
neutralizer injection. A set of corrosion monitoring probe (ER plus weight loss)
is specified in the line from 1st stage vacuum system to asses the degree of
corrosion and to optimize ammonia injection. An additional set of corrosion
coupons plus LPR probe on sour water from Hotwell is also recommended.
The scheduled ultrasonic thickness survey will confirm the accuracy of the
corrosion monitors and the efficiency of ammonia.
Line from 1st stage has been selected to monitor corrosion rate because, even
though it is a lower pressure, it is expected that the larger part of H2S and
other acidic compounds will be dissolved on this section creating the worst
condition among the three stages.
As more data become available from the monitors, the plant operators will be
in a better position to fine-tune the injection of the ammonia.
Corrosion allowance is not used on exchanger tubing and on ejector internals
because as material of construction is stainless steel. For condenser tubing,
due to high temperature and chloride presence a duplex grade such as 2205

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is specified to overcome chloride stress corrosion cracking issues and


generalized corrosion. SS316L clad on tubesheet is specified to minimize
corrosion issue on waterside.
Austenitic grade 316 is selected for ejector nozzle, diffuser and throats to
control corrosion issues.
Vacuum Hotwell will contain aggressive water and therefore it is specified in
carbon steel with 3mm CA and with cement lining (Gunite). As alternative to
cement lining 3 mm of 316L clad can be considered. Internals and internal
pipe are specified in 316L SS.
Sour Water Pumps is specified with casing and impeller in duplex (API Class
D1) as recommended by API 610.
On VDU slop Line, water presence is not envisaged during normal operation
and CS plus 3 mm is indicated as material of construction for piping. Vacuum
Oil Pump is specified as API S6 class (CS case with 13Cr impeller) as
recommended by API 610
The entire vacuum system, can contains free water and hydrogen sulphide
and therefore to take into account all the risk caused by wet H2S damages, it
is assigned to LSS.

5 FABRICATION AWARENESS

• When welding is involved low carbon grade SS are recommended except


for use at operating temperatures higher than 425C and when intergranular
corrosion exacerbated by sensitisation is not an issue. In occasions to meet
the low carbon characteristics and to have the strength of the ordinary grade
dual certified grade e.g. 304/304L or 316/316L, is utilised.

• Galvanizing the pipes to ISO 1461 requires a minimum average coating


thickness of 85 micrometer. In practice it is possible to produce the
galvanized surface in excess of 130 micrometer, depending on the
metallurgical and surface condition of the base Carbon steel. Assuming an
average annual corrosion rate of 8 micrometer per year a 130 micrometer
galvanized coating would have a coating life longer than the required 15
years lifetime. Therefore, for this project, when galvanised steel is used in
water service, it has to be specified with a minimum coating thickness of 130
micrometer.

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APPENDIX A: MATERIALS OF CONSTRUCTION

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Appendix A1: Air Cooler

Item Service Materials PWHT Sour


Service
Header Tubes
UNIT 010
010-AC-004 KEROSENE PRODUCT COOLER A516 - 70 + 3 mm CA A179 N N
010-AC-005 AGO PRODUCT COOLER A516 - 70 + 3 mm CA A179 N N
010-AC-007 CRUDE COLUMN OVHD CONDENSER SA240 S32760 SA789 S32760 N Y
010-AC-008 RECONTACTOR COOLER ASTM A240 - S32205 ASTM A789 - S31803 N Y
010-AC-009 NAPHTHA STABILISER OVHD ASTM A240 - S31803 ASTM A789 - S31803 N Y
CONDENSER
010-AC-010 STABILISED NAPHTHA COOLER A516 - 70 + 3 mm CA A179 N N
010-AC-014 VACUUM DIESEL PRODUCT COOLER A516 - Gr 70 + 3mm ASTM A179 N N
010-AC-015 VGO PRODUCT COOLER A516 - Gr 70 + 3mm ASTM A179 N N
010-AC-016 VACUUM DIESEL PA COOLER A516 - Gr 70 + 3mm ASTM A179 N N

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Appendix A2: Heat Exchangers

Item Service Materials Sour Service PWHT Remarks

Shell Tubes Tubesheet Channel


UNIT 010
010-E-017 KEROSENE PRODUCT A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
TRIM COOLER
010-E-035 RECONTACTOR TRIM A516 -70 + 6 mm A213 TP316 A266 Cl.2 + 6mm+ A516 -70 + 3mm HSS Shellside Y Shellside (a) SS316
COOLER 3mm SS316L Clad (a) Tubesheet is an
acceptable
alternative
010-E-036 NAPHTHA STABILISER A516 -70 + 6 mm A179 (12 BWG) A266 Cl.2 + 9mm A516 -70 + 3mm HSS Shellside Y Shellside
FEED / BOTTOMS
EXCHANGER
010-E-037 NAPHTHA STABILISER A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm LSS Y
TRIM COOLER Shellside Shellside
010-E-038 NAPHTHA STABILISER A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
REBOILER
010-E-040 STABILISED NAPHTHA A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
TRIM COOLER
010-E-042 DE-ETHANISER OVHD A516 -70 + 3 mm A334 Gr6 SA350 LF2 Cl1 + 6mm A516 -70 + 3mm LSS Y
CONDENSER Shellside Shellside
010-E-043 DE-ETHANISER REBOILER A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
010-E-044 SOUR LPG PRODUCT A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
TRIM COOLER
010-E-046 DEPROPANISE OVHD A516 Gr60 + 3mm A334 Gr6 SA350 LF2 Cl1 + 6mm A516 -70 + 3mm N N
CONDENSER
010-E-047 DEPROPANISER A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
REBOILER
010-E-048 C4 LPG PRODUCT TRIM A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
COOLER

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Item Service Materials Sour Service PWHT Remarks

Shell Tubes Tubesheet Channel

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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Item Service Materials Sour Service PWHT Remarks


Shell Tubes Tubesheet Channel
010-E-122/222 FLASHED CRUDE / VGO A516 -70 + 3 mm A179 A266 Cl.2 + 6mm A516 -70 + 3mm N N
EXCHANGER
010-E-123/223 FLASHED CRUDE / HOT ASTM A516 Gr70 A268 TP410 A266 Cl.2 + 3mm A516 -70 + 3mm N N
HAGO PA EXCHANGER + SS410S Clad TP410S Clad

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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Appendix A3: Pumps

Item Service Material PWHT Sour


Service
Case Impeller API Class
UNIT 010
010-P-001A/B DESALTER WATER MAKE-UP PUMP CS 12 Cr S-6 Y LSS
010-P-102A/B & DESALTER WATER CIRCULATION PUMP Duplex SS Duplex SS D-1 N N
202A/B
010-P-002A/B DE-ETHANISER BOTTOMS PUMP CS CS S-5 N N
010-P-004A/B TOP PA PUMP CS 12 Cr S-6 Y LSS
010-P-005A/B KEROSENE PA PUMP CS CS S-5 N N
010-P-006A/B LAGO PA PUMP CS 12 Cr S-6 N N
010-P-007A/B ATM RESIDUE PUMP 12 Cr 12 Cr C-6 N N
010-P-008A/B KEROSENE PRODUCT PUMP CS 12 Cr S-6 N N
010-P-009A/B LAGO PRODUCT PUMP CS 12 Cr S-6 N N
010-P-010A/B CDU OVHD LIQUIDS PUMP CS 12 Cr S-6 Y Y
010-P-011A/B CDU SOUR WATER PUMP Duplex SS Duplex SS D-1 N Y
010-P-013A/B UNSTABILISED NAPHTHA PUMP CS 12 Cr S-6 Y Y
010-P-014A/B RECONTACTOR SOUR WATER PUMP CS 12 Cr S-6 Y Y
010-P-015A/B NAPHTHA STABILISER REFLUX PUMP CS 12 Cr S-6 Y Y
010-P-016A/B NAPHTHA STABILISER OVHD PUMP CS 12 Cr S-6 Y Y
010-P-017A/B STABILISED NAPHTHA PUMP CS CS S-5 N N
010-P-018A/B DE-ETHANISER OVHD PUMP CS 12 Cr S-6 Y Y
010-P-019A/B C3 LPG PUMP LTCS CS mod S-5 N N

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Item Service Material PWHT Sour


Service
Case Impeller API Class
010-P-020A/B C4 LPG PUMP CS CS S-5 N N
010-P-021A/B VACUUM DIESEL PUMP CS CS S-5 N N
010-P-022A/B/C VGO PUMP CS 12 Cr S-6 N N
010-P-023A/B HVGO PUMP 12 Cr 12 Cr C-6 N N
010-P-024A/B RECYCLE PUMP 12 Cr 12 Cr C-6 N N
010-P-025A/B VAC. RESIDUE PUMP 12 Cr 12 Cr C-6 N N
010-P-027A/B HOT WELL OIL PUMP CS 12 Cr S-6 Y LSS
010-P-028A/B VDU SOUR WATER PUMP Duplex SS Duplex SS D-1 N Y
010-P-029A/B HAGO PRODUCT PUMP 12 Cr 12 Cr C-6 N N
010-P-030A/B HAGO PUMPAROUND PUMP 12 Cr 12 Cr C-6 N N
010-P-031A/B RICH AMINE PUMP CS 316 SS S-8 Y Y
010-P-033A/B RICH AMINE PUMP CS 316 SS S-8 Y Y
010-P-034A/B AMINE BLOWDOWN DRAIN PUMP CS CS S-5 Y Y

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Appendix A4: Vessels and Columns

Item Service Material PWHT Sour Remarks


Service
Shell/Heads Internals
010-C-001 CRUDE DISTILLATION COLUMN (top-D1): A516 - 70N + 3mm clad 6% As Shell / Clad N LSS (a) Alloy 625 (UNS N06625) or
Mo SS (a) Trays (1-D1): 6% Mo SS Alloy C-276 (UNS N10276)
(D1-D3): A516 - 70N+ 3mm (a) are acceptable alternatives
(D3-bottom): A516 - 70N + 3mm clad Trays (5-44): 12Cr +
12Cr 1.5mm
010-C-002 KEROSENE STRIPPER A516 - 70N +3mm Trays:12 Cr N N Demister: SS 304L
010-C-003 LAGO STRIPPER A516 - 70N +3mm Trays:12 Cr N N Demister: SS 304L
010-C-004 NAPHTHA STABILISER A516 Gr70 N + 3mm (a) Trays 1-5:SS 316L Y LSS (a) From column top to tray 5,
Trays 6-44:12Cr shell/head/nozzle to have
3mm SS 316L clad
Distributor: SS 316L
010-C-005 DE-ETHANISER A516 - 70N +3mm Trays:12 Cr Y (a) LSS (a) MDMT= -43 C
a) top down to tray 5
010-C-006 DEPROPANISER A516 - 70N +3mm Trays:12 Cr N N MDMT= -45 C
010-C-007 VACUUM DISTILLATION COLUMN (top - D1) : A516 Gr70N + 3mm (1- D1) : 316L N LSS Demister: SS316L
(remaining) : A516 Gr70N + 3mm clad (remaining) : 12Cr + (top to tray Distributor: SS 316L
12Cr SS 1.5mm D1)
010-C-008 HAGO STRIPPER A516 Gr70 N + 3mm clad 12 Cr SS Trays:12 Cr+ 0.8mm N N

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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Item Service Material PWHT Sour Remarks


Service
Shell/Heads Internals
010-V-004 FUEL GAS KO DRUM ASTM A 516-70N + 3mm 12 Cr N N
010-V-005 CRUDE COLUMN OVHD RECEIVER ASTM A 516-70N + 6mm SS 316L Y HSS SS 316 clad below vessel
centerline. Fully clad vessel is
an acceptable alternative
010-V-006 OFFGAS COMP. SUCTION DRUM ASTM A 516-70N + 3mm SS 316L Y LSS Demister: SS 316L
010-V-007 RECONTACTOR DRUM ASTM A 516-70N + 6mm SS 316L Y HSS Boot: 3mm clad SS 316L

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

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