MECHANICAL-PROCESS SECTION

(M-P) Publication-1
Published on 20.04.2019
Presented by N V Raghavaiah, SO/F
Venue: HRD Section

Basis of Materials Selection for H2S service in HWP (Manuguru)

 Materials that selected in H2S- environment are based on maximum design pressure and design
temperature, together with the fluid in the system that must qualify National Association of Corrosion
Engineers (NACE) MR01-75 standards.
 Most of the materials used are carbon steels and low alloy steels with Hardness HRC 22 maximum
(equivalent to BHN 238 maximum) after heat treatment, provided they contain less than 1 % Nickel.
(Lower the Nickel, more the ductility).
 Modified material: For carbon steels and alloy steel materials, Chemical Composition was modified
with NACE limits for Sulfur (S ≤ 0.002%) as increase in Sulfur content results in red-shortness,
Phosphorus (P ≤ 0.020%) as increase in phosphorus increases cold-shortness and Carbon (C ≤
0.10%) as the ductility of plain carbon steels increases with the decrease of carbon content.
 Carbon steel material must have fine grained structure with ASTM grain size No: 5 to 8 for low
temperature applications. (LTCS material). It improves impact toughness at lower temperatures.
 A material with same mechanical properties (tensile strength, yield strength, elongation, reduction in
area and hardness) and with different chemical composition are available. For ex: ASTM A 516 Gr 70
and ASTM A 516 Gr 70M have same mechanical properties, but different chemical composition.
 NACE Test Methods: For sour service steel pipe, plate, fittings, commonly there are two test methods
referred in NACE. Hydrogen Induced Cracking (HIC) and Sulfide Stress Cracking (SSC).
 HIC is Hydrogen Induced Cracking. HIC test is a mandatory test for NACE pipe and fittings. But if
there is certificate of proof for the material (Raw material for making pipes or fittings) complying to
NACE, then there is no need to do this test again.
 SSC is Sulfide Stress Cracking. SSC test is a long time lasting experiment. The test is specially carried
on alloy steels keeping test material in corrosion environment and with constant pulling force. Under
this environment (Corrosion + Force), material is tested at about 40000 psi and material shall not fail.
SSC cracking is one of the most harmful corrosion types, during corrosion, if there is any small cracks,
the broken speed is far more soon than other type of corrosion. So SSC corrosion is a “Corrosion
Disaster”. This phenomenon is affected by complex interaction of parameters including (1) Metal
chemical composition, strength, heat treatment and micro structure, (2) pH, (3) hydrogen sulphide
concentration and total pressure (4) total tensile stress, (5) temperature and (6) time.
 Metallic coatings (electroplated or electroless), conversion coatings, and plastic coatings or linings are
not acceptable for preventing SCC of base metals.
 Induced hardness in bolts is limited to 27 HRC keeping corresponding limiting induced stress value to
40,000 PSI to avoid SCC.

Basics:

 Carbon Steel: An alloy of carbon and Iron containing carbon up to about 2% and manganese up to
about 1.65%, containing residual quantities of other elements except those intentionally added for de-
oxidation (usually silicon).
 Stainless Steel: Steel containing sufficient chromium (usually more than approximately 11%) to
render the steel corrosion resistant. Other elements may be added to secure special properties.
 Hardness: Resistance of metal to plastic deformation, usually by indentation.
 Rockwell “C” Hardness (HRC) is one the measurements in which, hardness value obtained by use of a
cone shaped diamond indentor and a load of 150 kilograms.
 In the Brinell hardness test (BHN), a hard object such as a steel ball is pressed into the material being
tested. The ball is of a specified diameter, usually 1 centimeter. The Brinell hardness is the amount of
force applied to the ball divided by the area of the indentation the ball makes in the material. The result
is measured in kilograms of force per square millimeter but should be stated as an empirical reading,
without units.
 Materials used in H2S Environment

Ref Code : American Society for Testing and Materials (ASTM)

Specification Description Applicable Use in HWP(Manuguru)

Grade
A-53 Pipe, Steel, Black and Hot- Gr.B General purpose piping for water
Dipped, Zinc-Coated, Welded and air
and Seamless
A-105 Carbon Steel Forgings for --- Pipe fittings for steam and
Piping Applications condensate
A-106 Seamless Carbon Steel Pipe Gr.B Piping for steam and
for High-Temperature Service condensate, LPG
A-182 Forged or Rolled Alloy-Steel Gr F304 Pipe Flanges, Forged Fittings,
Pipe Flanges, Forged Fittings, F316L and Valves
and Valves and Parts for
High-Temperature Service
A-193* Alloy Steel and Stainless B7M Bolts and studs
Steel Bolting Materials
A-194* Carbon and Alloy Steel Nuts 2HM Nuts
for Bolts
A-213 Seamless Ferritic and TP316 Heat-Exchanger Tubes
Austenitic Alloy-Steel Boiler,
Super heater, and Heat-
Exchanger Tubes
A-240 Heat-Resisting Chromium and TP316L Stainless Steel Plate used in
Chromium-Nickel Stainless TP304L Heat and mass transfer trays
Steel Plate, Sheet, and Strip
for Pressure Vessels
A-312 Seamless and Welded TP316L Stainless Steel Pipes
Austenitic Stainless Steel TP304L
Pipes
A-333* Seamless and Welded Steel Gr.6 H2S laden liquid piping
Pipe for Low-Temperature
Service
A-350* Carbon and Low-Alloy Steel LF.2 H2S laden liquid piping
Forgings, Requiring Notch connected forgings
Toughness
Testing for Piping
Components
A-420* Piping Fittings of Wrought WPL6 Piping Fittings in H2S service
Carbon Steel and Alloy Steel
for Low-Temperature Service
A-516* Pressure Vessel Plates, Gr.70 Exchange unit Towers, dump
Carbon Steel, for Moderate- tanks, CRT, HRT, Heat
and Lower- exchanger shell and dishes
Temperature Service

Note: * marked specifications are LTCS materials having charpy notch requirement of
20J energy absorption at - 46OC.