Petroleum Development Oman L.L.C.

Materials Selection for Oil and Gas

Production Systems
(Amendments/Supplements to ISO-21457) -
Specification

Document ID SP-2337

Document Type Specification

Security Restricted

Discipline Materials & Corrosion

Owner UEC

Issue Date 05/07/2023

Version 2
Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the
whole nor any part of this document may be disclosed to others or reproduced, stored in a retrieval
system, or transmitted in any form by any means (electronic, mechanical, reprographic recording
or otherwise) without prior written consent of the owner.

2
This page was intentionally left blank

3
Document Authorisation

Authorised For Issue

Document Authorisation

Document Owner Document Custodian Document Author

(CFDH)
NABHANI,TALAL UEC Hajri, Zaher UEC1 Rusheidi, Ruqaia UEC121
Date : 16-08-2020 10:30 Date : 19-07-2020 9:07 AM Date : 19-07-2020 7:59 AM
AM

4
Revision History
The following is a brief summary of the recent revisions to this document.

Version No. Date Author Scope / Remarks

1 13/07/2020 Mohamed AlGhafri
2 05/07/2023 Rusheidi, Ruqaia UEC121 This SP is revised to align full SP
Ghafri, Mohamed DET with international standards,
Yahyai, Huwaynaa UEC32 address the requirements from
Wahaibi, Arwa DET2 SP-2161 (version 2) and update
Hubaishi, Mohammed non-metallic inputs.
UEC57

Related Corporate Management System (CMS) Documents

The related CMS Documents can be retrieved from the Corporate Management Portal (CMS).

SP-2161 Materials for Use in H₂S Containing Environments in Oil and Gas Production
for Surface Facilities (Amendments/Supplements to ISO-15156 Fourth
edition 2020)
SP-2193 Materials Selection & Corrosion Control for Well Equipment and Components
SP-1246 Specification for Painting and Coating of Oil and Gas Production Facilities
SP-1128 Cathodic Protection (AMENDMENTS/SUPPLEMENTS TO ISO 15589-
1:2015)
SP-2427 Corrosion Control Specification
SP-2379 Specification For Pipeline External Coatings (Amendments/Supplements to
ISO 21809-1:2018)
SP-2319 Specification for Flexible Composite Pipes
SP-2389 External Field Joint and Rehabilitation Coating System for Buried Pipelines
SP-2092 GRP Specification
SP-2094 Specification for Polyethylene liners in carbon steel flow lines, pipelines and
piping
SP-2217 Specification for Internal FBE Powder and Liquid Coating Systems For
Carbon Steel Piping and Line pipes
SP-1173 Welding of Pressure Containing Equipment and Piping (Amendments and
Supplements to IOGP S-705 V 1.0 )
SOP-307 Material Selection Process MSR
SOP-1094 FEED Office Material Selection Report Process
SOP-1043 Temporary Deviation to Approved MSR
SOP-1044 Approval of FEED / DD MSR

5
TABLE OF CONTENTS
Document Authorisation ................................................................................................................. 4
Revision History ............................................................................................................................. 5
Related Corporate Management System (CMS) Documents ....................................................... 5
Introduction .................................................................................................................................... 8
1 Scope ...................................................................................................................................... 9
3 Terms, definitions, and abbreviated terms ........................................................................... 10
3.1 Terms and definitions ...................................................................................................... 10
3.2 Abbreviated terms ........................................................................................................... 10
5 Materials selection report...................................................................................................... 12
6 General guidelines for corrosion evaluations and materials selection ................................. 12
6.2 Internal corrosion in oil and gas production and processing .......................................... 12
6.2.1 Corrosion evaluation .................................................................................................... 12
6.2.2 Corrosion mechanisms ................................................................................................ 12
6.2.3 Corrosion parameters ................................................................................................ 12
6.6 External corrosion ........................................................................................................... 13
6.6.3 External non-marine atmospheric environments ....................................................... 13
6.6.4 Buried and submerged installations ........................................................................... 13
6.6.5 Corrosion under insulation ......................................................................................... 14
6.7 Polymeric materials ......................................................................................................... 14
6.7.1 HDPE (PE100) / PERT lined CS: .............................................................................. 14
6.7.2 LLRTP (FCP): ............................................................................................................ 15
6.7.3 Other thermoplastic materials and limits:................................................................... 15
6.8 Glass-fiber-reinforced plastic pipes ................................................................................ 17
6.9 Mechanical properties and material usage limitations .................................................... 17
6.9.1 General ...................................................................................................................... 17
6.9.2 Submerged installations ............................................................................................. 18
6.10 Non-metallic material limitation ..................................................................... 18
7 Materials selection for specific applications and systems .................................................... 20
7.2 Oil and gas production and processing systems ............................................................ 20
7.2.1 General ...................................................................................................................... 20
7.2.3 Wellhead, production and process systems .............................................................. 20
7.2.4 Flare systems ............................................................................................................. 20
7.2.5 Produced water .......................................................................................................... 21
7.3 Injection systems ............................................................................................................ 21
7.3.2 De-aerated seawater ................................................................................................. 21
7.3.3 Aerated seawater ....................................................................................................... 21
7.3.6 Steam injection systems ............................................................................................ 21
7.4 Utility systems ................................................................................................................. 21
7.4.2 Fresh-water systems ....................................................................................................... 21
6
7.4.3 Seawater and brackish carrying systems ....................................................................... 22
7.4.4 Other utility systems ........................................................................................................ 22
7.4.4.1 Glycol dehydration system ............................................................................ 25
8 Corrosion control .................................................................................................................. 27
8.1 Chemical treatment ......................................................................................................... 27
8.3 Selection of internal and external coatings ..................................................................... 27
8.5 Cathodic protection ......................................................................................................... 27
8.6 Corrosion protection of closed compartments ................................................................ 27
8.7 Connection of dissimilar materials .................................................................................. 27
8.8 Sealing materials ............................................................................................................ 27
8.8.1 Qualification of elastomers......................................................................................... 27
8.8.2 Elastomer selection .................................................................................................... 28
8.9 Fasteners ........................................................................................................................ 30
8.10 Weld overlay.................................................................................................. 31
8.12 Corrosion management................................................................................. 31
9 Appendix ............................................................................................................................... 32
Annex A Design basis for hydrocarbon systems ......................................................................... 32
Annex B: Liquid Metal Embrittlement (LME) of Stainless Steel and Nickel Alloy Materials in Case
of Fire Scenario ............................................................................................................................ 34
Annex C: Materials requiring specific approval ........................................................................... 35
Annex D: Intergranular corrosion testing (IGC) & corrosion testing ............................................ 37
D.1 IGC requirements for SS316L and SS316 C&A items .......................................................... 38
Annex E: Insulation gaskets......................................................................................................... 39

7
Introduction
This specification is written as amendments and supplements to ISO-21457 (First Edition,
September 2010). For ease of reference, the clause numbering in ISO-21457 has been used
throughout this part of the specification.
All clauses of ISO-21457 which are not modified in this specification shall remain valid as written.
This document shall be used in conjunction with SP-2161, as appropriate.

8
1 Scope
Replace 1st paragraph with the following:

This specification identifies the corrosion mechanisms and parameters for

evaluation when performing selection of materials for pipelines, piping and
equipment related to transport and processing of hydrocarbon production and water,
including utilities, water treatment and injection systems. This includes all equipment
from and including well hook up piping, to and including pipelines for stabilized
products.

This specification is not applicable to wellheads, Christmas trees and downhole

components as it is covered by SP-2193 “Materials Selection & Corrosion Control
for Well Equipment and Components”.

Proprietary materials may be considered upon successful qualification and approval

from MCI Corporate Function Discipline Head (CFDH).

9
3 Terms, definitions, and abbreviated terms

3.1 Terms and definitions

Add the following:
Note: Throughout all ISO-21457 standard “should” and “may” shall be replaced by “Shall”.

Replace the definitions as following:

3.1.20
type 316
austenitic stainless steel alloys of type UNS S31600/S31603 with minimum molybdenum
content of 2 %
3.1.21
type 6Mo
6Mo materials is a super austenitic stainless steel with minimum nitrogen content of ≥ 0.18%
and 40,0 ≥ PREN
3.1.22
type 22Cr duplex
ferritic/austenitic stainless steel alloys with 34,0 ≤ PREN < 40,0, nitrogen content ≥ 0.14 m%.
3.1.23
type 25Cr duplex
ferritic/austenitic stainless steel alloys with PREN ≥ 40,0 and Nitrogen content ≥ 0.20 m%
(mass fraction).

3.2 Abbreviated terms

Add the following:

ASTM American Society Testing Materials

CET Critical Exposure Temperature
CFDH Corporate Function Discipline Head
CSCC Chloride Stress Corrosion Cracking
DCAF Discipline Controls and Assurance Framework
ECTFE Ethylenechlorotrifluoroethylene
ETFE Ethylene Tetrafluoroethylene
FCP Flexible Composite Pipe
FFKM Perfluoro Elastomer
FKM Fluorocarbon Co-polymer
HDPE High Density Polyethylene
HNBR Hydrogenated Nitrile Butadiene Rubber
HSE Health Safety Environments
IGC Intergranular Corrosion
ISO International Organization Standardization
LLRTP Long length Reinforced Thermoplastic Pipe
MAT Minimum Allowable Temperature
MCI Materials, Corrosion and Inspection
MMT Minimum Metal Temperature

10
MOT Maximum Operating Temperature
NBR Nitrile Butadiene Rubber
ND Nominal Diameter
PDO Petroleum Development Oman
PE-LD Polyethylene, low density; preferred term for
LDPE
PE-MD Polyethylene, medium density; preferred term for
MDPE
PEEK Polyetheretherketone
PERT Polyethylene of Raised Temperature resistance
PEX Cross-linked Polyethylene
PFA Perfluoroalkoxy Copolymer
PR Procedure
PVC-C Chlorinated Polyvinylchloride
PVC-U Unplasticised Polyvinylchloride
PVDF Polyvinylidenefluoride
PWHT Post weld heat treatment
RGD Rapid Gas Decompression
SCE Safety Critical Equipment
SP Specification
TA2 Technical Authority 2
TSA Thermal Sprayed Aluminium

11
5 Materials selection report
Add the following:
For MSR development guidelines at different design stages, refer to MSR Standard Operating
Procedures (SOP-307, SOP-1094, SOP-1044).
For Temporary Deviation to Approved MSR follow SOP-1043.
The MSR shall be reviewed and approved as per DCAF.

6 General guidelines for corrosion evaluations and materials

selection

6.2 Internal corrosion in oil and gas production and processing

6.2.1 Corrosion evaluation
In the 2nd paragraph, replace the following “The corrosion evaluation should be based on a
corrosion prediction model” with “The corrosion evaluation shall be based on w-HYDROCOR”

6.2.2 Corrosion mechanisms

6.2.2.4 Sulfide stress cracking (SSC)/stress corrosion cracking (SCC) caused by H2S
Replace with following:
Refer to SP-2161 for material requirements in sour service.

6.2.2.5 Alkaline stress corrosion cracking

Replace 2nd paragraph as below;
Carbon steel in such environment Shall be PWHT after welding. Protective coatings shall not
be used as barrier against SCC.

6.2.3 Corrosion parameters

6.2.3.2 CO2 and H2S contents

rd
Replace 3 paragraph as below;
The H2S content in gas phase shall be used. The determination of partial pressure of H 2S shall
be according to SP-2161.
Replace 5th paragraph as below;
Default values of pH, chloride…etc. shall not be used for corrosion and cracking evaluations.
pH shall be based on situ measurement or model calculation otherwise the company provided
data shall be used.

Add the following new clause:

6.2.3.10 Liquid metal embrittlement

Refer to annex B of this specification.

12
 6.6 External corrosion

6.6.3 External non-marine atmospheric environments

Add the following:

The threshold temperatures given in Table 1 of this specification shall be used as default
values. Where below the threshold temperatures, no mitigation against external CSCC is
required and above the threshold temperatures, shall require mitigation against CSCC with
Thermal Sprayed Aluminium (TSA).

Table 1 CSCC threshold temperature limits for stainless steel materials in desert
environment and oxygen contaminated exposures
Maximum
Operating Safety Critical Coating Requirement
Material Temperature ◦C Note 3, 4
Element? Note 2
(Desert) Note 1

> 60 ◦C No Organic Coating Note 5

Austenitc Stainless steel
> 60 ◦C Yes TSA

> 120 ◦C No Organic Coating Note 5

DSS/SDSS/ 6 Mo
> 120 ◦C Yes TSA

Nickel Alloys NA No coating

Note:
1- Costal temperatures (within 10km (6 miles) of coastal waters) shall be; 50 ◦C for Austenitic Stainless
Steel and 100 ◦C for DSS/SDSS/ 6 Mo.
2- Safety Critical Element (SCE) Identification & Performance Standard Implementation within the
CMMS Asset Register shall be as per SP-1992
3- The selection of organic coating systems shall be as per SP-1246

4- If application of TSA is not feasible for small bore (DN 50) and below, use of aluminium foil, or
upgrade to higher CRA materials is acceptable. Organic coating may be used if the risk is
demonstrated as ALARP.

5- Organic coatings specified in SP-1246 can be utilized provided that; a robust coating
inspection/maintenance program shall be in place every 5-7 years.

Add the following:

PCS-1A shall be selected for MAF/ terminal, Amal, Nimr fields or when specified in MSR.

6.6.4 Buried and submerged installations

Add the following:
Refer to SP-2379 for Specification for Pipeline External Coatings (Amendments/Supplements to
ISO 21809-1:2018) and refer to SP-1246 for Specification for Painting and Coating of Oil and Gas
Production Facilities.
Delete 2nd paragraph.

13
 6.6.5 Corrosion under insulation
Add the following:
External coating systems for CUI is defined in below tables.
Table 2 Carbon steel coating requirements for CUI

Operating Condition Coating Requirement

Any Temperature Organic Coating Note 1
Coastal/Steam Organic Coating Note 1 / TSA
Cyclic Temperature TSA

Table 3 CRA coating requirements for CUI

Safety
Temperature ◦C Critical Coating
Material
(Desert) Note 1 Element? Requirement Note 3,4
Note 2

< 60 ◦C No No coating
Austenitic < 60 ◦C Yes Organic Coating Note 5
Stainless Steel > 60 ◦C No Organic Coating Note 5
> 60 ◦C Yes TSA
< 120 ◦C No No coating
DSS/SDSS/ 6 Mo < 120 ◦C Yes Organic Coating Note 5
> 120 ◦C No Organic Coating Note 5
> 120 ◦C Yes TSA
Nickel Alloys - NA No coating

Notes:
1- Costal temperatures (within 10km (6 miles) of coastal waters) shall be; 50 ◦C for Austenitic Stainless
Steel and 100 ◦C for DSS/SDSS/ 6 Mo.
2- Safety Critical Element (SCE) Identification & Performance Standard Implementation within the
CMMS Asset Register shall be as per SP-1992
3- The selection of organic coating systems shall be as per SP-1246

4- If application of TSA is not feasible for small bore (DN 50) and below, use of aluminium foil, or
upgrade to higher CRA materials is acceptable. Organic coating may be used if the risk is
demonstrated as ALARP.
5- Organic coatings addressed in SP-1246 can be utilized provided that; a robust coating
inspection/maintenance program shall be in place every 5-7 years; inspection window shall be
provided in the insulation material and shall be included in the coating monitoring surveys.

6.7 Polymeric materials

Replace the section with the following:

Selection of thermoplastic material shall be based on evaluation of the functional requirements

for the specific application. Material limitations for GRE, HDPE (PE100)/PERT Lined carbon
steel and FCP are in table 5 of this specification.
Stand-alone HDPE (PE100)/PERT pipes requirements shall be in accordance with table 4 of
this specification.

Add following new clauses:

6.7.1 HDPE (PE100) / PERT lined CS:

General material requirements:

14
 1. The selection of HDPE (PE100) lined CS pipelines SHALL [PS] include the effect of
chemicals that are added upstream of the HDPE (PE100) lined CS pipeline, including any
well stimulation chemicals and the resultant flow back of the treatment fluids into the
pipeline.
2. HDPE (PE100) lined CS pipelines SHALL [PS] be designed for temperatures up to the
maximum operating temperature, including those encountered during upset conditions. .
3. HDPE (PE100)/PERT lined CS shall not be used in aromatic hydrocarbon. If there is
aromatic in the process fluids, it shall be reviewed and approved by Non-metallic TA2.
4. HDPE(PE100)/PERT Lined CS shall not be used for cyclic pressure service >7000 cycles
for design life.
5. All vents in the HDPE(PE100)/PERT lined CS pipelines shall have valves. For H2S
application SP-1190 part 1- 4 shall be followed.
6. For corrosion allowance of HDPE (PE100)/PERT lined CS, the following shall be used:
 CA is not required for above ground pipeline and piping, including short buried
sections/ road crossing of above ground pipelines and flowlines.
 All buried applications (pipeline/headers/piping) shall have 1 mm CA
7. Refer to SP-2094 for manufacturing, jointing and quality requirements for Polyethylene
liners in carbon steel flow lines, pipelines, and piping.

6.7.2 LLRTP (FCP):

General Material requirements for FCP:

1. FCP shall be designed and installed in accordance to SP-1208 as permanent installation

for the intended design life of the flowline. The maximum design life for FCP is 20 years.
The FCP selection shall be based on life cycle cost analysis.
2. Temporary & re-use of FCP pipes shall be authorized by TA2 Materials & Corrosion
based on technical feasibility and commercial advantage.
3. The FCP lines, fittings and joints shall be designed and qualified in accordance with SP-
2319, and API15S requirements. FCP shall not be applied in conditions outside the
qualified range limits.
4. The thickness of the thermoplastic liner shall not be less than 3 mm in spoolable pipes.
5. Metallic material end fittings that are used to join LLRTP pipes shall be selected based
on the process conditions and fluid service parameters in accordance with SP-2161 and
shall be protected from external corrosion as per PCS-4 as per SP-1246.
6. For sour service applications, the steel strips or wires used in pipes manufactured in
accordance with API 17J or API 17K shall comply with the sour service requirements of
steel reinforcements of API 17J or API 17K.

6.7.3 Other thermoplastic materials and limits:

Thermoplastic materials used in Pipelines, Piping, Seals, Washers, Injection lines can be selected
from Table 4 below depending on the service fluids and design parameters required.
Table 4: Thermo Plastic Materials
Component Material Standard reference Remarks
description
Pipelines PE-LD, PE-MD, ISO 23936-1 ISO23936 supplements, but does not
PE-X replace, the materials requirements of
Piping
the appropriate design codes,
PP-H, PP-R, PP-B,
Seals standards or regulations such as ASME
PP
B31.3
Washers
PVDF
Injection lines
PA 11, PA 12

15
Component Material Standard reference Remarks
description
PPS, PEEK,
PTFE, PAI, PEI,
POM, PCTFE
ECTFE, ETFE
HDPE (PE100)

Piping U PVC ISO 1452-1 to 4 ISO 15493 Characteristics and

requirements for piping systems made
C PVC ASTM F442
from ABS, PVC-U or PVC-C intended
to be used by authorities, design
engineers,
certification bodies, inspection bodies,
ISO 15493 test laboratories, manufacturers and
users

Piping/Pipelines Stand alone HDPE ISO4427 -1,2,3,5 HDPE(PE100) Stand alone pipes can
(PE100) be used within the allowable design
API15LE
limits specified in the standards
Stand alone PERT
ISO 24033, ISO API15LE/ISO4427.
22391
Stand alone HDPE (PE100) and PERT
can be used for design pressure <16
bar and design temperature < 60 C for
HDPE (PE100), and 85 C for PERT.
Stand alone HDPE (PE100) and PERT
shall be used for water and air only.

Thermo plastic Chemical ISO10358 Chemical compatibility thermoplastic

materials compatibility – pipe materials – Maximum allowable
applications Thermo plastic temperatures
materials PE, PVC,
PVDF, PEX etc.,
Thermo plastic PP-H, PP-B, PP-R, EN 13121-1 to 4 Liner material used in GRP tanks only.
liner in GRP PVC -U
tanks

Piping systems PA-11 ISO16486 part 1 to 6 Plastics piping systems for the supply
of gaseous fuels – Unplasticized
PA -12
polyamide (PA-U) piping systems with
API TR 17TR2 fusion jointing and mechanical jointing

Ageing of PA shall be based on

guidelines provided in API TR 17TR2
Fluoro PTFE, ECTFE, ISO 23936-1 PVDF standalone piping can be used
Polymers PFA, FEP, PVDF for high concentration HCl service up
Material specification,
(lining, piping, to 60 °C.
qualification and
seals, washers
chemical
and gaskets) Fluoro polymers shall not be used in
the following environments:

16
Component Material Standard reference Remarks
description
compatibility of the a. fluorine gas;
fluoro polymers. b. strong reducing agents, such as
alkaline metals;
c. sodium;
Chemical d. potassium, and;
compatibility and e. reactions of sodium metal in
temperature anhydrous solvents, such as
limitations of the naphthalene and
thermoplastic anhydrous ammonia
polymers with
the contained fluids
shall be in
accordance with EN
13121
Seals/ back up PPS, ISO23936-1 The maximum design temperatures
support to seals provided in ISO 23936-1 for load
PEEK
carrying components are upper limits
and depend on the stress level.

6.8 Glass-fiber-reinforced plastic pipes

Add the following:

The selection of Glass Reinforced Epoxy (GRE) material is based on the qualified material & the
limitations as stated in table 5 of this specification. Whereas diameter, pressure and type of joints
limitations are as specified table 1 of SP- 2092.

General Material Requirements:

1. Safety critical GRE system SHALL [PS] not be installed above ground in areas classified
as zone 0, zone1 and zone 2 in accordance with IEC60079-10-1 (area zone 0, 1, 2).
2. Above ground GRE system shall be designed for preventing mechanical movements,
stresses ,surges and third party damage to a risk level equivalent to buried GRE.

6.9 Mechanical properties and material usage limitations

6.9.1 General
Add the following:
Steels shall be impact tested at the lowest temperature for which the standard specification
specifies the toughness.
In all cases, the impact test temperature in the specification shall be -20 °C or colder.

Add the following new clauses:

6.9.1.1 Carbon and low alloy steels with less than 2% nickel
Impact tested carbon and low alloyed steels with less than 2% nickel shall not be used where
the MMT is colder than -50 0C.
6.9.1.2 Duplex Stainless steels
The use of duplex and super duplex stainless steels shall be limited to applications where the
following applies:
 MMT is equal to or warmer than -50 °C and the thickness is less than 40 mm.
 DSS/SDSS shall comply with ISO 17781- Test Methods for Quality Control of
Microstructure of Ferritic/Austenitic (duplex) Stainless Steels”

17
 6.9.1.3 Pressure vessels
The minimum design metal temperature specified in the datasheet shall be used to evaluate the
impact test requirements and exemptions as per the design code. Further reduction in the
minimum design metal temperature (e.g. reduction for thickness ratio) for impact test exemption
is not allowed.

6.9.2 Submerged installations

Delete, not applicable for PDO.

Add new section:

6.10 Non-metallic material limitation

Table 5: Material limitations for GRE, HDPE (PE100)/PERT Lined carbon steel and FCP
Required GRE HDPE (PE100) PERT Lined CS FCP FCP
Paramet lined CS
Non metallic Metallic
er
Reinforced Reinforced
Water Y Y Y Y Y
Oil Y4 Y Y Y ♦13
Wet Gas Y4 X X Y
♦13
Multiphase Y Y3 Y3 Y
♦13
H2S ≤7 mol% up ≤ 3 mol%6 ≤ 3 mol%6 Up to 1000 Up to 0.35
to 100°C ppm Kpa
≤10 mole %
up to 75° C
Design As per table ≤ 220 bar8 ≤ 220 bar8 ≤100 bar12 ≤150 bar12
Pressure 1 of SP
2092
CO2 Gas No limit No limit No limit No limit Up 1 bar
partial
pressure15
Temperatur DT ≤ 100° For Water For Water DT Up to 85 C14 DT Up to 85 C14
e 1,9, 10 C7 Liner Pipe: MOT Liner Pipe: MOT
≤70°C ≤85°C
Fittings (LDPE Fittings (ETFE
Rotolining) :MOT Rotolining): MOT ≤
≤ 60°C 85°C
For Multiphase For Multiphase
Liner pipe: MOT≤ LinerPipe:
65°C MOT≤85°C
Fittings (LDPE Fittings (ETFE
Rotolining): Rotolining): ♦
MOT≤60°C
Fluid ≤4 m/s liquid ≤ 5m/s liquid ≤ 5m/s liquid ≤ 5m/s liquid ≤ 5m/s liquid
velocity velocity velocity velocity velocity velocity
≤ 10 m/s gas
velocity
GLR (Gas No limit 3003 3003 30011 30011
Liquid
Ratio)

18
 Notes for table 5:
1. PERT and HDPE (PE100) lined CS pipes design temperature is based on maximum
operating temperature (MOT) of the line.
2. For rotolining, the spool dimensions and weight limitations shall be followed. Maximum
spool weight <2.25 tons, maximum spool length < 3.2 meters. For higher values, refer to
vendor recommendation.
3. Consult MCI engineer for GLR more than 300.
4. Electrical conductivity of the fluid shall not be less than 10,000 pS/m.
5. If sand is > 50g/m3 & in wax/asphalt production areas, it is not recommended to use all non
metallic materials mentioned in the table without flow assurance study. Consult M & C Engineer.
6. Venting H2S service fluids – Applicable HSE/Safety precautions and permissions shall be
obtained during venting operation. Vent design and Venting procedures shall be designed for
safe venting operations. For H2S application SP-1190-1 to 4 shall be followed.
7.Consult MCI engineer (non-metallic SME) for design temperature of fluids more than 95deg
C for qualifications.
8. This limit is mainly for flange joint sealing. More than 220bar design pressure flange joint
sealing capabilities shall be demonstrated through pressure test. Consult MCI engineer (non-
metallic SME).
9. HDPE (PE100) lined CS pipes design is based on maximum operating temperature (MOT) of
the line. For MOT up to 60°C, HDPE (PE100) lined CS shall be designed to default temperature
60°C. For MOT above 60°C, HDPE (PE100) lined CS shall be designed to default 70°C for
water and 65°C for hydrcarbon service.
10. HDPE (PE100) lined CS pipelines or flowlines shall be protected from temperature upset
conditions with suitable safeguarding to ensure that Temperature shall not exceed specified
MOT.
11. LLRTP pipe where there is no provision for venting to release the permeated gases through
HDPE (PE100)/PERT lined CS, the GLR limit is 300. If there is provision to provide the vents,
then no GLR limit.
12. Design pressure of FCP (LLRTP) pipes depends on the vendor qualified pressure ratings.
Consult non metallic materials TA2 for further details. Max diameter for the LLRTP is 6”.
13. Steel reinforcements FCPs are not recommended for Hydrocarbon service. Consult non
metallic materials TA2 for any specific multiphase/hydrocarbon service applications. Max
diameter of steel reinforced FCP is 8”.
14. Design temperature of FCP (LLRTP) pipes depends on the vendor qualified temperature
and on the material used for the liner layer of the pipe. Generally, FCPs with HDPE (PE100)
lined CS are designed for 60 to 65 C. FCPs with PERT liners are designed for 82 to 85C.
15. For CO2 partial pressure higher than 1 bar, consult with non metallic materials TA2.

Symbols:
X – Shall not be used.
Y – The material may be considered within the boundaries specified in the table.
♦ - Consult with the PDO materials function TA2 authority.

19
7 Materials selection for specific applications and systems

7.2 Oil and gas production and processing systems

7.2.1 General
Add the following Notes:
 PDO has previous issues with the application of 904L grade, CFDH approval is required
in case 904L grade is specified / selected as a material of construction. 904L clad or
weld overlay shall not be used.
 Material adequacy assessment shall consider new facility impact such as process
condition and composition on tie-in systems and connected downstream existing
facilities.
 Credible upset operating conditions during plant start-up and initial operation impact on
the material selection shall be addressed in critical safety and operability reviews such
as HAZOP and transferred into design and operational documents.
 Weld overlay of alloy 825 shall not be used as material for all equipment.
 Austenitic stainless steels containing lower chromium, nickel and molybdenum than AISI
316L shall not be applied for any hydrocarbon equipment/piping.
 Where galling resistance is required, one of the following shall be applied:
1. Anti-galling compounds;
2. Electroplating via immersion method rather than via brush application;
3. Use of different materials for the two parts that come into contact.
4. An alternative anti-galling approach that assures a minimum difference in
hardness of 25 HRB of the components.
 Use of materials specified in Annex C of this specification shall be subject to approval
from PDO Materials and Corrosion TA2 .
 All corrosion testing shall be carried out in a PDO approved Lab or ISO 17025 accredited.
 For corrosion test and Intergranular corrosion testing (IGC) requirements, refer to Annex
D of this specification

7.2.3 Wellhead, production and process systems

Add the following:
- For wellhead equipment/Xmas trees material selection shall be as per PDO SP-2193.
- For instrumentation and C&A wetted items, the selection shall follow piping class valve
trim material as minimum.
- For sour service instrument impulse tubing shall be alloy 825/625, while non-sour service
shall be 316L as minimum. Refer to SP-2161 for material limit.

7.2.4 Flare systems

Replace Table 5 with Table 6 of this specification.
Table 6 Flare systems
Equipment Material
Flare knockout drum Based on SLC. Use SP-2161 if sour is expected.
Piping on flare structure Coated carbon steel may be used up to a design temperature
of 350 °C. Above 350 °C, use 316L. If sour is
expected, use SP-2161, for materials selection note 1
Flare tip Alloy 800H, Alloy 800HT, Alloy 625, AISI 310S may be used
up to maximum design temperature of 650 °C note 2

20
 Flare Structure Use coated carbon steel ( design temp.max.350 0C), if SS316L
is used on the piping on the flare structure
Notes of table 6:
1- Flare piping and headers in critical sour facilities:
o Assessment of carbon steel option for flare piping/headers shall consider worst case
operating scenario in calculation of SLC.
o If utilization factor is used to optimize material selection and SLC: predicted corrosion rate
calculations shall consider worst case operational upsets. Conservative utilization factors
should be considered if it depends on the availability of rotating equipment, especially if
significantly high corrosion rates are expected.
2- Alloy 800H, Alloy 800HT shall be used only for sweet service

7.2.5 Produced water

Add the following:
Refer to SP-2161 for material limits, provided that oxygen ingress shall be maintained up to 10-
20 ppb only. If higher; material selected shall be upgraded.
Delete: bare CS from Table 6.

7.3 Injection systems

7.3.2 De-aerated seawater
Delete, not applicable for PDO.

7.3.3 Aerated seawater

Delete, not applicable for PDO.

Add the following new clause:

7.3.6 Steam injection systems

a) For production fluids, refer to material limits in SP-2161. For the assessment of the
corrosivity of the system, Hydrocor shall not be used. The selection of material shall be
based on corrosivity assessment of similar service application and laboratory testing.
b) For steam generation, refer to Table 7 of this specification.

Table 7 Steam flood material recommendation

Item Materials
Feed water piping CS + CA / non-metallics / CRA
Boiler tube Tube: CS
Shell: CS + CA
Steam piping / flowlines CS + CA
Valves Body: CS
Trim : CRA and hard facing

7.4 Utility systems

7.4.2 Fresh-water systems

Replace first paragraph with the following:

21
 Potable water, demineralized water, de-ionized water and desalinated water are considered as
fresh water. The acceptable chloride concentration is up to 200 mg/l.

Remove the following: galvanized (HDG) CS from Table 9

Change section 7.4.3 title as following:

7.4.3 Seawater and brackish carrying systems

7.4.4 Other utility systems

Replace Table 11 with the following three tables (8,9, and 10) in this specification:
Table 8 Guidance for materials for miscellaneous utility systems
Fluid Material selection Temperature limits °C

Air, instrument piping AISI 316L Note 1 - 20 to 200

Air, instrument buffer vessels GRP or epoxy-coated carbon - 20 to 100

steel with 1mm CA

Air, utility (or follow instrument air) 316L Note 1 0 to 60

Nitrogen/inert gas (dry) Carbon steel 1 mm CA or AISI 0 to 120
316L

Hydraulic oil AISI 316L - 20 to 120

Lubrication/seal oil (sweet) AISI 316L - 20 to 120

Lubrication/seal oil (fH2S < 0.1 bar) AISI 316L - 20 to 120

Jet fuel AISI 316L - 20 to 120

Close drains - piping GRP (UG), carbon steel with a - 20 to 100

suitable corrosion allowance
(AG)

Open drains - piping GRP (UG) - 20 to 100

Drains and sewers - vessels Epoxy coated carbon steel 3 mm 0 to 100

CA
Note 1: Bare Carbon Steel option shall not be used for instrument air service. Galvanized CS
may be used if the existing instrument air is galvanized CS.

Replace fire-fighting system material selection in Table 11 with the following table below:

Table 9 Fire-fighting system material selection

Item Materials Comments

Bottom, Shell: ICCP shall be as per SP-1128
CS + 1.5 mmCA + Internal
coating (GRP lined) Coating shall be as per SP-1246
Fire water tanks Roof (inside): CS +Internal Note: For CS option external paint PCS-
Coating (PCS 7b) 1 as per SP-1246 & PCS-6 for Shell
Or Bottom Plate + impressed current CP
Solid GRP (depending on size) (soil side)
SS316L
Basket Strainers
SDSS

22
Item Materials Comments
Fire water pumps
(electrical/diesel Pump material shall be selected
main and jokey as per SP-2339.
pumps)

Fire water piping A/G: CS+ HDPE

downstream and (PE100)/Rotolining
upstream of tanks
External Paint: as per SP-1246
and pumps
(above ground) U/G: GRP

Valve body and Trim:

Ni-Al-Bronze

SS316L
Fire water ring
SDSS
main
cast iron (body)+Ni-Al-
Br/316L/SDSS (trim)

CS+HDPE (PE100)/Rotolining
Valve body and Trim:

Hydrant Piping Ni-Al-Bronze ,SS316L

(A/G) SDSS
Cast iron (body)+Ni-Al-
Br/316L/SDSS (trim)
CS + HDPE(PE100)/ Rotolining
Valve body and Trim:

Monitor Piping Ni-Al-BronzeSS316L

(A/G) SDSS

cast iron (body)+Ni-Al-

Br/316L/SDSS (trim)

Monitor Piping
GRP
(U/G)

Deluge (A/G) -
Galvanized CS
Wet & Dry
Body: CS + 3mmCA + Internal
coating
Valves body and trims: Ni-Al
bronze
Monitor and SS316L
Hydrants SDSS
cast iron (body)+Ni-Al-
Br/316L/SDSS (trim)

23
Item Materials Comments
A/G: CS +3mmCA
Drain lines & vent Valve material body: CS
Note: above ground drain lines shall be
lines Trim: SS316L or Ni-Al-Bronze slopped

U/G: GRP
Foam package

Tank

Pump

Proportioner Vendor Package

Minimum shall be SS316L
Piping within
package and
upstream of
Proportioner

Foam Piping CS+ HDPE(PE100) /Rotolining,

SS316L
downstream of
Valve body: SS316L
Proportioner (foam
+ fire water mixed) Trim: SS316L or Ni-Al-Bronze

Table 10 Materials for handling inhibitors and other production chemicals

Fluid Material selection Temperature
limits °C
Corrosion inhibitor (neat or AISI 316L - 20 to 120
dissolved in solvent)
Scale inhibitor AISI 316L - 20 to 120
Wax inhibitor AISI 316L - 20 to 120
Coagulant/Anti-foam AISI 316L - 20 to 120
De-emulsifier (pure / diluted) AISI 316L - 20 to 120
Sodium hypochlorite (conc.) Titanium 0 to 50
Sodium hypochlorite (diluted.) C-PVC or GRP - 10 to 50
Oxygen scavenger (conc.) AISI 316L - 20 to 120
Biocide AISI 316L - 20 to 120
Odorant (ethyl mercaptan) Carbon steel 1 mm CA 0 to 120
Glycol (pure) Carbon steel 1 mm CA 0 to 200
Glycol (contaminated) Carbon steel 3 mm CA 0 to 200
Methanol (pure) Carbon steel 1 mm CA 0 to 120
Ferrous sulphate dosing GRP/ABS/PVC 0 to 100
Ferric chloride Titanium - 20 to 120
LDHI/Hydrate Inhibitor 25CR SDSS - 50 to 150

24
 Add the following clause:

7.4.4.1 Glycol dehydration system

1. Table 11 in this specification shall be used for the selection of materials for glycol
systems.
2. Organic coatings (such as epoxy and vinyl ester) shall not be used in the contactor.
3. Use of systems susceptible to chloride attack due to entrainment of saline water shall
be subject to the approval of the Materials and Corrosion Technical Authority of the
Principal.
4. Column and vessel internals (e.g., demisters, dip pipes, packing, Schoepentoeters,
reboiler tubes) shall be AISI 316L stainless steel.
5. Piping for rich glycol shall be AISI 316L stainless steel.
6. For lean glycol, carbon steel piping with 1 mm (0.04 in) corrosion allowance may be
used.
7. Vapour outlet line piping shall be AISI 316L or 22Cr duplex stainless steel.
8. Tube fin material shall be aluminium, or marine bronze for offshore applications.
Table 11 Glycol dehydration systems
Component Acceptable material Notes
Contactor Shell: carbon steel with a A 3 mm thick AISI 316L
minimum corrosion allowance stainless steel cladding to be
of 3 mm. applied below the bottom tray
when bubble caps are used or
All internals: AISI 316L
below the chimney tray when
stainless steel.
structured packing or swirl
Internal gaskets: tubes are used.
Fluoroelastomer
Reboiler AISI 316L clad steel.
Still column, still overhead AISI 316L stainless steel. Still regenerator vapour outlet
condenser line piping: AISI 316L or 22Cr
duplex stainless steel.
Condenser exchanger or coil AISI 316L stainless steel. Removable for easy
replacement.
Glycol-glycol exchangers (plate AISI 316L stainless steel
type heat exchangers) plates.
Gaskets: metal reinforced
flexible graphite.
Glycol-glycol exchangers Tube fin material: aluminium, or Only applicable if finned tubes
(double pipe type heat marine bronze for offshore are applied.
exchangers) applications.
Surge drum Carbon steel with a minimum
3 mm corrosion allowance.
Glycol flash vessel, filters, Carbon steel with a minimum 316L SS piping required for rich
solvent recovery drum and 3 mm corrosion allowance. glycol sections.
solvent water separator

25
Component Acceptable material Notes
Glycol stripping column Carbon steel with a minimum Only applicable if gas stripping
3 mm corrosion allowance. of lean glycol is applied.

7.5 Pipelines and flowlines

Follow SP-2161 for material limits.
For dehydrated dry gas service, the difference between water dew point and operating
temperature shall be >10 deg C
Replace table 12 with the Table 12 in this specification:
Table 12 Pipelines and flowlines
Service Material Comments
Production pipelines Non-metallic as Refer to non metallic material limits
(Hydrocarbon/water/gas/oil) applicable in table 5 of this specification
CS+CA+CI
CRA As per material limit in SP-2161
Dry gas CS+ CA Note:
* For dry gas service, the difference
between water dew point and
operating temperature shall be >10
deg C

26
8 Corrosion control

8.1 Chemical treatment

For chemical treatment requirement refer to SP-2427

8.3 Selection of internal and external coatings

Replace this section with the following:
Internal and external coating system selection shall be as per SP-1246.
External field joint and rehabilitation coating system for buried pipelines shall be as per SP-2389.
Pipeline external coating shall as per SP-2379.
Internal FBE Powder and Liquid Coating Systems For Carbon Steel Piping and Line pipes shall
be as per SP-2217.

8.5 Cathodic protection

Replace the section with the following:
Cathodic protection requirement shall be as per SP-1128.

8.6 Corrosion protection of closed compartments

Replace the section with the following:
Cathodic protection requirement shall be as per SP-1128.

8.7 Connection of dissimilar materials

Refer to Annex E for Insulation Gasket requirements.

8.8 Sealing materials

Replace full section with the following:

8.8.1 Qualification of elastomers

8.8.1.1 General
1. Unless otherwise stated, elastomers shall be qualified in accordance with ISO 23936-Part 1
and Part 2.
2. This section covers elastomers used in bonded flexible hoses, Blow-out preventers, packers,
flexible joints. ISO 23936-2 also covers testing requirements for ageing, rapid gas
decompression (RGD) and mechanical and physical testing.
3. For both sweet gas services and sour gas services, resistance against ageing and rapid
decompression shall be demonstrated by qualification testing in accordance with ISO 23936-
2.
4. Temperature limits depends on application and elastomer materials (as per guidelines in ISO
23936 and ISO 13628 series)

8.8.1.2 Ageing
To determine the long-term effect on the material properties when exposed to fluids at elevated
temperatures, ageing tests shall be performed in accordance with ISO 23936-2.

27
 8.8.1.3 Rapid gas decompression
1. To determine the resistance of elastomer seal materials against rapid depressurization for
critical sealing, seat and back-up materials for permanent subsea use, and for topside valves
in critical gas systems, RGD tests shall be performed in accordance with ISO 23936-2.
2. The rating procedure for RGD damage shall be in accordance with ISO 23936-2 with the
following acceptance criteria:
 A damage rating less than 4.
 A damage rating of 0 for critical applications as defined by the Principal (i.e., no visible
damage after RGD testing when performed at the maximum specified design pressure
and temperature).

8.8.1.4 Swelling
Acceptance criteria for swell depend on the specific design and functional requirements of the
elastomer.
 Swell is part of the qualification testing and shall be in accordance with ISO 23936-2.
 The design shall account for swell and associated reduction in mechanical properties of
the elastomer such as strength, stiffness and viscoelastic properties.
 Vendor shall provide swell data that covers field conditions.

8.8.2 Elastomer selection

1. Temperature limits for typical upstream service conditions for NBR, HNBR, FKM, FFKM and
FEPM shall be in accordance with Table 13 in this specification.
2. For elastomers not listed in Table 13 of this specification or for fluids, concentrations and
temperatures exceeding the ranges provided in Table 13 the vendor shall demonstrate
performance and qualify in accordance with ISO 23936-2.

28
 Table 13 : Elastomers Selection
Material Type NBR/Nitrile (1)(2) HNBR Hydrogenated Nitrile (2),(8) FKM (2),(5) FEPM (2) FFKM (2)
VLow Low High VHigh VLow Low High VHigh VLow Low High VHigh VLow Low High VHigh VLow Low High VHigh
°C °C °C °C °C °C °C °C °C °C °C °C °C °C °C °C °C °C °C °C
°C -40 -29 115 125 -40 -29 127 160 -26 -15 200 204 -10 0 200 204 -26 -15 260 315
°F -40 -20.2 239 257 -40 -20.2 260.6 320 -14.8 5 392 399.2 14 32 392 399.2 -14.8 5 500 599
Crude Oil OK (1) OK OK OK OK
Hydrocarbons (1)(2) OK (1) OK OK OK OK
(2) (2) (2) (2) (2)
Hydrocarbons containing BTX
(6)
Methane gas OK OK OK OK OK
Water OK OK OK OK OK
Hydrogensulfide
Up to 149°C (300 °F) Up to 204°C (400 °F)
H2S < 100 ppm OK OK OK OK (4)
100 ppm < Hydrogensulfide H2S < 1000 ppm No OK Up to 149°C (300 °F) OK OK (4) Up to 204°C (400 °F)
Hydrogensulfide H2S > 1000 ppm No No Up to 149°C (300 °F) OK OK (4) Up to 204°C (400 °F)
(6)
Carbon Dioxide gas (CO2) OK OK OK OK OK
Water based muds OK OK Up to 149°C (300 °F) OK OK
Oil based muds OK OK OK OK OK
Brine completion fluid OK OK Up to 149°C (300 °F)(12) No OK OK
Sea water OK OK Up to 149°C (300 °F) No OK OK
Zinc Bromide No No Up to 149°C (300 °F) No OK No Up to 204°C (400 °F) No
Amine inhibitors (7),(8) OK 121°C (250 °F) OK 121°C (250 °F) Up to 93°C (200 °F) No OK No Up to 204°C (400 °F) No
HCl Acid (7) OK 121°C (250 °F) OK 121°C (250 °F) Up to 149°C (300 °F) 149°C (300°F) OK No Up to 204°C (400 °F) No
(7)
Methanol OK 121°C (250 °F) OK 121°C (250 °F) Up to 149°C (300 °F) 149°C (300°F) OK OK
Glycol OK OK OK OK OK
Steam No No No OK OK (11)
Normal Range: The elastomer type and its common compounds should survive a normal duration pumping or flowing operation within or up to the specified temperature limitations.
Selected coumpound is suitable for Vlow or Vhigh: The suitability of the elastomer type outside the "green range", but in the "amber range" must be verfied with the supplier, but the temperature
Legenda & Notes
limitations shown should be respected for all compounds
The elastomer is not suitable
 Notes to the Table 13:
1. Although nitriles are considered as oil-resistant, they typically swell more than fluoroelastomers in
hydrocarbon liquids, and this needs to be taken into account in the design for the specific equipment
(e.g., seal/groove design, gasket design).
2. Nitriles are not suitable for services in contact with aromatics (e.g., toluene). The level of swelling of
elastomers in hydrocarbon fluid mixtures in general show a strong relation to the aromatics content. The
presence of aromatics typically results in a high level of swelling. Often low aromatics content (< 1 %)
can lead to exceeding the maximum swell criteria. The exact level of swelling depends on the specific
elastomer compound, the exposure temperature and the overall fluid composition. For applications
containing aromatics, consult a polymer specialist for advice.
3. FEPM swells more in aromatics than other fluoroelastomer types and are not suitable for services in
contact with such liquids.
4. FEPM is suitable for sour service up to 205 °C.
5. There are several classes of FKM (according to ASTM D1418) and each has different monomer mix
and property set. The common classes are FKM 1, 2 and 3. Each fluoroelastomer Manufacturer/Supplier
offer these types.
Methane and CO2 gases listed as OK for all materials. Chemically this is correct; however, if either gas
(or mixtures) is at elevated pressure, the threat of RGD damage is real, particularly at high temperatures.
Appropriate advice and testing in accordance with ISO 23936-2 are required.
Concentration is not included as a variable for acids, amines. [In the first instance the supplier should
be given the concentration and the seals performance confirmed.
6. HNBR will be OK at -40 °C (need a low temperature grade) in contact with sour fluids; the low temp
means that chemical reaction rates will be extremely slow; useful life decreases as temperature rises.
When compounded properly, HNBR can be suitable for services up to 180 °C.
7. FKM types as defined in ASTM D1418: FKM types 1 and 3 are not resistant to neat methanol; swelling
is significant;
FKM type 2 swells very little in neat methanol.
FKM 1 and 3 are OK in methanol, provided a few per cent of water is added.
FKM type 5 (relatively new) is likely to be more resistant to inhibitors than types 1-3.
8. If muds contain inhibitors, these can attacked elastomers. Compatibility of the elastomer with inhibitors
would need to be demonstrated by testing under simulated field conditions by the
Manufacturer/Supplier.
9. There are many grades of FFKM available. Some are designed for high temperature (HT), others for
steam resistance etc.
10. Formate brines can be alkaline, pH > 8, the life of FKM types 1-3 will be limited at 149 °C.

8.9 Fasteners
For coating requirements, refer to Table A (Coating systems for bolts & fasteners) of SP-1246.
Refer to below table 14 in this specification for acceptable grades of materials for bolts and nuts
1. Coated CS bolts & nuts shall be used for the identified critical sour & steam facilities For
dissimilar materials refer to Annex F of this specification.
Table 14: Grades of Materials for Bolts and Nuts
Piping material Bolt material Nut material Allowable design Diameter
(ASTM) (3) (ASTM) (3) temp. range °C range
mm (in)
Non-sour service: A 193-B7 A 194-2H -40 to 400 12.5  d  100
Carbon steel, Low alloy (1/2  d  4)
steel, Stainless steel,
duplex stainless steel,
Non-ferrous metal, Non-
metal
Sour service: Carbon A 193-B7M A 194-2HM -48 to 400 12.5  d  100
steel
(1/2  d  4)
 Revision:
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Piping material Bolt material Nut material Allowable design Diameter

(ASTM) (3) (ASTM) (3) temp. range °C range
mm (in)
Non-sour service: A 320-L7(1) A 194-4 -101 to 343 12.5  d  63.5
Carbon steel LT, -101 to 343 (1/2  d  2-1/2)
Stainless steel, duplex A 320-L43 A 194-4 >63.5  d  100
stainless. steel, Super
duplex stainless steel, (>2-1/2  d  4)
Non-ferrous metal
Sour service: A 320-L7M(1) A 194-7M -73 to 343 12.5  d  100
Carbon steel LT, (1/2  d  4)
Stainless steel, duplex
stainless steel
Stainless steel(2) A 453-660 A 453-660 -29 to 538 12.5  d  90
class C class C
(1/2  d  3-1/2)
Stainless steel LT A 193-B8M2 A 194-8 -200 to 300 >38  d  76
class 2B
(1-½  d  3)
Cu- Ni Piping systems Alloy 651 or Alloy 651 in – –
Alloy 655 in accordance
accordance with with ASTM
ASTM B98 F467
NOTES:
1. Use of L7 Series is preferred.
2. For critical instrumentation, MP35N (UNS R30035) bolts may be used.
3. Other grades can be considered subject to suitable environment condition.

8.10 Weld overlay

Replace as below:
For weld overlay application refer to SP-1173.

8.12 Corrosion management

Replace the full section with the following:
For corrosion management refer to SP-2427.

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9 Appendix

Annex A Design basis for hydrocarbon systems

Replace Appendix A with basic information required for MSR as following
Refer to SOP – 307 for Material Selection Process (MSR) SOP
Basic Information Required for Materials Selection
Field Name
Design Life
Stream
Unit
number
Description
Presence of free Water Y/N
Maximum Operating Pressure bara
Maximum design pressure bara
Maximum Operating Temperature C
Maximum design Temperature C
Minimum design Temperature C
Ambient Temperature C
CO2 content in gas phase mol%
H2S content in gas phase mol%
Bubble point pressure bara
H2S content in gas at bubble point condition mol%
For liquid systems (liquid outlets from primary separators and
downstream equipment):  mol%
 H2S & CO2 concentration in gas at the last separation unit  bara
 Design pressure of the last separation unit
Elemental sulphur ppm
For dry gas system, specify the water dew point temperature and C
pressure bara
Multiphase/gas/oil/
Type of fluid
water
Gas flow Rate mIn Sm3/d
Oil Flow rate m3/d
Water flow Rate m3/d
Liquid Velocity m/s
Size inch
Length Km
Water cut %
GLR
Sand content g/m3
Bacteria (SRB) counts /ml
Water analysis
Cond/form/iron
type of water
saturated
Bicarbonates (total alkalinity expressed as bicarbonates) ppm
Sulphates ppm
Chlorides ppm
Dissolved Fe2+ in Water ppm
Total dissolved solids g/l
Dissolved oxygen in water ppm

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Total suspended solids ppm

pH (measured), include conditions at measurement (P, T)
Sodium ppm
ORGANIC ACIDS
Formic acid ppm
Acetic acid ppm
Propionic acid ppm
Mercury ppm
Fluid Properties (for flow modeling and oil wetting)
Gas molecular weight kg/kmol
Gas compressibility factor
API gravity
Oil density kg/m3
Oil viscosity @ reference temp Ns/m2
Oil viscosity reference temp deg C
Gas liquid surface tension N/m

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Add following new annex:

Annex B: Liquid Metal Embrittlement (LME) of Stainless Steel and Nickel

Alloy Materials in Case of Fire Scenario
Based on DEM-1 statements, all projects shall address the risk of LME due to molten zinc based
on the following criteria:

Material of Construction:
Stainless steel, Duplex Stainless Steel No
or Nickel alloys

Ye
s
Safety Critical Element No

Yes

Zinc contamination in case of fire No Risk

scenario from other equipment No of Molten
(PDO definition of other equipment is
other isolated inventory) Note 1 Zinc LME

Yes

Thermal Insulation
Yes

No

Refer
to mitigation options in Table
below to prevent molten zinc
LME

Table 15 Acceptable mitigation options to comply with DEM-1 requirement and prevent LME
due to molten zinc

SN Mitigation options
1 Re-route Pipe to avoid galvanized structures/items
2 Use other materials resistance to LME underneath galvanized structures/items
3 Use different grating material e.g. GRE
4 Cover stainless steel & nickel alloys with half-shell aluminised carbon steel or stainless
steel shields Note 2
5 Apply TSA coating on piping and equipment underneath galvanized items
6 Place painted CS plate underneath galvanized grating to shield SS from molten zinc during
fire
Note 1: Conclusion of other equipment fire impact shall be based on fire risk assessment or equivalent
Note 2: The cladding is applicable for pipe, elbow, Tee & Reducers only. Cladding is not applicable for other
components: flanges, valves, inline instruments, ETC. Other mitigations from the table 15 shall be used.

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Annex C: Materials requiring specific approval

Table 16: Materials requiring Principal approval

Material Class Typical uses Restricted for Reason Acceptable
following replacement
service
Carbon steel Firewater Corrosion See sec 7.4.4
systems product blocks
filters.
Graphite gaskets Stainless Stainless steel or Crevice Non-metallic gaskets
steel or copper alloy corrosion
copper alloy flanges in (CC), galvanic
flanges in seawater corrosion (GC)
seawater
9Cr, 410 stainless, Tubing, Raw water Pitting (P) 25Cr duplex, 925, 718,
13Cr, Super 13Cr Completion injection or 725, 625PH, 945
tools seawater
injection with
intermittent
oxygen
contamination
K500 Bolting CP in seawater Hydrogen 718, 925, A-286,
Sour production Embrittlement 625PH, 725, 945
(HE)
UNSC72400 Bolting CP in seawater HE 718, 925, A-286,
625PH, 725, 945
17-4PH, 17-7PH, Fittings, CP in seawater P, CC, HE 718, 925, A-286,
X4CrNi16-4, and downhole Sour production P,CC, SCC, 625PH, 725, 945, see
all other accessories, at >50% SMYS HE, SSC EEMUA 194 Section
precipitation valve stems, High chloride P, CC, SCC, 9.2.3.4
hardened compressor (sweet or sour) SSC
stainless steels components
X-750 Springs Sour production SSC 925, 718, 625, MP35N,
Elgiloy, 945, 625PH,
Acidizing
and 725
conditions
Sweet coupled
to CS
Duplex and Super Production All wells with High corrosion Single phase alloy with
duplex environment, acidizing using rates resistance to hot acids
seawater mineral acids or materials that can
be protected with
corrosion inhibitors
Brasses (without Heat Water service Dezincification Arsenical brass or
arsenic) exchanger bronze
tubes

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Material Class Typical uses Restricted for Reason Acceptable

following replacement
service
ENP Valves, etc. Any production Poor QC Solid CRA or CRA
(Electroless Nickel environment makes it weld overlay
Plating) where its unreliable.
function is Accelerates
corrosion corrosion of
control. (Use for steel
surface profile substrate.
control is
permitted).
O-rings in Explosive Blistering Refer to sec 8.8
Valves decompression
Fluoroelastomers
Thiocyanates Component of Any wells SCC due to Refer to Principal for
completion H2S generated approval
fluids by thermal
degradation of
thiocyanates
CS + FBE Piping scenarios where High corrosion Refer to Principal for
other material rates approval
Flowlines
options are not
PDO previous
Pipelines technically or
experience of
economically
failures and
acceptable
leaks
Integrity of
coating cannot
be assured

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 Revision:
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Annex D: Intergranular corrosion testing (IGC) & corrosion testing

Table 17 below shall be used for Corrosion testing of CRA materials.

For IGC requirements for SS316L and SS316 C&A items, refer to clause D.1 in this annex

Table 17: Corrosion Testing of CRA

Material Type of Test Note1, 2 Test Method Acceptance criteria
Inconel 625 IGC ASTM G28 0.9mm/year
Plate, Forgings, Pipes & Wrought Method A
Fittings, clad plate, bar , and No intergranular
welds attack visible at 50
times magnification.
Inconel 625 & 825 Castings IGC ASTM G48 0.9mm/year
Method A
No intergranular
attack visible at 50
times magnification.
Inconel 625 IGC ASTM G28 0.9mm/year
Weldoverlay Method A
No intergranular
ASTM G48 attack visible at 50
Method A times magnification.
Inconel 825 IGC ASTM G28 0.9mm/year
Plate, Forgings, Pipes & Wrought Method A
Fittings, clad plate, bar , and welds No intergranular
attack visible at 50
times magnification.
Austenitic Stainless Steel IGC ASTM A 262 Pr.E No signs of fissures
Plate, Castings & Forgings, Pipes Or ISO 3651-2 or
& Wrought Fittings, clad plate, bar method A cracks at 20X
, Weldoverlay and welds magnification
Super Austenitic Stainless Corrosion testing ASTM G48 Refer to ISO 17781
Steel Method A
DSS Corrosion testing ASTM G48 Refer to ISO 17781
Plate, castings & forgings, Pipes Method A
& Wrought Fittings, bar , and
welds
SDSS Corrosion testing ASTM G48 Refer to ISO 17781
Plate, castings & forgings, Pipes Method A
& Wrought Fittings, bar , and
welds
Others ( e.g Hastelloy B2, All NA NA
Hastelloy C276, Alloy 718,
Martensitic SS
(grade F6NM, UNS 41000))

Notes
1) Where PWHT is required, the corrosion testing shall be carried out after PWHT (one
cycle). Where PWHT does not apply, IGC test shall be performed on the as-received
material. Corrosion test shall be conducted with the simulated actual PWHT cycles
(integral of the main body or exposed with similar heat treatment cycles)

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2) IGC testing is not required in non-corrosive environment such as: lube oil, instrument air,
potable water, nitrogen, chemical services, HVAC air ducts and demineralized water
system. In addition, IGC testing is not required for removable vessel/column internals and
non-safety critical element that are not pressure containing items.

D.1 IGC requirements for SS316L and SS316 C&A items

1. Utilities (e.g fuel gas and IA) and non-wetted components of hydrocarbon service – IGC can
be waived of.
2. Thin or very small components ( <1 mm thickness, or < 60 mm length), or complex component
that will be evaluated on case-by-case- where IGC testing is not Practical- doesn’t require IGC
testing.
3. Manufacturer and/or Sub-vendor provides evidence that they have conducted IGC test
(statistical data) within 2 years, even for non-PDO projects (in house testing is acceptable) to be
reviewed by M&C project lead
4. If Manufacturer and/or Sub-vendor does not have statistical data as per point 3 above, IGC
test shall be conducted once per PO (and can be used for the next two years).
5. The above one to four is only applicable for SS316L (solution annealed and low carbon
(0.03)).
6. For SS316 non welded component wetted part to follow above approach (points 1-4). For
SS316 welded part, IGC testing shall be conducted once in every PO. Statistical data is not
applicable for SS316 welded part.
7. M&C TA2 shall approve any deviation for IGC testing

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Annex E: Insulation gaskets
For protection against galvanic corrosion, Insulating Gasket Tool shall be utilized to
check insulation gasket requirements.

Copy of
INSULATING GASKET REQUIREMENTS TOOL Rev-1.xlsm