Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Section Page
1989 ASME Boiler and Pressure Vessel (B&PV) Code Sections ........... 18
Addenda ................................................................................................. 20
Interpretations......................................................................................... 20
Code Cases ............................................................................................ 20
API Standards......................................................................................... 21
National Association of Corrosion Engineers (NACE) Standards ........... 21
Saudi Aramco Engineering Standards (SAES) ....................................... 21
Saudi Aramco Material System Specifications (SAMSS)........................ 22
Saudi Aramco Process Flow Diagrams (PFDs) ...................................... 22
REFERENCES............................................................................................................. 27
It must be emphasized that the PFD does not always contain all
of the required information about stream chemical composition.
For example, potential corrodents such as chloride, dissolved
oxygen, and hydrogen sulfide are not included on the PFD
unless they are present in significant quantities. Consequently,
a stream may be very corrosive, but this corrosivity is not
reflected by the information contained in the PFD. It is
necessary to discuss stream chemical composition with a
process engineer prior to preparing a list of candidate (possible)
materials.
Corrosion
• Low Cost
Locating the 380 psia and 427 °C (800 °F) point on the table on
page 69 in the Appendix, we note that a satisfactory material is
either 1Cr-1/2Mo or 1 1/4Cr-1/2Mo. However, a base 1Cr-
1/2Mo or 1 1/4Cr-1/2Mo vessel would be subject to severe
sulfidation attack due to the high-temperature
hydrogen/hydrogen sulfide environment. For a hot wall reactor
the solution is to internally clad or weld overlay the inside
surface with an appropriate sulfidation-resistant material such
as austenitic stainless steel (for example AISI type 347 weld
overlay). An alternative approach is to use a cold wall reactor
design. In a cold wall design, an insulating refractory is used to
internally line the vessel. The purpose of the lining is to reduce
the vessel wall temperature to about 232 °C (450 °F). At this
temperature, sulfidation is not a problem, and carbon steel
provides adequate resistance to high-temperature hydrogen
attack. Although this approach may reduce initial installation
costs, maintenance costs are usually higher due to periodic
lining inspection and repairs. Most refractory repairs consist of
patching or relining relatively small local areas to eliminate “hot
spots”. As discussed in Module 6, “hot spots” are caused by
local lining failure.
The product air cooler (E-2) sees the reactor effluent stream
leaving the reactor D-2 but the temperature has been lowered to
200 °C (400 °F) by exchanger E-1. At this temperature, the
cooler is not subject to high-temperature hydrogen attack or
sulfidation. The header boxes should be fabricated from killed
carbon steel with a 4 mm (0.150 in) corrosion allowance and
stress relieved. Tubes should be 12 gage killed carbon steel.
General Corrosion
Rate
For a given environment, the data square or grid indicates
general corrosion rates plotted as a function of temperature and
percent concentration in water for various materials of
construction. The materials addressed include carbon steel,
cast iron, stainless steel, copper-base alloys, nickel-base alloys,
titanium, and other less commonly used metals and alloys. The
symbols used in the matrix for average penetration rate are:
Susceptibility to Pitting,
Stress Corrosion
Cracking, Intergranular
Attack and Crevice
Corrosion
The susceptibility of a particular material to pitting, stress
corrosion cracking, and so forth, in a particular environment is
indicated on the data squares or grids by referencing the
appropriate Footnote from the Key to Footnotes. The data
square or grid also indicates the conditions of temperature,
concentration, pH, dissolved oxygen content, and so on, that
apply to the particular Footnote.
Isocorrosion
Charts
In the Survey, isocorrosion charts for materials with reported
corrosion rates of < 20 mpy are indicated for:
Tensile
Strength/Maximum
Allowable Working
Stress
In COE 105.04, the ultimate tensile strength of a material was
determined by drawing a horizontal line from the maximum point
on the stress-strain curve to the vertical stress values on the
left. The value obtained is called the ultimate tensile strength,
or tensile strength. The ASME Boiler and Pressure Vessel
(B&PV) Code Selection VIII, Div. I defines the maximum
allowable stress value for a material as the lowest value of:
Hardness/Wear
Resistance
In COE 105.04, hardness was defined as the ability of a
material to resist deformation by an indenter. Hardness can be
used to assess ductility; the lower the hardness the greater the
ductility. Conversely, materials with higher hardness often
demonstrate improved wear resistance in certain environments.
Fabrication
The manufacture of the various product forms of steel was
reviewed in COE 105.07. The manufacture of castings,
forgings, plate, seamless pipe and clad materials was covered
in considerable detail. In addition, the basic welding processes
and the weldability of ferritic and high-alloy materials were
reviewed. Information about the use of weld metal overlays to
perform repairs or to provide a layer of corrosion-resistant
material was also provided.
Low-Temperature
Toughness
In COE 105.04, toughness was defined as the ability of a
material to absorb energy and deform plastically prior to
fracture. In general, the toughness of a steel decreases with
decreasing temperature. To avoid brittle fracture, materials are
subjected to Charpy V-Notch impact tests to determine the
relationship between impact strength (energy) and temperature.
For equipment subject to low temperatures during startup,
operation, or shut down, the ASME B&PV Code, Sec. VIII, Div.
1 contains impact requirements for pressure vessels and heat
exchangers, as does the B31.3 Code for piping.
High-Temperature
Limitations
It is not practical to use certain materials when designing
equipment for high-temperature, high-pressure service due to
low values of maximum allowable stress. It should be noted
that if these materials were used, vessel walls would be
extremely thick. For a cost-effective operation, it is important
that vessel wall thickness be minimized; consequently,
compatible materials with higher values of allowable stress at
the design temperature should be used. This may involve the
use of a high-strength Cr-Mo steel clad with stainless steel or
the fabrication of a layered vessel, where the soft internal layer
is surrounded by layers of high-strength steel.
American Society
for Testing and
Materials (ASTM)
Standards
ASTM Standards provide extensive information on a material’s
chemical composition, mechanical properties, and material’s
testing requirements.
Section III*
Division 1
2* Nuclear Components.
Addenda
Colored-sheet Addenda, which include additions and revisions
to individual Sections of the Code, are published annually and
are automatically sent to purchasers of the applicable Sections
up to the publication of the 1992 Code.
Interpretations
ASME issues written replies to inquiries concerning
interpretation of technical aspects of the Code. The
Interpretations for each individual Section are published
separately and are included as part of the update service for
that Section. They are issued semiannually (July and
December) up to the publication of the 1992 Code.
Interpretations for Section III, Divisions 1 and 2, are included
with the update service to Subsection NCA. Interpretations are
not part of the Code or the Addenda.
Code Cases
The Boiler and Pressure Vessel Committee meets regularly to
consider proposed additions and revisions to the Code. It also
formulates cases to clarify the intent of existing requirements or
provide, when the need is urgent, rules for materials or
constructions not covered by existing Code rules. Those Cases
which have been adopted will appear in the appropriate 1989
Code Cases book: (1) Boilers and Pressure Vessels and (2)
Nuclear Components. Supplements are sent automatically to
the purchasers of the Code Cases book up to the publication of
the 1992 Code.
API Standards
There are a number of API Standards, Recommended
Practices, and Publications related to materials used in
petroleum equipment. Pages 87 to 89 of the Appendix contain
these documents. (Source: Reference No. 7)
National Association of
Corrosion Engineers
(NACE) Standards
NACE issues three classes of standards: recommended
practices (RPs), test methods (TM), and material requirements
(MR). Pages 90 to 94 of the Appendix list all the available
standards in the 1991 Book of Standards. Individual standards
may be ordered from NACE. (Reference No. 8)
Saudi Aramco
Engineering
Standards (SAES)
Saudi Aramco Engineering Procedure SAEP-125 establishes
guidelines for the development, publication, and use of Saudi
Aramco Engineering Standards (SAES’s).
Saudi Aramco
Material System
Specifications
(SAMSS)
Saudi Aramco Engineering Procedure SAEP-119 establishes
guidelines for the development, revision, approval, and
distribution of Saudi Aramco Material System Specifications
(SAMSS’s). The purpose of a SAMSS is to serve as an
attachment to a purchase requisition, request for quotation, or
purchase order to specify the minimum technical requirements
which a vendor must meet when supplying specific materials or
equipment for use by Saudi Aramco.
Saudi Aramco
Process Flow
Diagrams (PFDs)
Various Saudi Aramco PFDs are reviewed and stream chemical
composition, temperature, pressure, and corrosive species are
identified.
CASE STUDIES
GOSP
For the bottom head competitive bids can be obtained for Monel
or stainless steel clad carbon steel by roll bonding, explosion
cladding, or weld overlay.
Pages 146 and 147 of the Appendix contain a flow diagram and
a PFD for the DGA Gas Treating Facilities at the Shedgum
Natural Gas Center. Another example of materials selection
would be for the DGA contactor (R41-C-101). The sour gas to
the DGA contactor is stream 8. The PFD shows a winter and
summer temperature of 46 °C (115 °F) and a pressure of 160
psia. The data on chemical composition indicate the presence
of considerable quantities of CO2, H2S, and water. For these
conditions the top head and shell can be fabricated from carbon
steel. The recommended corrosion allowance is 6 mm (0.250
in). This is based on a predicted corrosion rate of approximately
0.25 mm/yr (10 mpy). This additional shell thickness should
provide a service life of at least 20 years. The bottom head will
be exposed to rich, sour DGA (DGA with H2S and CO2) solution
that could cause erosion-corrosion due to high fluid velocity at
the contactor outlet. To minimize the potential for corrosion it is
recommended that an alloy-clad head and outlet nozzle be
considered. Since Monel is not suitable for amine service, it is
suggested that the head be clad with Type 304L or Type 316L
stainless steel. The cladding could be applied by roll bonding,
explosion bonding, or weld overlay. The final selection should
be made based on cost and availability.
Pages 149 and 150 of the Appendix contain PFDs for the
Atmospheric Column System at Ras Tanura (stream analyses
are not included). Should the atmospheric column bottoms line
to the vacuum furnaces be carbon steel or 5 Cr-1/2 Mo?
At 357 °C (675 °F) the corrosion rates shown on page 151 are
approximately: 128 mpy for carbon steel, 73 mpy for 5 Cr-1/2
Mo, 23 mpy for 9 % chrome, and 4 mpy for 18 Cr-8 Ni.
Assuming there is no limitation on the life of the unit, 9 Cr-1 Mo
or 18 Cr-8 Ni should be considered after evaluating the amount
of sulfur in the crude that the unit will process. If 18Cr-8Ni
material is used for the atmospheric column bottoms line it
might be advisable to paint the external surface of the line with
high temperature silicone based paint. The paint will prevent
chlorides form coming into direct contact with the surface of the
material.
REFERENCES
7. API Standards
8. NACE