Provision of Engineering and Design Services for XXXX

Development Projects
(Contract No. XXX)

MODERNIZATION OF XXXX
Project Stage: FEED

Material Selection Report

REV DATE STATUS ISSUE PURPOSE ISSUED BY CHECKED BY APPROVED BY

COMPANY DOCUMENT NUMBER ATTRIBUTES:

Corporation Territory Originator Facility System Discipline Doc. Type Sequence
Code Code Code Code Code Code Code Number

Class 2
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DOCUMENT REVISION HISTORY SHEET

REV STATUS DATE ISSUED UPDATE/ AMENDMENT DETAILS

A IFR 24-NOV-2022 -

REFER TO TRACK CHANGES

A) PWT PACKAGE DETAILS UPDATED.

B) OTHER UTILITIES LIKE FLARE, HOT OIL, DIESEL
B IFR 15-APR-2023
ARE COVERED.
C) CLIENT COMMENTS INCORPORATED ON AIR
COOLER / EXCHANGER MATERIALS.

REFER TO TRACK CHANGES

A) REWORDED VESSELS INTERNALS FOR BETTER

C IFR 10-JUN-2023 CLARITY.
B) CLIENT COMMENTS INCORPORATED ON
SECTION 14.

REFER TO TRACK CHANGES

A) MAXIMUM OPERATING TEMPERATURE AND TYPE

OF INTERNAL COATING UPDATED FOR VESSELS
D IFR 12-JUL-2023
AND TANKS
B) CLIENT COMMENTS ON SECTION 12
INCORPORATED.

E IFR 10-AUG-2023 CLIENT COMMENTS ON SECTION 12 INCORPORATED.

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CONTENTS

1. INTRODUCTION .............................................................................................................5
1.1. Purpose ...........................................................................................................................................................5
1.2. Scope ............................................................................................................................................................... 5
1.3. Definitions and Abbreviations......................................................................................................................5
1.3.1. Definitions ......................................................................................................................................................5
1.3.2. Abbreviations ..................................................................................................................................................6

2. REFERENCE DOCUMENTS..........................................................................................7
2.1. COMPANY Documents ................................................................................................................................7
2.2. Project Documents ........................................................................................................................................ 7

3. CODES AND STANDARDS ............................................................................................9

4. ORDER OF PRECEDENCE ..........................................................................................11

5. SITE ENVIRONMENTAL DATA ................................................................................11

6. DESIGN LIFE..................................................................................................................12

7. TECHNICAL CONSIDERATIONS..............................................................................12

8. CORROSION RATES ASSESSMENT .........................................................................13

9. ASSUMPTIONS ..............................................................................................................13

10. APPLICABLE DAMAGE MECHANISMS .................................................................14

11. CORROSION RESISTANT ALLOY (CRA) SELECTION IN SOUR SERVICE...14

11.1. NACE Limits for SS316/316L Material .................................................................................................... 14
11.2. SS316/316L Usage in Block-XX Facilities ................................................................................................... 15
11.3. NACE Limits for DSS/SDSS Materials ..................................................................................................... 15
11.4. Additional Evaluation for DSS/SDSS Materials ....................................................................................... 16
11.5. SDSS Usage in Block-XX Facilities ............................................................................................................. 17
11.6. NACE Limits for Alloy 825 Materials ....................................................................................................... 17
11.7. Alloy 825 Usage in Block-XX Facilities ....................................................................................................... 18

12. MATERIALS SELECTION / RECOMMENDATION ...............................................18

12.1. Process Area Unit (Stage 2) ........................................................................................................................ 18
12.2. Desalting and Dehydration Unit (Stage 2)................................................................................................. 19
12.3. Fresh Water System .................................................................................................................................... 22
12.4. Crude Stripping Column Unit (Stage 2).................................................................................................... 23
12.5. Storage and Oil Export ............................................................................................................................... 24
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12.6. Hot Oil System (Stage 2) ............................................................................................................................. 25

12.7. Produced Water Treatment and Disposal (Stage 2, 3) ............................................................................. 26
12.8. Nitrogen Generation Package (Stage 2) .................................................................................................... 28
12.9. Compressed Air system (Stage 2)............................................................................................................... 29
12.10. Power Generation Unit ............................................................................................................................... 29
12.11. Closed Drain System ................................................................................................................................... 30
12.12. Flare System ................................................................................................................................................ 31
12.13. Chemical Injection Packages...................................................................................................................... 32
12.14. Instrument Tubing ...................................................................................................................................... 32
12.15. Valve Trim Material ................................................................................................................................... 33

13. CORROSION MONITORING REQUIREMENTS ....................................................33

14. EXTERNAL CORROSION CONTROL – PAINTING/COATING ..........................33

15. CORROSION CONTROL – CATHODIC PROTECTION .......................................34

16. APPENDICES ..................................................................................................................34

APPENDIX 1 PRODUCED WATER AND FRESH WATER COMPOSITIONS .............................................. 35
APPENDIX 1.1 - PRODUCED WATER COMPOSITION (REF: SOW, APPENDIX A3) ............................... 35
APPENDIX 1.2 - FRESH WATER COMPOSITION (REF: SOW, APPENDIX A3) ........................................ 36
APPENDIX 2 - CORROSION RATE SUMMARY TABLE ................................................................................. 37
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1. INTRODUCTION

1.1. Purpose
The purpose of this document is to describe the basis and justifications
for recommended materials pertaining to the
1.2. Scope
The Scope of this document is limited to the recommendation of the material
selection for the
The project scope includes the following modernizations:

 Installation of Nitrogen Station, Replacement of Nitrogen piping, Installation

of Utility Connections (Stage 2);

 Replacement of Air Compressor Station, Installation of Utility Connections

(Stage 2);

 Installation of the Dehydration and Desalting Unit with all required utility
systems (Stage 2);

 Installation of the Fired Heater with all required utility systems for New and
Existing Facility users (Stage 2);

 Installation of the Chemical Injection Skids for New and Existing Facility users
(Stage 2);

 Installation of the Produced & Oily Water Treatment Unit with all required
utility systems; the water pumping station & pipeline & disposal system (Stage
2, 3);

 Installation of the Stripping Column Unit with all required utility systems
(Stage 2);

 Installation of Diesel Generators, MCC for Power generation (Stage 2);

 Installation of Satellite Equipment House (SIH) for Instrumentation & Control

and Its interfaces with existing SIH (Stage 2)
1.3. Definitions and Abbreviations
1.3.1. Definitions
COMPANY :
CONTRACTOR :
Shall : Indicate a mandatory requirement.
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Should : Indicate a strong recommendation to comply with the

requirement.
Vendor : Any seller, provider, or supplier of goods.
1.3.2. Abbreviations
A/G : Above Ground
API : American Petroleum Institute
ASME : American Society of Mechanical Engineers
BOPD : Barrels of Oil per Day
CA : Corrosion Allowance
CRA : Corrosion Resistant Alloy
CS : Carbon Steel
DSS : Duplex Stainless Steel
FEED : Front End Engineering Design
FRP : Fiber Reinforced Plastic
GRE : Glass Reinforced Epoxy
HDPE : High Density Polyethylene
HIC : Hydrogen Induced Cracking
HP : High Pressure
ISO : International Organization for Standardization
LP : Low Pressure
mmpy : milli-meter per year
MOC : Material of Construction
MSD : Material Selection Diagram
NACE : National Association for Corrosion Engineers
OEM : Original Equipment Manufacturer
P&ID : Process & Instrumentation Diagram
PFD : Process Flow Diagram
pp : Partial Pressure
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ppb : parts per billion

RTRP : Reinforced Thermosetting Resin Pipe
SCC : Stress Corrosion Cracking
SDSS : Super Duplex Stainless Steel
SLC : Service Life Corrosion
SO : Service Order
SOW : Scope of Work
SS : Stainless Steel
SSC : Sulphide Stress Cracking
STB : Standard Barrel
TEMA : Tubular Exchanger Manufacturers Association
U/G : Under Ground
VTC : Vendor to Confirm
WC : Water Cut

2. REFERENCE DOCUMENTS

2.1. COMPANY Documents

Document No. Description

Service Order #6 – Scope of Work FEED of Modernization of

Service Order #1 - Technical Dossier FEED of Modernization of .

1971-00-XXXX-00-000-CP-SP-00001 Painting Specification

2.2. Project Documents

Document No. Description

1971-11-XX06-00-000-PC-BD-00001 Design Basis Memorandum – Process
1971-11-XX06-22-000-PC-RP-00001 Process Simulation Report
1971-11-XX06-22-000-PC-PF-00001 Process Flow Diagram – Process Area
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Document No. Description

1971-11-XX06-22-410-PC-PF-00001 Process Flow Diagram – Storage & Oil Export
Area
1971-11-XX06-22-410-PC-PF-00002 Process Flow Diagram – Flare KO Drum & Slop
Tank
1971-11-XX06-22-215-PC-PF-00001 Process Flow Diagram – Desalting &
Dehydration Unit
1971-11-XX06-22-220-PC-PF-00001 Process Flow Diagram – Crude Stripping
Column Unit
1971-11-XX06-22-320-PC-PF-00001 Process Flow Diagram – Nitrogen Generation
Station
1971-11-XX06-22-320-PC-PF-00002 Process Flow Diagram – Compressed Air Station
1971-11-XX06-22-316-PC-PF-00001 Process Flow Diagram – Fired Heater & Hot Oil
System
1971-11-XX06-22-490-PC-PF-00001 Process Flow Diagram – Chemical Injection
Skid
1971-11-XX06-22-484-PC-PF-00001 Process Flow Diagram – Produced Water
Treatment & Disposal
1971-11-XX06-22-470-PC-PF-00001 Process Flow Diagram – Power Generation Unit
1971-11-XX06-00-000-CP- MSD – Process Area
MD-00001, SHT 1
1971-11-XX06-00-000-CP- MSD – Desalting & Dehydration Unit
MD-00001, SHT 2
1971-11-XX06-00-000-CP- MSD – Crude Stripping Column Unit
MD-00001, SHT 3
1971-11-XX06-00-000-CP- MSD – Storage & Oil Export Area
MD-00001, SHT 4
1971-11-XX06-00-000-CP- MSD – Flare KO Drum & Slop Tank
MD-00001, SHT 5
1971-11-XX06-00-000-CP- MSD – Fired Heater & Hot Oil System
MD-00001, SHT 6 and 7
1971-11-XX06-00-000-CP- MSD – Compressed Air Station
MD-00001, SHT 8
1971-11-XX06-00-000-CP- MSD – Power Generation Unit
MD-00001, SHT 9
1971-11-XX06-00-000-CP- MSD – Nitrogen Generation Station
MD-00001, SHT 10
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Document No. Description

1971-11-XX06-00-000-CP- MSD – Produced Water Treatment & Disposal
MD-00001, SHT 11
1971-11-XX06-00-000-CP- MSD – Chemical Injection Skid
MD-00001, SHT 12 and 13
1971-11-XX06-22-000-PC-HM-00001 Heat & Material Balance

3. CODES AND STANDARDS

Following Codes and Standards shall form the basis of design for material selection including
exceptions as per Vendor’s standards and recommendations to be used for the Project, the latest
edition of all applicable addendums of the below International Codes and Standards as
applicable. Standards referenced within a given International Codes and Standard are also
applicable.
It is permissible to use additional standards, the references to which are made in the below
table. All contradictions between documents or standards from the table must be reported to
the COMPANY in writing for clarification.
If national and / or local regulations exist in which some of the requirements may be more
stringent than this specification, the SUPPLIER shall determine by careful scrutiny which of
the requirements are more stringent and which combination of requirements will be acceptable
as regards to safety, environmental, economic, and legal aspects. In all cases the SUPPLIER
shall inform the COMPANY / CONTRACTOR of any deviation from the requirements is
considered to be necessary in order to comply with the national and / or local regulations. The
COMPANY may then decide to negotiate with the Authorities concerned with the object of
obtaining agreement to follow this specification as closely as possible.

Code / Standard Description

ASTM A105 CS forgings for Piping Applications
ASTM A106 Seamless CS piping for high Temperature Service
Standard Specification for Forged or Rolled Alloy and Stainless-
ASTM A182 Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-
Temperature Service
Standard Specification for Alloy-Steel and Stainless-Steel Bolting
ASTM A193 for High Temperature or High-Pressure Service and Other Special
Purpose Applications
Standard Specification for Carbon Steel, Alloy Steel, and Stainless-
ASTM A194 Steel Nuts for Bolts for High Pressure or High Temperature Service,
or Both
Standard Specification for Steel Castings, Carbon, Suitable for
ASTM A216
Fusion Welding, for High-Temperature Service
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Code / Standard Description

Standard Specification for Piping Fittings of Wrought Carbon Steel
ASTM A234
and Alloy Steel for Moderate and High Temperature Service
Standard Specification for Seamless, Welded, and Heavily Cold
ASTM A312
Worked Austenitic Stainless-Steel Pipes
Standard Specification for Castings, Austenitic, for Pressure-
ASTM A351
Containing Parts
Standard Specification for Seamless and Welded Steel Pipe for
ASTM A333 Low-Temperature Service and Other Applications with Required
Notch Toughness
Standard Specification for Stainless Steel Bars and Shapes for Use
ASTM A479
in Boilers and Other Pressure Vessels
Standard Specification for Pressure Vessel Plates, Carbon Steel, for
ASTM A516
Moderate- and Lower-Temperature Service
Standard Specification for Chromium and Chromium-Nickel
ASTM A240 Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for
General Applications
Standard Practices for Detecting Susceptibility to Intergranular
ASTM A262
Attack in Austenitic Stainless Steels
Standard Specification for Castings, Iron-Chromium-Nickel-
ASTM A890 Molybdenum Corrosion-Resistant, Duplex (Austenitic/Ferritic) for
General Application
Standard Specification for Castings, Iron-Chromium, Iron-
ASTM A743
Chromium-Nickel, Corrosion Resistant, for General Application
Standard Specification for Seamless and Welded Ferritic/Austenitic
ASTM A790
Stainless-Steel Pipe
Standard Specification for Castings, Austenitic-Ferritic (Duplex)
ASTM A995
Stainless Steel, for Pressure-Containing Parts
ASME 31.3 Process Piping
Pipeline Transportation Systems for Liquid Hydrocarbons and other
ASME 31.4
Liquids
Specification for Horizontal End Suction Centrifugal Pumps for
ASME B73.1
Chemical Process
ASME Sec VII ASME Boiler and Pressure Vessel Code
ASME Sec VIII
ASME Construction of Pressure Vessel
Division I
ASME X Fibre-Reinforced Plastic Pressure Vessels
ASME 16.5 Pipe, Flanges and Flanged Fittings
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Code / Standard Description

NACE SP0775 Preparation, Installation, Analysis, and Interpretation of Corrosion
(formerly RP0775) Coupons in Oilfield Operations
NACE MR0175/ISO Petroleum and Natural Gas Industries – Materials for Use in H2S
15156 Containing Environments in Oil & Gas Production
Centrifugal pumps for Petroleum, Petrochemical and Natural Gas
API 610
Industries
Materials selection and corrosion control for oil and gas production
ISO 21457
systems
Test Method, Evaluation of Pipeline and Pressure Vessel Steels for
NACE TM0284
Resistance to Hydrogen-Induced Cracking
Standard Test Method, Laboratory Testing of Metals for Resistance
NACE TM0177 to Sulphide Stress Cracking and Stress Corrosion Cracking in H 2S
Environments

4. ORDER OF PRECEDENCE
The engineering and design shall at all times be executed in strict accordance with the
Contract, safety requirements and applicable international codes and standards.
Following order of precedence shall apply during the execution of this Service Order #6 in
case of any conflict of technical requirements:

 Laws and Regulations in .

 Contract.

 Data Sheets and Project Specifications.

 Applicable International Codes and Standards.

5. SITE ENVIRONMENTAL DATA

Parameter Description (Note 1)

Mediterranean climatic conditions characterized
Site Environment
by cold rainy winters and hot dry summers
Site Elevation 474 - 620 m above Mean Sea Level
Design Wind Speed 45 m/s
Average Wind Speed 1.66 – 2 m/sec
Prevailing Wind Conditions Stable Northern and North-Eastern
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Parameter Description (Note 1)

Maximum Ambient Temperature (Summer) 46 °C – This will be used for Air Cooler design
Minimum Ambient Temperature (Winter) -11 °C
Black body temperature 85 °C
Relative Humidity (Max / Nor / Min) 95% / 67% / 28%
Rain Fall (Annual Average) 300 - 560 mm

Note 1: This data will be confirmed and updated (as needed) based on Environmental Impact
Assessment (EIA).

6. DESIGN LIFE

The design life for newly installed equipment or system is fifteen (15) years.

7. TECHNICAL CONSIDERATIONS

Material selection is based on the following considerations:

 Intended process conditions that will be exposed to the piping/equipment.

 Material availability, fabrication limitations and economics.

 Applicable damage mechanisms / corrosion threats and Corrosion assessment.

 Design Life of 15 years.

 Relevant Industry Standards, Codes, COMPANY recommendations/Lesson Learned,

etc.

 The criticality of the system.

 Good Engineering Practice.

 Corrosion management Approach (External and Internal Corrosion).

 Inspection considerations & strategies.

 Material selection and equipment design is based on philosophy of minimum lifecycle

costs consistent with maintenance and operation philosophy.

 Items that impact the design such as HAZOP and value engineering shall be identified
and shall be incorporated into the materials selection design.

 Maintenance practices which affect the performance of the materials, such as scraping,
and the removal of deposits.
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 Materials selection is optimized to ensure the most economic materials selection is

applied throughout the plant design, to minimize the capital cost for the project.

8. CORROSION RATES ASSESSMENT

Corrosion rates are calculated for the applicable hydrocarbon process fluid service piping
streams to select the suitable corrosion allowance to CS material and also to conclude the base
material selection for the piping. For corrosion rates calculation purpose, ECE version 5 is used
which is based on Deward-Milliams equation and uses the flow conditions along with CO2
and H2S concentrations.
For material selection of the vessels/equipment, the damage risks from the intended process
conditions and localized corrosion risks are taken into account. Further, criticality of
equipment is considered higher than piping. Hence, equipment may be in higher material than
piping due to localized pitting corrosion risks for the design life.

Under flowing conditions, like in piping, these localized corrosion risks are less likely and
hence low risk is anticipated. Inlet piping stream to the respective equipment can be considered
as a basic guidance, however localized/pitting corrosion risks are governing for the equipment,
which cannot be predicted/assessed quantitatively.
Most preferred and default material recommendation will be CS with adequate corrosion
allowance. For CS material, corrosion rates will be assessed and based on service life corrosion
(SLC) for specified design life and required corrosion allowance will be defined. If the SLC is
higher than 6mm, then either CRA selection or corrosion controls such as corrosion inhibition
or coatings should be adopted.

9. ASSUMPTIONS

Material selection is truly dependent on the actual intended process conditions. However,
under certain stages, realistic data may not be available and for the current material selection
below basis/assumptions are considered:

 For the liquid piping streams (e.g., liquid HC and aqueous stream) that do not have the
CO2 and H2S in the vapor phase values, the CO2 and H2S content are taken from the
last stage separator vessels containing a free gas phase e.g., associated overhead gas
piping stream of the upstream separator.

 Well fluids from the reservoir doesn’t contain any solids/sand.

 Hydrocarbon fluids are considered as oxygen free (dissolved oxygen < 10ppb).

 No acetic acid presence is considered in the process fluid. If any acetic acid component
is present, it will further reduce pH of the system, and hence increase corrosivity of the
fluid.
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10. APPLICABLE DAMAGE MECHANISMS

Based on the process conditions and site ambient conditions, below corrosion/damage
mechanisms are applicable:
Internal Damage Mechanisms:
a. Localized General (metal loss) thinning and Pitting corrosion.
b. H2S-related Cracking (SCC, HIC, SSC).
c. H2S Corrosion Modelling (Isolated pitting corrosion rates from ECE)
d. Microbiologically Induced Corrosion (MIC).
e. Oxygen corrosion.
f. Chloride Stress Corrosion Cracking for CRA Materials like SS and other Alloys
g. Under Deposit Corrosion.
h. Galvanic corrosion.
i. Erosion Corrosion.
External Damage Threats:
a. Atmospheric corrosion.
b. Corrosion Under Insulation (CUI).
c. Chloride Stress Corrosion Cracking (CSCC) of stainless steel.
d. Soil corrosion (for buried scope of items/tanks etc.).

11. CORROSION RESISTANT ALLOY (CRA) SELECTION IN SOUR SERVICE

11.1. NACE Limits for SS316/316L Material

CRAs are also susceptible to environmental cracking in the form of Stress Corrosion
Cracking, in presence of H2S at defined temperature along with chloride containing
fluids. NACE MR0175 / ISO15156 provides fully comprehensive tables, detailing the
risk of cracking and the range of application (regarding pH2S, chlorides, temperature
and pH) of CRAs exposed to production fluids.
For austenitic stainless steels (316L grades) selection, below table (reference to NACE
MR0175/ISO 15156-3, Table A.2) is considered as basis for the environmental
limitations as per intended sour service conditions.
Table-11.1 SS316/316L Limits in Sour Service [Ref: ISO 15156-3, Table A.2]
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316/316L Op.T, ppH2S, Chlorides,

pH Remarks
Limits deg C mbar ppm
60 1000 No limit No limit
No No
50 No limit
limit limit
60 10000 50000 ≥4.5
ISO 15156-3,
table A.2 90 10000 1000 ≥3.5
limits 90 10 50000 ≥4.5
93 100 5000 ≥5
120 1000 1000 ≥3.5
149 100 1000 ≥4.0
These conditions
are suitable for
Sour service SS316/316L
conditions in material from the
110 < 1000 < 50 >5.5
d/s of second above ISO 15156-
stage desalter 3 stated limits at
d/s of second stage
desalter.

11.2. SS316/316L Usage in Block-XX Facilities

Based on the Table 11.1 and intended sour conditions within Block-XX facilities
under Stage-2 & 3, the desalted oil from Second Stage Desalter onwards, it is
permitted to use SS316/316L material as there will be lower chlorides and ppH2S
will be less than 0.5bar.
11.3. NACE Limits for DSS/SDSS Materials
For duplex stainless steels selection, below table (reference to NACE MR0175/ISO
15156-3, Table A.24) is considered as basis for the environmental limitations as per
intended sour service conditions.
Table-11.2 DSS / SDSS Limits in Sour Service [Ref: ISO 15156-3, Table A.24]

DSS / SDSS Op.T, ppH2S, Chlorides,

pH Remarks
Limits deg C mbar ppm
232 100 180,000 No limit
DSS Limits
No Limit No Limit 50 No limit
232 200 180,000 No limit
SDSS Limits
150 5000 1000 >3.3
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DSS / SDSS Op.T, ppH2S, Chlorides,

pH Remarks
Limits deg C mbar ppm
No Limit No Limit 50 No limit
These sour process
Sour service
conditions are
conditions
applicable up to
from Stage 2 110 < 200 9990 -
Desalter stage
Separator to
from 2nd stage
Desalter
separator.
11.4. Additional Evaluation for DSS/SDSS Materials
Even though, NACE MR0175/ISO 15156-3, Table-A.24 doesn’t permit SDSS above
ppH2S of 0.2bar, there are some instances and testing on SDSS materials proved that
SDSS is allowed to use at above 0.2 bar and up to 1 bar of ppH2S for certain
combinations of chlorides and pH. Below graph indicates such specific conditions for
the SDSS material, especially UNS32760.

Fig-11.1 SDSS permitted limits under Sour conditions Beyond NACE Limits
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Fig-11.2 SDSS permitted limits by ECE CRA Evaluation Criteria

In addition, ECE Corrosion Resistant Alloy (CRA) evaluator tool provides basic
guideline on the suitable CRA material for the intended sour conditions, from the
above ECE CRA predictor image, it can be seen that SDSS is within allowed limits
for the Block-XX process conditions up to 0.8 to 1.0bar ppH2S.
11.5. SDSS Usage in Block-XX Facilities
As detailed in sections 11.3 & 11.4, SDSS is allowed to use when there is no welding’s
involved and accordingly, Valve trims, pumps are permitted to use SDSS material
(UNS32760 or higher grade of SDSS with PREN>40) even for higher ppH2S above
0.2bar against NACE MR 0175/ISO 15156-3 Table A.24. In addition, existing facilities
are using the oil/water pump in SDSS material since past 10 years and understand that
no such sour SSCC risks are foreseen for SDSS material. In General, when there is
welding involved for SDSS material, there will be significant risks involved and not
recommended to use beyond the NACE recommended environmental limits as per
technical assessment. However, majority of the pumps, valves trims are either forged
or cast SDSS parts without involving any significant amount of welding, hence for the
current Project facilities, SDSS as valve trims and pumps material is fit for purpose
recommendation.
11.6. NACE Limits for Alloy 825 Materials
For Alloy 825 selection, below table (reference to NACE MR0175/ISO 15156-3, Table
A.13) is considered as basis for the environmental limitations as per intended sour
service conditions.
 Op.T, ppH2S, Chlorides,
pH Remarks
Alloy 825 deg C mbar ppm
Limits No No No Limit No
Limit Limit Limit
These process
Sour service conditions will be
conditions for used as basis for
Produced Water Alloy 825 type
System and No CRA material
110 >200 9990
from Separator limit recommendation,
Outlet Pumps to especially for
Second Stage Produced Water
Desalter System and
Exchanger Tubes.

11.7. Alloy 825 Usage in Block-XX Facilities

When the intended sour conditions are beyond the SS316 and SDSS limits it is
recommended to use Alloy 825. Especially, for valve trims in sour service with 6mm
CA piping classes, pressure vessels with Alloy 825 cladding when internal coating is
not feasible due to size/geometry, exchanger tubes, etc.

12. MATERIALS SELECTION / RECOMMENDATION

This section describes the recommended materials for the Modernization of Bejil EWT
Facilities in Stage 2 & 3.
12.1. Process Area Unit (Stage 2)
The EWT Bejil Plant takes the oil emulsion from the existing low-pressure separator,
V-110. The oil piping contains dissolved CO2 and H2S with chlorides of 9990ppm. Oil
emulsion piping from V-110 feeds the new desalter vessels via new separator outlet
pumps, 210-00-P-110A/B.
For produced water composition details, refer to APPENDIX 1.1.

 Water content: 5 to 40% water cut.

 Salt Content - 9990 ppmw of chlorides.

The MOC of oil emulsion piping from Stage 2 Separator to Separator Outlet Pumps
(stream 12) is recommended in CS+6mm CA considering the lower corrosion rates,
less than 0.01mmpy even with conservative consideration of dissolved gases in the oil
& water. Pitting corrosion risk is also low considering formation of iron Sulphide scale
and oil wetting factor. However, higher CA is considered to provide adequate corrosion
mitigations against localized corrosion risks as it may be experienced in the dead
legs/stagnant piping sections due to layout routing of this piping.
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The valve trims are recommended in Alloy 825. SDSS is also acceptable considering
maximum operating temperature of 60 0C and ppH2S < 0.2 bar at upstream of Desalter
Feed Heater. This is in line with Table A.13 and Table A.24 of NACE MR0175 / ISO
15156. However, for the project purpose, to avoid many piping classes under CS+6mm
CA, Alloy 825 trims are acceptable to use for entire 6mm CA considered piping classes.
Separator outlet pump mainly receives the oil with varying water levels. Pump MOC
is recommended in CS casing and SS316 impeller as this pump receives oil with water,
and predominantly protected by oil emulsion. Impeller act as non-pressure retaining
item hence SS316/316L impeller is recommended.
Table-12.1 Equipment MOC within Process Unit (Stage-2)

Equipment Recommended SOUR Service (NACE

Equipment No.
Description MOC MR0175 /ISO 15156)
Casing: CS
Impeller:
Separator Outlet SS316/316L
210-00-P-110A/B Yes
Pumps
Shaft: SDSS
(Note-1)
Notes:

1. Existing oil pump material is in complete SS316 material; however, this pump
mainly operates with oil emulsion with water, hence strong oil wetting is corrosion
protection for the casing of pump and impeller in SS316 is non-pressure retaining hence
recommended.

12.2. Desalting and Dehydration Unit (Stage 2)

The EWT Bejil central production and pumping facility has not been designed for an
oil dehydration and desalting unit. An oil dehydration and desalting unit shall be
installed which shall be capable of dewatering and desalting oil to the required
commercial quality:

 Water content ≤ 0.3 vol%.

 Salt Content ≤ 50 ppmw.

The crude emulsion from Separator Outlet Pumps (stream 13) contains dissolved H2S
and CO2 at maximum operating temperature of 60 0C. As per corrosion assessment,
the dominant corrosion mechanism is H2S controlled and predicted corrosion rates are
< 0.01 mm / year considering the iron sulfide scale formation. Pitting corrosion risk is
also low considering formation of iron Sulphide scale and oil wetting factor. Hence,
CS with 6mm corrosion allowance is recommended material for piping from Separator
Outlet Pumps to Desalter Feed Heater considering design life of 15 years.
The operating temperature downstream of Desalter Feed heater is maximum 110 0C.
The predicted corrosion rates are negligible. Hence, CS with 6mm corrosion allowance
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is recommended material for piping from Desalter Feed Heater to Second Stage
Desalter.
The partial pressure of H2S in the gas phase is up to 0.28 bar which is outside the limits
of SS316L and SDSS material as per NACE MR0175 / ISO 15156 considering
maximum operating temperature of 110 0C and chloride content of 9990 ppm, hence
valve trims for piping up to Second Stage Desalter are recommended in Alloy 825
material in compliance with Table A.13 of NACE MR0175 / ISO 15156. Following
are the limitations for SDSS material as per table A.24 of NACE MR0175 / ISO 15156.
Table-12.2 Sour Conditions for SDSS (Stage-2)

SDSS Op.T, ppH2S, Chlorides,

pH Remarks
Limits deg C bar ppm
SDSS Limits 232 0.2 180,000 No limit
SDSS No
No Limit 50 >3.3
(PREN>40) Limit
SDSS
150 5 1000 >3.3
(PREN>40)

The limit of 0.2 bar ppH2S for SDSS material is with chloride content of 180,000 ppm.
However, since the chloride content in crude emulsion is < 10,000 ppm. As detailed in
section 11.4, for valve trims, SDSS also can be considered as no welding involved in
the valve trims.
However, Alloy 825 is selected for valve trims to minimize pipe classes under CS +
6mm CA in the Project.
All recommended materials shall comply with the sour service requirements as per
NACE MR 0175/ISO 15156.
The material of construction of equipment is summarized in table below:
Table-12.3 Equipment MOC for Desalter Unit

Equipment SOUR Service (NACE

Equipment No. Recommended MOC
Description MR0175 /ISO 15156)

Casing: SDSS -Note 1

Wash Water Impeller: SDSS
215-00-P-001A/B Yes
Recycle Pumps
Casing: Alloy 825
Impeller: Alloy 825
Shell: CS + 3mm CA
Desalter Feed Yes - for tube side
215-00-E-001 Channel: CS + 6mm CA
Heater (channel and tubes)
Tubes: Alloy 825
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Equipment SOUR Service (NACE

Equipment No. Recommended MOC
Description MR0175 /ISO 15156)
HIC testing for Channel:
Yes
PWHT for Channel: Yes
Shell: CS + 3mm CA +
Internal Coating, 1 coat x
600-1000 μm DFT of
solvent free two-
component ultra-hybrid
First Stage epoxy (Belzona 1591 Yes
215-00-V-001
Desalter XHT) + Internal CP
Internals: VTA
HIC testing: Yes
PWHT: Yes
Note 4
Shell: CS + 3mm CA +
Internal Coating, 1 coat x
600-1000 μm DFT of
solvent free two-
component ultra-hybrid
Second Stage epoxy (Belzona 1591 Yes
215-00-V-002
Desalter XHT) + Internal CP
Internals: VTA
HIC testing: Yes
PWHT: Yes
Note 4
Frame: CS
Wash Water Plates: Alloy N08926
215-00-E-002 Yes
Economizer (6Mo) or Titanium
Note-3

Notes:
1. Alloy 825 is within the limits of ISO 15156-3. However, there are issues in
manufacturing and fabrication of Alloy 825 pumps. UNS32760 with PREN>40
is beyond the NACE ISO 15156-3 permitted environmental limits, however as
detailed and justified in Section 11.4, pumps will not have any major welding
hence the pump is recommended in SDSS material.
2. For 15-years design life, Alloy 825 tubes is Low risk option and same is
recommended.
3. Both Alloy 6Mo (N08926) and Titanium are technically acceptable. Final
material of construction shall be concluded based on cost and availability.
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4. The maximum operating temperature of first stage and second stage desalters
is 110 0C as per revised H&MB. The recommended internal coating system for
desalters in Painting Specification (971-00-RNME-00-000-CP-SP-00001) is
Glass Flake Reinforced Vinyl Ester which is limited up to 95 0C temperature
only. Hence, solvent free two-component ultra-hybrid epoxy (Belzona 1591
XHT) is recommended for internal coating of desalters which is suitable for
operating temperature of 110 0C. Alternatively, Phenolic / Novolac Epoxy
products (such as Enviroline 2405@500-micron DFT) can also be used subject
to confirmation from Paint Manufacturer for suitability with process operation
conditions, fluid composition and temperature of 110 0C.
12.3. Fresh Water System
A freshwater system is installed for desalting purposes which consists of freshwater
tank and pumps. The freshwater quality is summarized in APPENDIX 1.2 and contains
very low chlorides of less than 50ppm and TDS less than 500. Since the wash water is
E oxygenated with very low chloride content, SS316L is recommended for freshwater
piping and pumps. Once the oxygen scavenger injection is provided, CS + 3mm CA
with SS316L valve trims is suitable for piping in downstream of static mixer. However,
SS316L is selected for fresh water piping up to the injection point of fresh water in oil
as the time for neutralizing of O2 takes some time. Therefore, inlet pipe of fresh water
will be subjected for corrosion by oxygen even at downstream of oxygen scavenger
injection too hence overall freshwater piping till injection location in oil piping is
recommended in SS316/316L.
The material of construction of equipment is summarized in table below.
Recommendation / Note: Current material selection for the fresh water is based on
the water composition provided which contains very low chlorides & TDS, hence
SS316/316L is recommendation, in case of any change to water composition, shall
subject to change in material. Existing water pump using DSS material, however based
on lower chloride levels in water, SS316 pump and piping recommended in current
MSR & MSD.
Table-12.4 Equipment MOC for Fresh Water Unit

Equipment No. Equipment Recommended

Remarks
Description MOC
Shell: CS +
3mm CA + 2 Sour service is not
coats x 125μm applicable.
Fresh Water of polyamine
330-00-TK-001 cured pure External side of tank bottom
Storage Tank plates in contact with soil
epoxy Internal
Coating + needs to be protected with
Internal CP CP.
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Equipment No. Equipment Recommended

Remarks
Description MOC
Removable
Internals:
SS316/316L
Casing: SS316L
Fresh Water Impeller: Sour service is not
330-00-P-001A/B
Pumps SS316L applicable.

Fresh Water
SS316/316L Sour service is not
330-00-E-001 Storage Tank
applicable.
Heater

Sour service is not

330-00-MX-001 Static Mixer SS316L
applicable.

12.4. Crude Stripping Column Unit (Stage 2)

Stripping column unit shall consist of following equipment and accessories:

 Stripping column.

 Two (2) pumps for pumping treated oil from the column.

 An air-cooling unit for treated oil at the outlet of the heat recovery exchanger.
The Crude Stripping Column operates at maximum 107.31 0C with chloride salt content
≤ 50 ppmw. The predicted corrosion rates are negligible. Also, the pitting risk is low
due to lower chloride content in the desalted crude. Hence, CS + 3mm CA is the
suitable material for piping from Second Stage Desalter to Stripping Column.
However, considering various operating scenarios and potential deadlegs, 6mm
corrosion allowance is selected for this piping. Similarly, the stripper bypass line is also
selected in CS + 6mm CA.
Stripping column overhead gas piping to flare system is recommended in CS
E (Sour)+6mm CA. It is also recommended to provide provision for installation of
corrosion injection quill to facilitate chemical injection during operation in case of
higher corrosion rates are evident during operation.
The piping in downstream of Stripping Column operates at maximum 103 0C with
chloride content ≤ 50 ppmw and H2S content ≤ 10 ppmw. The predicted corrosion rates
are negligible. Hence, the piping in downstream of Stripping Column is recommended
in CS + 3mm CA.
Since the chloride content is ≤ 50 ppmw, the valve trims are recommended in SS316L
material in downstream of second stage desalter in compliance with Table A.2 of
NACE MR0175 / ISO 15156. However, is Project basis to use minimized piping
classes based on selected corrosion allowance, pipe classes with SDSS or Alloy 825
valves trims is technically acceptable to use in stripping unit.
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All recommended materials shall comply with the sour service requirements as per
NACE MR 0175/ISO 15156.
The material of construction of equipment is summarized in table below.
Table-12.5 Equipment MOC for Crude Stripper Unit

Equipment Recommended SOUR Service (NACE

Equipment No.
Description MOC MR0175 /ISO 15156)

Shell: CS + 6mm CA
Removable Internals:
Stripping SS316/316L
220-00-T-001 Yes.
Column HIC Testing: Yes
PWHT: Yes
Casing: CS
Stripper
220-00-P- Impeller:
Bottom Yes.
001A/B SS316/316L
Pumps
Header: SS316L
Stripper
220-00-E-001 Tubes: SS316L Yes.
Cooler

12.5. Storage and Oil Export

Off-Spec (De-emulsification) pumps are recommended in CS casing and SS316L
impeller with NACE compliance.
Table-12.6 Equipment MOC for Storage and Export Area

SOUR Service
Equipment Recommended
Equipment No. (NACE MR0175
Description MOC
/ISO 15156)

Case: CS
Off-Spec (De- Impeller:
410-00-P-
emulsification) SS316/316L Yes.
300A/B
Pumps Shaft: SDSS

Crude emulsion and Off-spec oil piping is recommended in CS + 6mm CA with Alloy
825 trims. Produced water and treated water piping is recommended in CS + 6mm CA
with Alloy 825 trims. SDSS valve trims can also be considered as detailed in section
11.4.
Stabilized oil piping is specified in CS + 3mm CA with SS316L trims.
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All recommended materials shall comply with the sour service requirements as per
NACE MR 0175/ISO 15156.
12.6. Hot Oil System (Stage 2)
Hot oil system shall consist of following equipment and accessories:

 Fired heater with blowers for hot oil heating.

 Heated hot oil circulation pumps.

 A hot oil expansion tank, hot oil supply pumps for the hot oil circulation and
heating system.

 A diesel fuel storage tank for the fired heater, diesel fuel supply pumps;
necessary instrumentation and control system devices.
Hot Oil is non-corrosive fluid. Hence, CS + 1.5mm corrosion allowance with SS316
valve trims is selected for piping which is industry proven material selection in this
service. Vessels are specified in CS + 3mm CA. The material of construction of
equipment is summarized in table below.
Table-12.7 Equipment MOC for Hot Oil Unit

Equipment Equipment
Recommended MOC Remarks
No. Description
Hot Oil Shell: CS + 3mm CA
No sour service
316-00-V-001 Expansion Removable Internals: applicable
Vessel SS316/316L
Shell: CS + Refractory Lining
(VTC) No sour service
316-00-H-001 Fired Heater
Tubes: CS or 1.25 Cr-0.5Mo applicable
(VTC based on temperature)
Shell: CS + 3mm CA
Hot Oil No sour service
316-00-V-002 Removable Internals:
Storage Drum applicable
SS316/316L
Shell: CS + 3mm CA
Hot Oil Side No sour service
316-00-FL-001 Removable Internals:
Stream Filter applicable
SS316/316L
Hot Oil Case: CS
316-00-P- No sour service
Circulation
001A/B Impeller: 12% Cr SS applicable
Pumps

Hot Oil Case: CS

316-00-P- No sour service
Loading
003A/B Plunger: VTA applicable
Pump
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Equipment Equipment
Recommended MOC Remarks
No. Description
316-00-P- Hot Oil Feed Case: CS No sour service
004A/B Pump Gear: SS316L applicable
Header: CS + 3mm CA No sour service
316-00-E-001 Trim Cooler
Tubes: CS applicable
Hot Oil Sheath: SS316L (VTC)
No sour service
316-00-E-002 Storage Heating Element: 80-20 Ni-Cr applicable
Vessel Heater (VTC)
Diesel Casing: CS
470-00-P- No sour service
Booster
003A/B Impeller: 12% Cr SS applicable
Pumps

Fired heater Design (Special Note):

Fired Heater design is Vendor package; however, design depends on the source of fuel
as well. As per current design diesel or propane is indicated. In case of fuel gas also to
be considered as one of source, such fuel gas shall contain less than 50ppm H 2S as per
typical Vendors recommendations. In case, higher H2S content in the fuel gas is used
as feed gas to fire heater burners, it may lead to burner clogging issues due to elemental
Sulphur deposition when H2S mixes with oxygen in the burners and hence not
recommended to use such high H2S containing gas like slug catcher vapor outlet gas.
In such case, where wet sour gas to be used as one of the potential sources for fired
heater then fired heater vendor design inputs shall be further to be considered including
any H2S removal unit requirement as applicable.
12.7. Produced Water Treatment and Disposal (Stage 2, 3)
Water treatment system shall consist of following equipment and accessories:

 Water treatment unit.

 Provision for degassing to exclude the release of hydrocarbon and hydrogen

sulfide gas. The degasser combined with a buffer tank to minimize the
equipment required.

 The discharge of separated gas to an existing high-pressure flare.

 Chemicals for the treatment of the water.

 Water pumping station.

 Pipeline from future water pumping station to water disposal well BJ-06.

 Wellpad facilities for water disposal well BJ-06.

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Below are conditions of treated water product from produced water and oily water
treatment unit:

 H2S content ≤ 20 ppmw.

 Oil in water ≤ 50 ppmw.

 TSS content ≤ 50 ppmw.

The predicted corrosion rates in produced water piping from desalters are negligible.
However, the pitting risk can be high due to chlorides in produced water and lower
liquid velocities. Hence, produced water piping is recommended in CS + 6mm CA
considering the stagnancy in piping sections. Further in produced water network,
chemical injections like corrosion inhibitor will be considered which minimizes the
corrosion risks.
The maximum partial pressure of H2S in the oily water separation drum gas outlet is
0.6 bar. Hence, valve trims in produced water system are recommended in Alloy 825
considering maximum operating temperature up to 98.5 0C, chloride content of 9990
ppm and ppH2S up to 0.6 bar. The partial pressure of H2S is outside the limits of SDSS
material. However, considering high pH (>5.5) and chlorides less than 10000 ppm,
SDSS can also be considered for valve trims as detailed in the section 11.4.
Water disposal pipeline is buried for which non-metallic materials are recommended.
Based on Company’s experience, Nonmetallic composite products are to be
considered.
Oily Water Separation Drum is recommended with internal coating and internal
sacrificial cathodic protection.
The water disposal pumps and produced water transfer pumps are also recommended
in SDSS.
The recommended material of construction of equipment is summarized in table below.
Table-12.8 Equipment MOC for Produced Water Package Unit

SOUR Service
Equipment Equipment
Recommended MOC (NACE MR0175
No. Description
/ISO 15156)
CS + 3mm CA + Internal
Coating, 1 coat x 600-1000
μm DFT of solvent free two-
Oily Water component ultra-hybrid
epoxy (Belzona 1591) + Yes.
484-00-V-001 Separation
Drum Internal CP
Removable Internals:
SDSS
HIC testing: Yes
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SOUR Service
Equipment Equipment
Recommended MOC (NACE MR0175
No. Description
/ISO 15156)
PWHT: Yes
Note 2
E SH: CS + Alloy 825 Clad
Removable Internals &
484-00-V- Hydrocyclone Yes.
Liners: SDSS
002/003 Vessel
HIC testing: No
PWHT: No
Water Casing: SDSS
484-00-P-
Disposal Impeller: SDSS Yes.
001A/B/C
Pumps API Class: D-2
Produced Casing: SDSS
484-00-P- Water
Impeller: SDSS Yes.
002A/B/C Transfer
Pumps API Class: D-2

Produced Header: Alloy 825

484-00-E-001 Yes.
Water Cooler Tubes: Alloy 825

Notes:
1. Indicated material of construction inside produced water treatment package
is minimum requirement. Material of construction shall be proposed by
Package Vendor and reviewed by Contractor / Company.
2. The maximum operating temperature of Oily Water Separation Drum is 98.5
0
C. The internal coating system recommended in Painting Specification
(971-00-RNME-00-000-CP-SP-00001) is Glass Flake Reinforced Vinyl
Ester which is limited up to 95 0C. Hence, solvent free two-component ultra-
hybrid epoxy (Belzona 1591 XHT) is recommended for internal coating of
Oil Water Separation Drum which is suitable for maximum operating
temperature of 98.5 0C. Phenolic / Novolac Epoxy products can also be used
subject to confirmation from Paint Manufacturer for suitability with process
fluid at 98.5 0C.
12.8. Nitrogen Generation Package (Stage 2)
Nitrogen system shall consist of two (2) Nitrogen production lines with following
equipment and accessories:

 Two (2) nos. Screw-type oil-injected air compressor (1 working + 1 standby)

with Variable Speed Drive (VSD) and compressed air treatment system.
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 Two (2) nos. Nitrogen generation package (1 working + 1 standby) –

Membrane type.

 Nitrogen receiver.
Nitrogen is dry and internal corrosion is not a concern. Hence, CS + 1.5 mm corrosion
allowance with SS316 valve trims is specified for Nitrogen service.
Material of construction inside Vendor package should be as per Manufacturer’s
standard.
12.9. Compressed Air system (Stage 2)
Air compressor system shall consist of two (2) instrument air production lines with
following equipment and accessories:

 Two (2) nos. Screw-type oil-injected air compressor (1 working + 1 standby)

with Variable Speed Drive (VSD) and compressed air treatment system.

 Two nos. desiccant type heatless air dryer packages.

 Instrument air receiver.

The instrument air is dry and internal corrosion is not a concern. Hence, CS + 1.5mm
corrosion allowance with SS316 valve trims is specified for instrument air service.
The service air is wet. Hence, Galv. CS is recommended for service air piping.
Material of construction inside Vendor package should be as per Manufacturer’s
standard with SS304L or SS316L as minimum recommended MOC.
In summary, below are the material recommendations for Service Air, Instrument Air.

E  Inside package: SS 304L or SS316L for piping & valves - same requirements
to be covered in Package specification.
 Dry air header outside the package: CS+1.5mm CA, which is also same at
existing EWT.
 Wet air header (service air): Galvanized CS and A1R1 is piping class.
12.10. Power Generation Unit
Power generation unit shall consist of the following equipment and accessories:

 Power Generation Unit

 Diesel Storage Tank and Heater

 Diesel loading pump and Feed pumps.

Diesel is non-corrosive fluid. Hence, CS + 1.5mm corrosion allowance with SS316
valve trims is selected for piping which is industry proven material selection in this
service.
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Diesel Storage Tank (470-00-TK-001A/B) is specified in CS + 3mm CA with internal

epoxy coating on bottom plates and shell up to 1m height from bottom.
The material of construction of equipment is summarized in table below.
Table-12.9 Equipment MOC for Power Generation Unit

SOUR Service
Equipment Equipment
Recommended MOC (NACE MR0175
No. Description
/ISO 15156)
Shell: CS + 3mm CA +
2 coats x 150 μm DFT of
phenolic/Novolac epoxy
470-00-TK- Diesel internal coating on bottom
Not Applicable.
001A/B Storage Tank plates and shell up to 1m
height from bottom.
Removable Internals:
SS316L

Diesel Sheath: SS316L (VTC)

470-00-E-
Storage Tank Heating Element: 80-20 Not Applicable.
001A/B
Heater Ni-Cr (VTC)

Diesel Case: CS
470-00-P-
Loading Not Applicable.
001A/B Impeller: 12% Cr SS
Pump

470-00-P- Diesel Feed Case: CS

Not Applicable.
002A/B Pumps Impeller: 12% Cr SS

12.11. Closed Drain System

The closed drain system shall consist of following equipment and accessories:

 Closed Drain Vessel.

 Closed Drain Heater.

 Closed Drain Transfer Pumps.

The closed drain header aboveground section piping is specified in CS + 6 mm
E corrosion allowance with Alloy 825 valve trims. As per the current operating
conditions, maximum of 110 deg C may be routed into closed drain underground piping
header. Hence, underground section is also specified in CS + 6mm CA with 3LPP
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external coating. It is recommended to achieve backfill soil resistivity > 10,000 ohm-
cm. If the soil resistivity is < 10,000 ohm-cm, then the buried section should also be
E provided with external cathodic protection.
For the project purpose, to avoid many piping classes under CS+6mm CA, Alloy 825
trims are acceptable to use for entire 6 mm CA considered piping classes.
The piping in downstream of Closed Drain Transfer Pumps is specified with 6mm
corrosion allowance considering potential stagnancy / dead leg scenario.
All recommended materials shall comply with the sour service requirements as per
NACE MR 0175/ISO 15156
The material of construction of equipment is summarized in table below.
Table-12.10 Equipment MOC for Closed Drain System

Equipment Recommended SOUR Service (NACE

Equipment No.
Description MOC MR0175 /ISO 15156)

Shell: CS + 3mm CA
+ 2 coats x 600-
750μm DFT of Glass
Flake Reinforced
Vinyl Ester Internal
Closed Drain Coating + Internal
451-00-V-001 CP Yes.
Vessel
Removable Internals:
SDSS
HIC Testing: Yes
PWHT: Yes
Sheath: SDSS /
Alloy 825 (VTC)
Closed Drain
451-00-E-001 Heating Element: 80- Yes.
Heater
20 Ni-Cr (VTC)

Closed Drain Case: SDSS

451-00-P-
Transfer Impeller: SDSS Yes.
001A/B
Pumps

12.12. Flare System

The vent gas piping from PWT package to flare header is exposed to acid gases (up to
31.8 mol% CO2 and 41.25 mol% H2S). The estimated corrosion rates are low (< 0.05
mm / year) considering formation of FeS scale and very low gas flow rate. The pitting
risk is high however the estimated pitting rates are less than 0.1 mm/yr. Hence, CS with
6mm corrosion allowance is recommended for vent gas piping from PWT package.
The valve trims are recommended in Alloy 825 in line with Table A.13 of NACE
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MR0175 / ISO 15156 considering maximum operating temperature of 98.5 degC and
partial pressure of H2S up to 0.6 bar.
The vent gas piping from Stripper package contains 0.77 mol% H2S and 0.04 mol%
CO2. The estimated corrosion rates and pitting rates are negligible due to low acid gas
content. However, CS + 6mm CA is selected for vent gas piping from stripper to flare
header.
The overhead gases from desalter package are also recommended in CS + 6mm CA in
line with upstream piping.
The overall flare header is selected in CS + 6mm CA with Alloy 825 valve trims.
All recommended materials shall comply with the sour service requirements as per
NACE MR 0175/ISO 15156.6
12.13. Chemical Injection Packages
The following chemical injections are envisaged.

 Demulsifier.

 Corrosion Inhibitor.

 Antifoam.

 Oxygen Scavenger.

 Biocide.

 H2S Scavenger.
The chemical injection piping is specified in SS316L. During chemical selection
process, it must be ensured that the selected chemicals are suitable with SS316L
material.
HDPE / FRP are recommended for the chemical storage tanks. However, suitability of
these non-metallic materials shall be confirmed with Selected Chemical
E
Manufacturer/Supplier (Not chemical injection package fabricating vendor, the
compatibility of chemicals with materials to be confirmed by chemical
manufacturers/suppliers). If HDPE / FRP material is not feasible due to compatibility
or fabrication issues, SS316L can be considered as an alternative with
suitability/compatibility confirmations from chemical manufacturer/supplier(s).
12.14. Instrument Tubing
For instrument tubing, Alloy 825 material is recommended in sour service and SS316L
is recommended in utility service, as minimum.
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12.15. Valve Trim Material

The recommended material of construction for valve trims are summarized in table
12.11 below. Section 12.1 to 12.13 of this report provide multiple technically
acceptable options for valve trims, however final valve trim material in the Project
facility shall be as concluded in below table.
Table-12.11 Valve trim material

Valve Trim
S. No. Piping Material Services
Material

CS + 6mm CA Crude oil, produced water,

1 Alloy 825
(NACE) Closed drain, Flare Header

CS + 3mm CA
2 SS316L Stabilized oil
(NACE)

3 SS316L (non-NACE) SS316L Chemicals, Fresh water

CS + 1.5mm CA (non- Hot oil, Nitrogen, Instrument

4 SS316L
NACE) Air, Diesel

5 Galv. CS (non-NACE) SS316L Service Air

13. CORROSION MONITORING REQUIREMENTS

At several locations, intrusive corrosion monitoring is also required to be considered. As
minimum below locations should be accounted for such corrosion monitoring:
1. Oil Emulsion Piping:
a. At inlet to Desalters.
b. Outlet of Desalter to Crude Stripping Column.
2. Produced Water Piping:
a. At outlet of Desalters to Produced Water Treatment.
b. Treated Produced Water to Storage Tank piping.
In addition to above intrusive corrosion monitoring locations, there shall be detailed corrosion
monitoring locations shall be taken into consideration in detailed engineering stage based on
matured plant layout, dead leg associated corrosion risks etc.

14. EXTERNAL CORROSION CONTROL – PAINTING/COATING

External and internal coating shall be carried out in accordance with Painting Specification,
1971-00-RNME-00-000-CP-SP-00001.
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15. CORROSION CONTROL – CATHODIC PROTECTION

Within Project facilities, external corrosion control for soil corrosion applicable items shall be
achieved by external cathodic protection.
For the current scope of facilities, below table lists out applicable items for cathodic protection
requirements. During detail engineering stage, these CP details shall be further developed
which includes:

 Development of CP specification.

 CP design development including CP drawings for those applicable items.

Table 15-1: CP Requirements
Sr. Recommended
CATHODIC PROTECTION Remarks
No MOC
Internally coated
Internal CP is required for those internally coated
1 Vessels as per
vessels. Exception is for air service vessels.
Section 12
External CP is necessary for buried CS piping
within facilities. Type of CP, sacrificial anode or
Buried CS piping,
2 ICCP to be confirmed based on detailed scope
if applicable
applicability for buried items and site CP survey
during detail engineering stage.
Bigger storage tanks, external CP for underside of
bottom plate if in contact with soil shall be
applicable, ICCP type CP.
3 Storage Tanks
For internal CP of storage tanks, refer to section
12, wherever specified the internal CP shall be
considered.

16. APPENDICES

 APPENDIX 1 - PRODUCED WATER AND FRESH WATER COMPOSITIONS

 APPENDIX-1.1 - PRODUCED WATER COMPOSITION (REF: SOW, APPENDIX

A3)

 APPENDIX-1.2 - FRESH WATER COMPOSITION (REF: SOW, APPENDIX A3)

 APPENDIX 2 - CORROSION RATE SUMMARY TABLE

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APPENDIX 1 PRODUCED WATER AND FRESH WATER COMPOSITIONS

APPENDIX 1.1 - PRODUCED WATER COMPOSITION (REF: SOW, APPENDIX A3)
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APPENDIX 1.2 - FRESH WATER COMPOSITION (REF: SOW, APPENDIX A3)

Above parameters are also confirmed by lab results and below table indicates same.

Parameters Units Lab Results

pH 7.5 – 7.64 @25 0C
Conductivity µS/cm 479.8 – 492 @25 0C
Chloride mg/l 6–7
Sulphate mg/l <10
Bicarbonate mg/l 62 - 64
Carbonate mg/l <2
Total Dissolved Solids (TDS) mg/l 286 – 290
Total Suspended Solids mg/l <3
Turbidity NTU 0.45 – 0.5
Total Hardness as CaCO3 mg/l 227 - 251
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APPENDIX 2 - CORROSION RATE SUMMARY TABLE

E Water
Oil Vol CO2
Vol Flow
Flow @Std Std Gas General
Pressure Temperature @Std
Stream Case Cond Flow Corrosion
(barg) (0C) Cond
(barrels/da (MMSCFD) Rate
(barrels/
y) (mm/year)
day)
STAGE-
0.15 57.88 10105.01 1919.88 0.00 < 0.01
2-2027
STAGE-
0.15 59.84 7597.74 3470.74 0.00 < 0.01
2-2029
STAGE-
0.15 57.84 5283.14 1497.68 0.00 < 0.01
2-2032
STAGE-
0.15 57.65 2042.91 395.96 0.00 < 0.01
2-2047
STAGE-
0.15 57.88 10105.01 1919.88 0.00 < 0.01
Stream 12 2.1-2027
Crude
Emulsion STAGE-
0.15 59.85 7598.06 3470.79 0.00 < 0.01
from Stage 2.2-2029
2 Separator STAGE-
0.15 57.84 5283.14 1497.68 0.00 < 0.01
2.2-2032
STAGE-
0.15 57.65 2042.91 395.96 0.00 < 0.01
2.2-2047
STAGE-
0.15 57.88 10105.01 1919.88 0.00 < 0.01
2.1A-2027
STAGE-
0.15 57.65 2042.91 395.96 0.00 < 0.01
2.2A-2047
STAGE-
9.21 58.09 10105.01 1919.88 0.00 < 0.01
2-2027
STAGE- 9.21
60.01 7597.94 3470.75 0.00 < 0.01
2-2029
STAGE- 9.21
58.03 5283.13 1497.68 0.00 < 0.01
2-2032
STAGE- 9.21
57.85 2042.91 395.96 0.00 < 0.01
2-2047
Stream 13 STAGE- 9.21
58.09 10105.01 1919.88 0.00 < 0.01
Crude 2.1-2027
Emulsion 9.21
from STAGE-
60.02 7598.05 3470.80 0.00 < 0.01
Separator 2.2-2029
Outlet STAGE- 9.21
Pumps 58.03 5283.13 1497.68 0.00 < 0.01
2.2-2032
STAGE- 9.21
57.85 2042.91 395.96 0.00 < 0.01
2.2-2047
STAGE- 9.21
58.09 10105.01 1919.88 0.00 < 0.01
2.1A-2027
STAGE- 9.21
57.85 2042.91 395.96 0.00 < 0.01
2.2A-2047
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Water
Oil Vol CO2
Vol Flow
Flow @Std Std Gas General
Pressure Temperature @Std
Stream Case Cond Flow Corrosion
(barg) (0C) Cond
(barrels/da (MMSCFD) Rate
(barrels/
y) (mm/year)
day)
STAGE-
7.1 95 10107.61 1917.27 0.00 < 0.01
2-2027
STAGE-
7.1 95 7583.28 397.12 0.00 < 0.01
2-2029
STAGE-
7.1 95 5273.27 276.10 0.00 < 0.01
2-2032
STAGE-
7.1 95 2038.98 106.75 0.00 < 0.01
2-2047
Stream 14 STAGE-
7.1 95 10107.61 1917.27 0.00 < 0.01
Crude 2.1-2027
Emulsion
from STAGE-
7.1 95 7583.57 397.14 0.00 < 0.01
Desalter 2.2-2029
Feed STAGE-
Heater 7.1 95 5273.27 276.10 0.00 < 0.01
2.2-2032
STAGE-
7.1 95 2038.98 106.75 0.00 < 0.01
2.2-2047
STAGE-
7.1 110 10109.59 1915.30 0.00 < 0.01
2.1A-2027
STAGE-
7.1 110 2039.38 106.35 0.00 < 0.01
2.2A-2047
STAGE-
7.1 94.79 10108.09 2426.22 0.00 < 0.01
2-2027
STAGE-
7.1 94.72 7583.65 791.31 0.00 0.01
2-2029
STAGE-
7.1 94.72 5273.5 548.24 0.00 < 0.01
2-2032
STAGE-
7.1 94.72 2039.07 212.7 0.00 < 0.01
2-2047
STAGE-
7.1 94.79 10108.09 2426.22 0.00 < 0.01
Stream 15 2.1-2027
Crude
Emulsion STAGE-
7.1 94.72 7583.93 791.33 0.00 0.01
to Mixing 2.2-2029
Valve STAGE-
7.1 94.72 5273.5 548.24 0.00 < 0.01
2.2-2032
STAGE-
7.1 94.72 2039.07 212.7 0.00 < 0.01
2.2-2047
STAGE-
7.1 109.8 10110.06 2424.37 0.00 < 0.01
2.1A-2027
STAGE-
7.1 109.73 2039.47 212.32 0.00 < 0.01
2.2A-2047
Stream 16 STAGE-
5.6 94.84 10108.10 2426.21 0.00 < 0.01
Crude 2-2027
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Water
Oil Vol CO2
Vol Flow
Flow @Std Std Gas General
Pressure Temperature @Std
Stream Case Cond Flow Corrosion
(barg) (0C) Cond
(barrels/da (MMSCFD) Rate
(barrels/
y) (mm/year)
day)
Emulsion STAGE-
5.6 94.78 7583.66 791.30 0.00 0.01
To First 2-2029
Stage STAGE-
5.6 94.78 5273.51 548.24 0.00 < 0.01
Desalter 2-2032
STAGE-
5.6 94.78 2039.08 212.69 0.00 < 0.01
2-2047
STAGE-
5.6 94.84 10108.10 2426.21 0.00 < 0.01
2.1-2027
STAGE-
5.6 94.78 7583.94 791.32 0.00 0.01
2.2-2029
STAGE-
5.6 94.78 5273.51 548.24 0.00 < 0.01
2.2-2032
STAGE-
5.6 94.78 2039.08 212.69 0.00 < 0.01
2.2-2047
STAGE-
5.6 109.85 10110.06 2424.37 0.00 < 0.01
2.1A-2027
STAGE-
5.6 109.79 2039.47 212.32 0.00 < 0.01
2.2A-2047
STAGE-
5.6 94.84 2.40 2395.80 0.00 < 0.01
2-2027
STAGE-
5.6 94.78 0.77 768.49 0.00 < 0.01
2-2029
STAGE-
5.6 94.78 0.53 532.37 0.00 < 0.01
2-2032
STAGE-
5.6 94.78 0.21 206.56 0.00 < 0.01
2-2047
STAGE-
5.6 94.84 2.40 2395.80 0.00 < 0.01
Stream 17 2.1-2027
PW Outlet
from First STAGE-
5.6 94.78 0.77 768.50 0.00 < 0.01
Stage 2.2-2029
Desalter STAGE-
5.6 94.78 0.53 532.37 0.00 < 0.01
2.2-2032
STAGE-
5.6 94.78 0.21 206.56 0.00 < 0.01
2.2-2047
STAGE-
5.6 109.85 2.4 2393.94 0.00 < 0.01
2.1A-2027
STAGE-
5.6 109.79 0.21 206.18 0.00 < 0.01
2.2A-2047
Stream 18 STAGE-
5.6 94.84 10105.70 30.41 0.00 < 0.01
Crude 2-2027
Emulsion STAGE-
5.6 94.78 7582.89 27.74 0.00 0.01
From 2-2029
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Water
Oil Vol CO2
Vol Flow
Flow @Std Std Gas General
Pressure Temperature @Std
Stream Case Cond Flow Corrosion
(barg) (0C) Cond
(barrels/da (MMSCFD) Rate
(barrels/
y) (mm/year)
day)
First Stage STAGE-
5.6 94.78 5272.98 15.87 0.00 < 0.01
Desalter 2-2032
STAGE-
5.6 94.78 2038.87 6.14 0.00 < 0.01
2-2047
STAGE-
5.6 94.84 10105.70 30.41 0.00 < 0.01
2.1-2027
STAGE-
5.6 94.78 7583.17 22.82 0.00 0.01
2.2-2029
STAGE-
5.6 94.78 5272.98 15.87 0.00 < 0.01
2.2-2032
STAGE-
5.6 94.78 2038.87 6.14 0.00 < 0.01
2.2-2047
STAGE-
5.6 109.85 10107.68 30.41 0.00 < 0.01
2.1A-2027
STAGE-
5.6 109.79 2039.27 6.14 0.00 < 0.01
2.2A-2047
STAGE-
5.6 92.17 10105.20 539.34 0.00 < 0.01
2-2027
STAGE-
5.6 92.04 7582.54 416.96 0.00 0.01
2-2029
STAGE-
5.6 92.04 5272.74 289.89 0.00 < 0.01
2-2032
STAGE-
5.6 92.04 2038.79 112.07 0.00 < 0.01
2-2047
STAGE-
5.6 92.17 10105.20 539.34 0.00 < 0.01
Stream 19 2.1-2027
Crude
Emulsion STAGE-
5.6 92.04 7582.83 416.97 0.00 0.01
To Mixing 2.2-2029
Valve STAGE-
5.6 92.04 5272.74 289.89 0.00 < 0.01
2.2-2032
STAGE-
5.6 92.04 2038.79 112.07 0.00 < 0.01
2.2-2047
STAGE-
5.6 107.25 10107.05 539.46 0.00 < 0.01
2.1A-2027
STAGE-
5.6 107.12 2039.17 112.10 0.00 < 0.01
2.2A-2047
Stream 20 STAGE-
4.1 92.24 10105.21 539.33 0.00 < 0.01
Crude 2-2027
Emulsion STAGE-
4.1 92.10 7582.55 416.95 0.00 < 0.01
To Second 2-2029
Stage STAGE-
4.1 92.10 5272.75 289.88 0.00 < 0.01
Desalter 2-2032
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Water
Oil Vol CO2
Vol Flow
Flow @Std Std Gas General
Pressure Temperature @Std
Stream Case Cond Flow Corrosion
(barg) (0C) Cond
(barrels/da (MMSCFD) Rate
(barrels/
y) (mm/year)
day)
STAGE-
4.1 92.11 2038.79 112.07 0.00 < 0.01
2-2047
STAGE-
4.1 92.24 10105.21 539.33 0.00 < 0.01
2.1-2027
STAGE-
4.1 92.10 7582.84 416.96 0.00 < 0.01
2.2-2029
STAGE-
4.1 92.10 5272.75 289.88 0.00 < 0.01
2.2-2032
STAGE-
4.1 92.11 2038.79 112.07 0.00 < 0.01
2.2-2047
STAGE-
4.1 107.31 10107.07 539.45 0.00 < 0.01
2.1A-2027
STAGE-
4.1 107.18 2039.17 112.09 0.00 < 0.01
2.2A-2047
STAGE-
4.1 92.24 0.51 508.92 0.00 < 0.01
2-2027
STAGE-
4.1 92.10 0.39 394.13 0.00 < 0.01
2-2029
STAGE-
4.1 92.10 0.27 274.02 0.00 < 0.01
2-2032
STAGE-
4.1 92.11 0.11 105.94 0.00 < 0.01
2-2047
Stream 21 STAGE-
4.1 92.24 0.51 508.92 0.00 < 0.01
Wash 2.1-2027
Water
From STAGE-
4.1 92.10 0.39 394.15 0.00 < 0.01
Second 2.2-2029
Stage STAGE-
Desalter 4.1 92.10 0.27 274.02 0.00 < 0.01
2.2-2032
STAGE-
4.1 92.11 0.11 105.94 0.00 < 0.01
2.2-2047
STAGE-
4.1 107.31 0.51 509.04 0.00 < 0.01
2.1A-2027
STAGE-
4.1 109.79 0.11 105.96 0.00 < 0.01
2.2A-2047
STAGE-
Stream 23 8 92.20 0.51 508.92 0.00 < 0.01
2-2027
Wash
STAGE-
Water 8 92.13 0.39 394.16 0.00 < 0.01
2-2029
From Wash
STAGE-
Water 8 92.14 0.27 272.10 0.00 < 0.01
2-2032
Recycle
STAGE-
Pump 8 92.16 0.11 105.94 0.00 < 0.01
2-2047
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Water
Oil Vol CO2
Vol Flow
Flow @Std Std Gas General
Pressure Temperature @Std
Stream Case Cond Flow Corrosion
(barg) (0C) Cond
(barrels/da (MMSCFD) Rate
(barrels/
y) (mm/year)
day)

STAGE-
8 92.20 0.51 508.92 0.00 < 0.01
2.1-2027
STAGE-
8 92.13 0.39 394.16 0.00 < 0.01
2.2-2029
STAGE-
8 92.14 0.27 272.10 0.00 < 0.01
2.2-2032
STAGE-
8 92.16 0.11 105.94 0.00 < 0.01
2.2-2047
STAGE-
8 107.29 0.51 509.03 0.00 < 0.01
2.1A-2027
STAGE-
8 107.24 0.11 105.96 0.00 < 0.01
2.2A-2047
STAGE-
5.3 86.52 2.40 2395.80 0.00 < 0.01
2-2027
STAGE-
5.3 74.65 0.77 768.49 0.00 < 0.01
2-2029
STAGE-
5.3 74.58 0.53 532.37 0.00 < 0.01
2-2032
STAGE-
5.3 74.65 0.21 206.56 0.00 < 0.01
2-2047
Stream 27 STAGE-
5.3 86.52 2.40 2395.80 0.00 < 0.01
Produced 2.1-2027
Water
From Wash STAGE-
5.3 74.65 0.77 768.50 0.00 < 0.01
Water 2.2-2029
Economise STAGE-
r 5.3 74.58 0.53 532.37 0.00 < 0.01
2.2-2032
STAGE-
5.3 74.65 0.21 206.56 0.00 < 0.01
2.2-2047
STAGE-
5.3 98.43 2.40 2395.94 0.00 < 0.01
2.1A-2027
STAGE-
5.3 82.09 0.21 206.18 0.00 < 0.01
2.2A-2047
STAGE-
3.4 92.27 10104.71 30.40 0.00 < 0.01
Stream 28 2-2027
Crude Oil STAGE-
3.4 92.13 7582.16 22.81 0.00 < 0.01
From 2-2029
Second STAGE-
3.4 92.14 5272.48 15.86 0.00 < 0.01
Stage 2-2032
Desalter STAGE-
3.4 92.14 2038.68 6.13 0.00 < 0.01
2-2047
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Water
Oil Vol CO2
Vol Flow
Flow @Std Std Gas General
Pressure Temperature @Std
Stream Case Cond Flow Corrosion
(barg) (0C) Cond
(barrels/da (MMSCFD) Rate
(barrels/
y) (mm/year)
day)

STAGE-
3.4 92.27 10104.71 30.40 0.00 < 0.01
2.1-2027
STAGE-
3.4 92.13 7582.45 22.81 0.00 < 0.01
2.2-2029
STAGE-
3.4 92.14 5272.48 15.86 0.00 < 0.01
2.2-2032
STAGE-
3.4 92.14 2038.68 6.13 0.00 < 0.01
2.2-2047
STAGE-
3.4 107.34 10106.57 30.40 0.00 < 0.01
2.1A-2027
STAGE-
3.4 107.21 2039.06 6.13 0.00 < 0.01
2.2A-2047
STAGE-
1.5 87.15 0.00 5.73 0.82 < 0.01
2.1-2027
STAGE-
1.5 87.23 0.00 5.72 0.57 < 0.01
2.2-2029
Stream 30
Overhead STAGE-
1.5 87.11 0.00 3.54 0.30 < 0.01
Gases 2.2-2032
From STAGE-
Stripping 1.5 87.11 0.00 1.86 0.57 < 0.01
2.1-2047
Column
STAGE-
1.5 101.97 0.00 0.00 0.82 < 0.01
2.1A-2027
STAGE-
1.5 101.94 0.00 0.00 0.57 < 0.01
2.2A-2047
STAGE-
1.8 85.74 9886.08 0.00 0.00 < 0.01
2.1-2027
STAGE-
1.8 85.91 7440.38 0.00 0.00 < 0.01
2.2-2029
Stream 31
Stabilized STAGE-
1.8 85.72 5165.80 0.00 0.00 < 0.01
Oil 2.2-2032
From STAGE-
Stripping 1.8 85.82 1950.99 0.00 0.00 < 0.01
2.1-2047
Column
STAGE-
1.8 100.40 9829.55 0.00 0.00 < 0.01
2.1A-2027
STAGE-
1.8 100.53 1987.65 0.00 0.00 < 0.01
2.2A-2047

Notes:
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1. The process data required for the corrosion assessment has been referred from the available Heat and
Material Balance (HMB).
2. For the liquid stream piping (e.g., liquid HC and aqueous stream) that do not have the CO 2 and H2S
values in the vapor phase, the CO2 and H2S content assumption for corrosion rate estimation purpose
have been taken from the last pressured equipment containing a free gas phase e.g., associated
overhead gas piping stream of the separator.