TECHNICAL CENTERS & PROJECTS (TC&P)
TECHNICAL CENTER (ENGINEERING)
ENGINEERING PROJECTS
EPC FOR BAB INTEGRATED FACILITIES PROJECT
(BIFP)
ADNOC Onshore Contract No.: 16376.01
ADNOC Onshore Project No.: P11570
SPECIFICATION
(This Document Is Not Developed From any FEED Document )
1
17-May-2018
SPB
QZ
MMN
Issued for Design
B
25-Apr-2018
YB
QZ
f/MMN
Issued for Approval
A
26-Mar-2018
SPB
QZ
MMN
Issued for Review
REV.
DATE
ORIGINATOR
REVIEWED
APPROVED
DESCRIPTION
THIS DOCUMENT IS INTENDED FOR USE BY ADNOC ONSHORE AND ITS NOMINATED CONSULTANTS, CONTRACTORS, MANUFACTURERS AND SUPPLIERS.
ORIGINATOR:
CHINA PETROLEUM ENGINEERING & CONSTRUCTION CORPORATION
Specification For Piping, Forging, Plates, & Castings For
Sour Service
Section
:
ADNOC Onshore Document No.
: 11-99-37-1609
Revision
:1
Originator No.
:
Date
: 17-May-2018
ADNOC Onshore Project No.
: P11570
Page
: 1 of 34
Security Code: 5 – Public
DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 2 of 34
The table below is a brief summary of the most recent revisions to this document. Details
of all revisions are held on document by the issuing department.
Sr. Rev.
No. No.
Issue
Date of issue
No.
Description of revision
1
A
26-Mar-2018
Issued for Review
2
B
25-Apr-2018
Issued for Approval
3
1
17-May-2018
Issued for Design
Security Code: 5 – Public
DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 3 of 34
Table of Contents
1
INTRODUCTION .................................................................................................. 6
1.1
General Project Information ........................................................................... 6
1.2
Bab Field Description ..................................................................................... 6
2
PROJECT OBJECTIVE ........................................................................................... 7
3
DEFINITIONS ..................................................................................................... 7
4
ABBREVIATIONS ................................................................................................. 8
5
COMPLIANCE TO SPECIFICATIONS...................................................................... 11
5.1
General ..................................................................................................... 11
5.2
Adherence to Specifications .......................................................................... 12
5.3
Order of precedence for project document ..................................................... 12
6
SCOPE............................................................................................................. 12
7
PURPOSE OF THIS DOCUMENT ........................................................................... 12
8
STANDARDS .................................................................................................... 13
8.1
International Standards codes ...................................................................... 13
8.2
Professional Documents ............................................................................... 14
8.3
Codes and standards ................................................................................... 15
8.4
COMPANY ADNOC Onshore Standards ........................................................... 15
8.5
Project Documents ...................................................................................... 15
8.6
Shell DEP standards .................................................................................... 16
9
PROCESS DESCRIPTION .................................................................................... 17
9.1
BCDS ........................................................................................................ 17
9.2
RDS .......................................................................................................... 17
10 REQUIREMENTS FOR CARBON STEEL AND LOW ALLOY STEELS .............................. 18
10.1
General ..................................................................................................... 18
10.2
HIC & SSC Testing ...................................................................................... 19
10.2.1
HIC Testing ........................................................................................... 19
10.2.2
SSC Testing .......................................................................................... 20
11 REQUIREMENTS FOR CRAs ................................................................................. 20
11.1
Stainless Steels .......................................................................................... 20
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DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 4 of 34
11.2
Nickel Base Alloys ....................................................................................... 21
11.3
Nickel-Copper Alloys ................................................................................... 21
12 PIPING ............................................................................................................ 21
12.1
General ..................................................................................................... 21
12.2
Carbon Steel Seamless Pipes ........................................................................ 22
12.3
Carbon Steel Welded Pipes ........................................................................... 23
12.4
Fittings and flanges ..................................................................................... 23
13 PLATES............................................................................................................ 23
13.1
Requirements for Carbon Steel Plates of Tanks ............................................... 23
13.1.1
Chemical Composition ............................................................................ 24
13.1.2
Carbon Equivalent .................................................................................. 24
13.1.3
H2S Corrosion Tests ............................................................................... 24
13.1.4
Hardness Testing ................................................................................... 24
13.2
Requirements for Carbon Steel Plates for Pressure Vessels ............................... 24
13.2.1
Manufacturing process ............................................................................ 24
13.2.2
Inclusion Shape Control .......................................................................... 25
13.2.3
Carbon Equivalent .................................................................................. 25
13.2.4
Micro-examination ................................................................................. 25
13.2.5
Ultrasonic examination ........................................................................... 25
13.2.6
H2S Corrosion Tests ............................................................................... 25
13.2.7
Hardness Testing ................................................................................... 26
13.2.8
Plate Material certificate ......................................................................... 26
13.2.9
Clad Plates ............................................................................................ 26
14 VALVES ........................................................................................................... 26
14.1
General ..................................................................................................... 26
14.1.1
Plain carbon steels ................................................................................. 27
14.1.2
Alloy steels ........................................................................................... 27
14.1.3
Stainless steels ...................................................................................... 27
14.1.4
Precipitation hardened steels ................................................................... 27
14.2
Special materials ........................................................................................ 28
14.3
Natural, synthetic, plastic and/or fabric materials ........................................... 28
14.4
Valve parts ................................................................................................ 28
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DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 5 of 34
14.4.1
Flanges................................................................................................. 28
14.4.2
Gates, discs, ball, plugs, clappers and seats .............................................. 29
14.4.3
Springs ................................................................................................. 29
14.4.4
Glands and bushings .............................................................................. 29
14.4.5
Bonnet Seal Rings .................................................................................. 29
14.4.6
Bearings ............................................................................................... 29
14.4.7
Bolting materials.................................................................................... 29
14.4.8
Miscellaneous items ............................................................................... 29
15 FORGINGS ....................................................................................................... 29
15.1
Carbon Steel Forgings ................................................................................. 30
15.2
CRA Forgings.............................................................................................. 30
15.3
Process of Manufacture ................................................................................ 30
15.4
Chemical composition .................................................................................. 31
15.5
Hardness Evaluation .................................................................................... 31
15.6
Fittings ...................................................................................................... 31
15.6.1
Manufacturing Process ............................................................................ 31
15.6.2
Hardness Evaluation ............................................................................... 32
16 CASTINGS ....................................................................................................... 32
16.1
General ..................................................................................................... 32
16.2
Steel Castings ............................................................................................ 32
16.3
Cast Iron ................................................................................................... 32
16.4
Carbon and Alloy steel Castings .................................................................... 33
16.5
Steel Making Process ................................................................................... 33
16.6
For pressure containing parts ....................................................................... 33
16.7
Hardness Evaluation .................................................................................... 34
Security Code: 5 – Public
DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 6 of 34
1
1.1
INTRODUCTION
General Project Information
Abu Dhabi Company for Onshore Petroleum Operations Ltd. (ADNOC Onshore) intends to
increase crude oil production from the current production rate of 1.4 Million Barrels Oil per
Day (MMBOPD) to 1.8 MMBOPD. This increase in production will be achieved by
developing different reserves (building block development) in ADNOC Onshore fields.
ADNOC Onshore plans to develop the new Thamama-A and Thamama-H zones in Bab field
to produce an additional 30 MBOPD which, along with other on-going developments, will
sustain a production of 400 MBOPD. At the same time, ADNOC Onshore plans to develop
the new Updip & Attic zone to sustain the current production of 300 MBOPD from ThamamaB zone.
Currently, in the Bab field, several projects (either completed or at the Execution Stage) are
undertaken to develop other new zones such as Thamama-G, Habshan-2 and Habshan-1
which form some of the building blocks producing the required additional 400 MBOPD.
These are dealt separately under various Bab field expansion projects.
1.2
Bab Field Description
The Bab field is located in a desert area, approximately 160 km southwest of Abu Dhabi city
(Figure 1.1). The field covers an area of approximately 45 km by 25 km. The main
processing facilities are located around Bab Habshan.
The field is sour with high H2S content (up to 11% H2S content). The wells to the northeast
of Bab field exhibit generally higher H2S content than wells to the southwest.
Aquifer water is injected into the producing zones for reservoir pressure maintenance.
Associated gas separated at BCDS is delivered to ADNOC Gas Processing for processing
and processed Crude Oil is pumped to ADNOC Onshore export network.
Figure 1.1 Bab Habshan Site Location
Security Code: 5 – Public
DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 7 of 34
2
PROJECT OBJECTIVE
The overall project objectives of the Bab Integrated Facilities Project are as follows:
1.
2.
3.
4.
5.
To create capacity for TH-H and TH-A new reservoirs to produce an additional 15
MBOPD each as part of 1.8 MMBOPD building blocks.
To sustain production from TH-B at 300 MBOPD by developing new TH-B UAD
reservoirs.
To reinstate BCDS Technical margin at 20% by handling the production coming from
Hb-1 (30 MBOPD), Hb-2 (30 MBOPD) and Th-G (60 MBOPD).
Implement Bab Master Plan (BMP) requirements (PAD Drilling etc.) in the project.
Replacement of 33 kV OHL wooden poles into Steel Lattice.
The project objective is to execute the EPC of the surface facilities design for new TH-A,
TH-H and TH-B UAD developments as well as processing the Habshan-1, Habshan-2, THG and TH-B (non-Updip & Attic) production to maintain a total sustainable oil production rate
of 450 MBOPD, reinstating the 20% technical margin.
3
DEFINITIONS
COMPANY
ADNOC Onshore (Abu Dhabi Company for Onshore
Petroleum Operation Ltd.)
CONTRACTOR
China Petroleum Engineering & Construction
Corporation (CPECC)
CONSULTANT
ADNOC Onshore, the party which has performed /
completed the Front End Engineering and Design.
MANUFACTURER/
SUPPLIER/VENDOR
The Party which manufactures and/or supplies
equipment, technical documents / drawings and
services to perform the duties specified by COMPANY
/ CONTRACTOR.
PROJECT
Bab Integrated Facilities Project
SUBCONTRACTOR
The party which carries out all or part of the design,
procurement, installation and testing of the systems
as specified by CONTRACTOR / SUPPLIER
PROJECT MANAGEMENT
TEAM (PMT)
COMPANY authorized party (Project Management
Team) responsible for the overall day-to-day
execution of the Project
THIRD PARTY
The party which performs studies/workshops as part
of EPC and as specified by
CONTRACTOR/SUPPLIER
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Project No.: P11570
DOCUMENT TITLE
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 8 of 34
4
SHALL
Indicates a mandatory requirement
SHOULD
Indicates a strong recommendation to comply with the
requirements of this document.
ABBREVIATIONS
Abbreviation
Description
ADNOC
Abu Dhabi National Oil Company
ADNOC
Processing
Gas Abu Dhabi Gas Industries Ltd.
ADNOC Onshore
Abu Dhabi Company for Onshore Petroleum Operations Ltd
AFC
Approved for Construction
ASME
American Society of Mechanical Engineers
ASTM
American Society of Testing Materials
BCDS
Bab Central Degassing Station
BLPD
Barrels Liquid per day
BMP
Bab Master Plan
BOL
Bottom of Line
BS
British Standard
C
Celsius
CA
Corrosion Allowance
CDS
Central Degassing Station
CLAS
Carbon Low Alloy Steel
CLSCC
Chloride Stress Corrosion Cracking
CMF
Corrosion Management Framework
CMM
Corrosion Management Manual
CP
Cathodic Protection
CRA
Corrosion Resistant Alloy
CS
Carbon Steel
CUI
Corrosion Under Insulation
DEP
Design Engineering Practice (Shell)
ECE 5
Electronic Corrosion Engineer Version 5
Security Code: 5 – Public
DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 9 of 34
EEMUA
Engineering Equipment and Materials Users Association
EFC
European Federation of Corrosion
EN
Euro Norm
EPC
Engineering, Procurement, Construction
ES
Engineering Standards (ADNOC Onshore)
ERP
Electrical Resistance Probe
PREN
Pitting Resistance Equivalent Number
FEED
Front End Engineering Design
FMEA
Failure Mode and Effect Analysis
GOR
Gas Oil Ratio
GRP
Glass Reinforced Polymer
Hb-1
Habshan-1
Hb-2
Habshan-2
HP
High Pressure
HAZID
Hazard Identification Study
HAZOP
Hazard and Operability Studies
H&MB
Heat and Mass Balance
HIC
Hydrogen Induced Cracking
HIPPS
High- Integrity Pressure Protection System
HSE
Health, Safety & Environment
HVAC
Heating, Ventilation and Air Conditioning
IOW
Integrity Operation Window
IP
Intermediate Pressure
ISO
International Organization for Standardization
IUPAC
International Union of Pure and Applied Chemists
LP
Low Pressure
LSAW
Longitudinally Submerged Arc Welding
M
Thousand
MBOPD
Thousand Barrels of Oil Per Day
MMBOPD
Million Barrels of Oil Per Day
MMSCFD
Million Standard Cubic Foot per Day
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DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 10 of 34
mm
millimeter
MM
Million
MOC
Material of Construction
MOL
Main Oil Line
MPFM
Multiphase Flow meter
MSD
Materials Selection Diagram
MSM
Multi Selector Manifold
MVA
Mega Volt Ampere
MW
Mega Watt
NACE
National Association of Corrosion Engineers
NORSOK
Norwegian Standards Institute
OHL
Overhead Line
P&ID
Piping and Instrument Diagram
PFD
Process Flow Diagram
pH
Measure of acidity or basicity
PMI
Positive Material Identification
PMT
Project Management Team
ppm
Parts Per Million
PS
Planning and Support
PSS
Power supply skid
psig
Pounds per square inch-Gauge
PTB
Pounds of salts per thousand Barrels of oil
Q1
Quarter 1
Q4
Quarter 4
QA/QC
Quality Assurance / Quality Control
QRA
Quantitative Risk Assessment
RBI
Risk Based Inspection
RDS
Remote Degassing Station
RMS
Remote Metering Station
RP
Recommended Practice
RTU
Remote Terminal Unit
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DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 11 of 34
5
5.1
SI
International System of Units
SCADA
Supervisory, Control and Monitoring System
SCF
Standard Cubic Feet
SS
Stainless Steel
SSCC
Sulphide Stress Corrosion Cracking
STB/d
Standard ton barrels per day
STD
Standard
T
Temperature
Th-A
Thamama-A
Th-B
Thamama-B
Th-G
Thamama-G
Th-H
Thamama-H
TL
Transfer Line
TEMA
Tubular Exchanger Manufacturing Association
TDS
Total Dissolved Solids
TSS
Total Suspended Solids
TM
Test Method
TOLC
Top of Line Corrosion
UAD
Updip and Attic Development
UAE
United Arab Emirates
UNS
Unified Numbering System
VRC
Vapor Recovery Compressor
WAG
Water Alternating Gas
WIC
Water Injection Cluster
WSW
Water Supply Well
COMPLIANCE TO SPECIFICATIONS
General
This specification is complementary to legislative requirements and guidance notes issued
by any authority & document referenced herein.
Security Code: 5 – Public
DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 12 of 34
5.2
Adherence to Specifications
VENDORS’s offer is deemed to be in full compliance with all specifications applicable in this
project. Any exemption or deviation that is not possible to be met due to technical constraints
shall be submitted with reasons/justification as an itemized list for COMPANY or
CONTRACTOR review and approval.
5.3
Order of precedence for project document
Except where noted otherwise, in any area of conflict, the order of precedence in the use of
the FEED technical documents shall be the following:










Basis of design
Philosophies
PFDs, H&Ms & MSR
MSD
P&ID
Data sheet, specifications, material requisition
Equipment list
Plot plans
Tie-in list and line list
Other FEED documents
In case of conflict, the most stringent requirement shall apply.
6
SCOPE
This is a General Specification for Piping, Forging, Plates and Castings for Sour service
conditions for BIFP Project.
This General Specification makes major reference to the NACE MR0175 / ISO 15156.
Transmission pipelines are outside the scope of this specification.
7
PURPOSE OF THIS DOCUMENT
This General Specification covers the specific requirements applicable to equipment such
as pressure vessels, heat exchangers, pumps, which are intended to be used for piping
material, forging, plates and casting in Severe Sour Service Conditions for BIFP Project.
This document is based on the guidelines specified in the ADNOC Onshore Corrosion and
Materials Selection Philosophy ES 30-99-00-0102.
This document is limited to the design of the new facilities and the tie-in modifications to the
existing facilities.
Security Code: 5 – Public
Project No.: P11570
DOCUMENT TITLE
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 13 of 34
8
8.1
STANDARDS
International Standards codes
The edition or revision of the Codes and Standards shall be the edition current at the
EFFECTIVE DATE of the AGREEMENT.
ASME SEC VIII, Div. 1, 2
Boiler and Pressure Vessel Code. Rules for Construction of
Pressure Vessels
ASME Section II
ASME Boiler and Pressure Vessel Code - Materials
ASME Section V
ASME Non-Destructive Examination
ASME Section IX
Qualification Standard for Welding and Brazing Procedures,
Welders, Welding and Brazing Operators
ASME B16.5
Pipe Flanges and Flanged Fittings NPS ½ through NPS 24
Metric / Inch Standard
ASME B16.47
Large Diameter Steel Flanges NPS 26 through NPS 60
Metric/Inch Standard
ASME B16.11
Forged Fittings, Socket-Welding And Threaded
ASME B16.9
Factory-made Wrought Butt welding Fittings
ASME B16.25
Butt welding Ends
ASME B31.3
Process Piping
EN 10204/ISO 10474
Metallic Products - Types of Inspection Documents
ASTM G1
Standard Practice for Preparing , Cleaning and Evaluating
Corrosion Test Specimens
ASTM G96
Standard Guide for Online Monitoring of Corrosion in Plant
Equipment (Electrical and Electrochemical Methods)
ASTM G84
Standard Practice for Measurement of Time-of-Wetness on
Surfaces Exposed to Wetting Conditions as in Atmospheric
Corrosion Testing
ASTM A 105/A 105M
Standard Specification for Carbon Steel Forgings for
Piping Applications
ASTM A 106
Standard Specification for Seamless Carbon Steel Pipe
for High- Temperature Service
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DOCUMENT TITLE
Project No.: P11570
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SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
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& CASTINGS FOR SOUR SERVICE
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ASTM A 216/A 216M
Standard Specification for Steel Castings, Carbon, Suitable
for Fusion Welding, for High-Temperature Service
ASTM A 234/A 234M
Standard Specification for Piping Fittings of Wrought Carbon
Steel and Alloy Steel for Moderate and High Temperature
Service
Standard Specification for Steel Castings, Ferritic and
Martensitic, for Pressure-Containing Parts, Suitable for LowTemperature Service
Standard Test Methods and Definitions for Mechanical Testing
of Steel Products
ASTM A 352/A 352M
ASTM A 370
ASTM A 420/A 420M
Standard Specification for Piping Fittings of Wrought Carbon
Steel and Alloy Steel for Low-Temperature Service
ASTM A 516/A 516M
Standard Specification for Pressure Vessel Plates, Carbon
Steel, for Moderate- and Lower-Temperature Service
ASTM A 578/A 578M
Standard Specification for Straight-Beam Ultrasonic
Examination of Plain and Clad Steel Plates for Special
Applications
Standard Specification for Steel Castings, General
Requirements, for Pressure-Containing Parts
ASTM A 703/A 703M
8.2
ASTM A 788
Standard Specification for Steel Forgings, General Requirements
ASTM A 841
Standard Specification for Steel Plates for Pressure Vessels,
Produced by Thermo- Mechanical Control Process (TMCP)
ASTM A 941 Rev A
Standard Terminology Relating to Steel, Stainless Steel,
Related Alloys, and Ferroalloys
ASTM E 112
Standard Test Methods for Determining Average Grain Size
ASTM E 140
Standard Hardness Conversion Tables for Metals Relationship
Among Brinell Hardness Vickers Hardness, Rockwell
ISO-15590-3
Hardness,
Knoop
Hardness,
and fittings,
Petroleum Superficial
and naturalHardness,
gas industriesInduction
bends,
Scleroscope
Hardness
flanges
for pipeline
transportation system Part 3.
ISO 9001
Quality Management Systems - Requirements
Professional Documents
EFC Publication No. 16 European Federation of Corrosion Publication No 16; Guidelines on
Material Requirements for Carbon and Low Alloy Steels for H2S - Containing Oil and Gas
field Service
EFC Publication No. 17 Corrosion Resistant Alloys for Oil and Gas Production: Guideline
on General Requirements and Test Methods for H2S Service
NACE MR0175/ISO 15156 Second Edition 23rd Nov 2015 Standard Recommended
Practice - Sulphide Stress Cracking
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DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 15 of 34
NACE Standard TM0284 Test Method - Evaluation of Pipeline and Pressure Vessels Steels
for Resistance to Hydrogen - Induced Cracking
NACE Standard TM0177 Test method - Laboratory Testing of Metals for Resistance to
Sulfide Stress Cracking in H2S Environments
NACE RP0775 - Preparation, Installation, Analysis, and Interpretation of Corrosion Coupons
in Oilfield Operations.
8.3
Codes and standards
The design and Installation shall comply with the latest version of the following codes and
standards:
ADNOC Onshore Engineering Standards (ES)
ADNOC Onshore amendments to Shell DEP
Shell Design and Engineering Practices (DEP) V.39
8.4
8.5
COMPANY ADNOC Onshore Standards
ES 30-99-90-0001
Engineering Procedure – Drawing, Design & Numbering
ES 30-99-00-0102
Corrosion and Material Selection Philosophy
ES 30-99-37-0013
ADNOC Onshore Amendments / Supplements to DEP 30.48.00.31Gen. Painting and Coating of New Equipment
ES 30-99-12-3209
Specification for Piping Valves
ES 30-99-23-0123
Specification for Pipeline Flanges
EP 30.99.97.0006-1
Project Quality System Requirement
CIMS-CM-1.0
Corrosion Monitoring
Project Documents
11-99-38-1601
Material Selection & Corrosion Control Philosophy
11-99-38-1604
Material Selection & Corrosion Control Report
11-99-37-1605
Specification for internal painting & coating of vessels & tanks
11-99-37-1604
Specification for external painting & coating equipment
11-99-37-1601
Specification for CRA Clad Pipelines & Piping Materials
11-99-12-1601
Piping Material Specification
11-99-37-1607
Specification for Positive Material Identification
11-99-12-1607
Amendment to ADNOC Specification for Piping Valves; ES 30-99-123209
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DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 16 of 34
8.6
Shell DEP standards
The edition or revision of the Codes and Standards shall be the edition current at the
EFFECTIVE DATE of the AGREEMENT.
CONTRACTOR shall advise of conflict among any referenced Codes and Standards and
any technical specification, and COMPANY will determine which shall govern.
The Shell DEP standards (V.39 & MESC version 13D) including amendments, attachments
and ADNOC Onshore amendments shall be applicable as follows but not limited to:
DEP 00.00.20.10-Gen
The use of SI Quantities and Units
DEP 31.21.70.31-Gen
Air-Cooled Heat Exchangers (Amendments / Supplements to ISO
13706)
DEP 31.21.70.10-Gen
Air-Cooled Heat Exchangers; selection and application
DEP 31.21.01.30-Gen
Shell and Tube Heat Exchangers (Amendments / Supplements to
ISO 16812)
DEP 30.10.02.13-Gen
Non Metallic Material Selection & Applications
DEP 31.22.00.31-Gen
Unfired Pressure Vessels
DEP 31.22.00.30-Gen
Equipment Criticality for use in pressure vessel design
DEP 31.24.00.30-Gen
Fired heaters (amendments/supplements to ISO 13705)
DEP 31.29.02.30-Gen
Centrifugal Pumps
DEP 31.29.00.10-Gen
Installation of Rotating Equipment (Amendments/Supplements to
API RP 686)
DEP 31.29.12.30-Gen
Reciprocating Positive Displacement Pumps
DEP 31.29.22.11-Gen
Positive Displacement Pumps – Rotary
DEP 31.29.42.30-Gen
Liquid Ring Vacuum Pumps and Compressors (Amendments /
Supplements to API 681)
DEP 31.01.10.10-Gen
Chemical Injection system for upstream production facilities
DEP 31.40.21.34-Gen
Carbon and Low alloy steel pipeline flanges for use in oil and gas
operations(Amendments/supplements to ISO 15590-3) and LTCS
flanges for piping(amendments/supplements to ASTM 350 Gr
LF2)
DEP 39.01.10.12-Gen
Selection of materials for life cycle performance (upstream
facilities) – Equipment
DEP 30.10.02.11-Gen
Metallic Materials - Selected Standards
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9
9.1
DEP 30.10.02.31-Gen
Metallic Materials - prevention of brittle Fracture in new assets
DEP 30.10.60.18-Gen
Welding of Metals (amendments / supplements to API RP 582)
DEP 30.10.02.17-Gen
Wet H2S requirements for downstream pressure vessels and
piping
DEP 30.10.02.15-Gen
Materials for use in H2S Containing Environments in Oil and Gas
Production (Amendments and supplements to ISO 15156)
DEP 31.10.00.10-Gen
Positive Material Identification (PMI)
DEP 31.29.02.11-Gen
Pumps-selection, testing and installation
DEP 31.38.01.11-Gen
Piping - General requirements
DEP 31.38.01.31-Gen
Shop & Field Fabrication of Piping
DEP 31.24.49.31-Gen
Fabrication of heater piping
DEP 34.51.01.33-Gen
Above ground vertical storage tanks
DEP 82.00.10.10-Gen
Project Quality Assurance
MESC SPE 76/210
Carbon steel forgings to ASTM A105.
MESC SPE 76/211
Carbon steel forgings to ASTM A350
MESC SPE 76/212
Alloy and SS forgings to ASTM A182
MESC SPE 76/213
Nickel alloy forgings to ASTM B564
PROCESS DESCRIPTION
BCDS
The chosen option for EPC involves the construction of a new separation train i.e. Train-8
at CDS to accommodate additional production from Thamama-A and Thamama-H and the
increasing water cut and GOR from existing wells/zones and to accommodate new
Thamama-B Updip and Attic wells for sustaining the Thamama-B production rates.
The design of new separation Train-8 at BCDS will be based on 176000 BLPD total liquid
capacity, 101,000 BOPD oil and 188 MMSCFD gas and capacity assessment of the existing
seven separation trains at BCDS shall be based on the BCDS overall production profile.
After proposed modifications, the BCDS design capacity shall provide a 20% technical
margin over the sustainable rate.
9.2
RDS
As part of BIFP project EPC detailed Engineering, dewatering at upstream has been
selected to avoid additional transfer line requirement and thereby avoiding field congestion
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and congestion at existing CDS. As part of aforesaid study, Dewatering stations are selected
at 5 out of 10 existing RDSs based on water cut and fluid handling capacity of existing 12
transfer lines from RDSs to BCDS. Selected 5 RDSs are RDS-1, RDS-4, RDS-6, RDS-8
and RDS-9.The main design intent of introduction of dewatering station is to separate about
90% of water at RDS by a 3 phase separator and dispose the water at nearby disposal
wells. Separated Oil (with about 3% v/v water in oil) and gas shall be mixed again and
transferred to CDS through existing transfer lines. The off gas (High H2S about 45 mol%)
from the water separation tank will be compressed via a VRC (Vapor Recovery Compressor
), a Liquid Ring Compressor that will be connected to the lowest available process pressure
at CDS i.e. H2S stripper overhead line to ADNOC GAS PROCESSING. Recovered oil from
oil compartment of water separation tank, closed drain liquid and liquid from flare KODs will
be pumped to transfer lines.
10 REQUIREMENTS FOR CARBON STEEL AND LOW ALLOY STEELS
10.1 General
Materials for use in sour service shall comply with the requirements of NACE MR0175/
ISO 15156 as supplemented in the following paragraphs:
1) The service conditions shall be evaluated as per NACE MR0175/ISO 15156 part 1 Para 6.
2) Part 2 of NACE MR0175/ISO 15156, Para 7 for Qualification and selection of carbon steel
and alloy steels material, resistance to SSC/SCC in the presence of sulphide.
3) Part 3 of NACE MR0175/ISO 15156 for Corrosion Resistance and other alloy materials.
Materials that are not pre-qualified may be qualified based upon prior field experience (Cl.
8.2 of NACE MR 0175/ISO 15156, Part 1), or by laboratory testing using simulated
appropriate H2S service conditions (Cl. 8.3 of NACE MR 0175/ISO 15156, Part 1).
4) Material may be qualified for use in sour service conditions by specific laboratory testing of
samples. Testing shall be as required by Annex B, NACE MR0175/ISO 15156 Part 2.
5) Materials may also be qualified by experience. There must be documented evidence that
a particular material has performed satisfactorily for at least 2 years under particular sour
service conditions. This is considered as qualification by field experience and is permitted
by NACE MR0175/ISO 15156 at Part 1 section 8.2. All such evidence shall be reviewed by
the CONTRATOR / COMPANY before proceeding with use of the same material type for
similar duties.
6) Base metal for all pipes, fittings and flanges shall have a maximum hardness of 22 HRC
(248 HV10), unless lower values are specified in the applicable standard.
7) Hardness requirements of Welds and HAZ shall be in accordance to NACE MR0175/ISO
15156-Part 2 section 7.3.
8) The sour service requirements for pipes and fittings have been drawn up for supply in
reasonably large quantities by the manufacturers directly. When procurement of these
items is sometimes required in small quantities for manufacture of vessels and other
equipment, these are usually supplied by the stockiest. Any deviations in NDE, chemical
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and mechanical requirements, shall be submitted to CONTRACTOR/COMAPNY for
approval.
9) CS and Low alloy steels are acceptable at 22HRC (248 HV10)( maximum hardness as per
NACE MR0175/ISO 15156 provided they contain less than 1% mass fraction nickel and is
supplied in one of the following conditions
 Hot-rolled
 Annealed
 Normalized
 Normalized and tempered
 Normalized, Austenitized, quenched, and tempered
 Austenitized, quenched, and tempered
10.2 HIC & SSC Testing
Testing will be for both base material and weldments and routine testing for SSC and HIC
shall accord with NACE TM0177 & NACE TM0284 respectively. Testing for SOHIC and soft
zone cracking (SZC) may require full ring testing with the welds produced using the actual
manufacturing weld procedure.
Testing may only be waived, at CONTRACTOR/COMPANY discretion, when the SUPPLIER
can produce clear evidence that the materials have been fabricated to a manufacturing
procedure specification that has been fully proven for the sour service conditions to which it
will be subject.
10.2.1 HIC Testing
When the HIC testing of materials is required by this Specification, the following shall be
applied:
HIC tests in accordance with NACE TM0284 shall be conducted on three specimens from
one coupon from every heat of steel from continuous casting whilst, when from ingot
method, two sets of three specimens shall be taken from opposite ends.
A coupon from the thinnest section from each heat shall be tested in accordance with
Section 8 of NACE TM0284 using test solution A. Specimens may be taken at supplier’s
option from plate per Section 5 of NACE TM0284 or per Section 4 from a “mother” pipe or
a finished fitting (testing of longitudinal weld is not required). After testing, the specimens
shall be cleaned, sectioned, examined and evaluated as provided by Section 9 of NACE
TM0284. Individual and average values shall be reported (refer to Section 10 of the
NACE TM0284 Standard).
Acceptance criteria shall be as follows (per Table B.3 NACE MR0175/ISO15156):




Maximum individual crack length in any section not to exceed 5 mm
Crack Length Ratio (CLR) not to exceed 15%
Crack Thickness Ratio (CTR) not to exceed 5%
Crack Sensitivity Ratio (CSR) not to exceed 2.0%
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Exception for HIC testing shall be as per NACE MR0175/ISO 15156 and as per ADNOC
Onshore Specification and Shell DEPs.
Above criteria shall apply to average ratios for 3 examined sections from one specimen.
10.2.2 SSC Testing
SSC testing shall be carried out, if material supply does not meet requirement of material as
per item 9) of clause 10.1, above. Procedure and Acceptance criteria shall be as per NACE
TM0177 & NACE MR0175/ISO 15156.
11 REQUIREMENTS FOR CRAs
11.1 Stainless Steels
CRA’s may be used in sour service. The particular grades shall be listed in NACE
MR0175/ISO 15156 and shall comply with all the requirements therein. In addition to above
the following shall be applicable:

Stainless steels shall be in the solution annealed condition. Heat treatment shall be
mandatory and procedures shall meet the requirements of NACE MR0175/ ISO
15156.

The use of cold worked stainless steels is subject to the limitations imposed by the
NACE MR0175 / ISO15156 and Shell DEP amendment to ISO 15156 DEP
30.10.02.15-Gen.

Annex “A”-Table A1 of NACE MR0175 / ISO15156 is a guide to use of the material
selection tables which cover environment cracking resistant CRA’s and other alloys.

Austenitic Stainless Steels may only be used according to the limitation on service
conditions shown in tables A2 through A7 for specific components and equipment.

High alloy austenitic stainless steel is permitted according to the limitation given in
Table A8 through A11.

To ensure defect free casting alloy, Destruction test, Radiographic inspection and
Liquid penetrant inspection shall be carried out as per supplementary requirements
S2, S5 and S6 of ASTM standard A 351.

The permitted service conditions for use of Ferritic, Martensitic and Duplex SS and
others corrosion resistant materials are given in Tables from A17 to A40.

Material may be qualified for use in sour service by specific laboratory testing of
samples. Testing shall be required by NACE MR0175/ISO 15156 Part 3 Annex B.

Materials may also be qualified by experience. There must be documentary evidence
that a particular material has performed satisfactorily for at least 2 years under
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particular sour service conditions. This is considered as qualification by the field
experience and is permitted by NACE MR0175/ISO 15156 at Part 1 section 8.2. All
such evidence shall be reviewed by the CONTRACTOR/ COMPANY before
proceeding with use of the same material type for similar duties.

All material shall be subject to hardness testing, and must be within the limit specified
for the particular material in NACE MR0175/ ISO15156.

Super duplex stainless steels shall have a PREN > 40.
11.2 Nickel Base Alloys

The permitted service conditions for use of nickel based alloys are given in the
subsequent Tables from A12 to A17 of NACE MR0175/ ISO15156. For this Project
ASTM A 494 CU5MCuC shall be applicable. To ensure defect free casting alloy,
Hardness test, Radiographic inspection and Liquid penetrant inspection shall be
carried out as per supplementary requirements S2, S3 and S10 of ASTM standard
A 494.

Nickel base alloys, e.g. solid solution alloys (solution annealed or annealed,
annealed and cold-worked) or precipitation-hardened alloys are acceptable provided
they comply with the environmental and materials limits set forth in NACE MR0175
/ ISO 15156.

Precipitation hardened nickel base alloys used in safety critical applications shall be
subjected to a microstructural examination. Continuous decorations of grain
boundaries, acicular δ-phase and excessive carbide precipitates are not acceptable.

Weldments, the hardness of the base metal after welding shall not exceed the
maximum hardness allowed for the base metal, and the hardness of the weld metal
shall not exceed the maximum hardness limit of the respective metal for the weld
alloy.
11.3 Nickel-Copper Alloys
Nickel-copper alloys are acceptable in the solution annealed or annealed condition at a
hardness of 35 HRC max (345 HV10).as outlined in NACE MR0175/ISO 15156.
Nickel-copper alloys such as UNS N04400 (Monel 400) and N04405 (Monel R405) shall be
limited to service temperatures less than 150°C (300°F).
12 PIPING
12.1 General

Primary steel from a basic oxygen furnace rather than an electric arc furnace used to remelt scrap (automobile bodies plus wiring, etc.) is preferred. Steel made using a direct
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

reduction process followed by electric arc furnace (with controlled scrap) can also result
in a superior product.
Ladle refining should be used to remove impurities and to make alloying additions at the
secondary steel making process
Vacuum degassing in the ladle is desirable.
Calcium treatment for sulphide shape control after de-sulfurizing for flat-rolled products
such as plate and strip for welded pipe, etc.
Inside-outside quenching of Q&T pipe if the diameter permits as opposed to OD
quenching only
Immersion in a quenching tank as opposed to using a water spray head;
Seamless pipe is preferred over welded pipe where possible, relevant and economic;

Testing will be for both base material and weldments and routine testing for SSC and HIC.

Testing may only be waived, at CONTRACTOR/COMPANY discretion, when the
SUPPLIER can produce clear evidence that the materials have been fabricated to a
manufacturing procedure specification that has been fully proven for the sour service
conditions to which it will be subject.

Qualification of welding procedures for sour service shall include hardness testing in
accord with NACE MR0175/ISO15156. Hardness testing for welding procedure
qualification is carried out on the Vickers scale using 10-kg or 5-kg load in accordance
with ISO 6507-1, or the Rockwell method in accordance with ISO 6508-1 or ASTM A370,
E18, and E92 using the 15N scale.




12.2 Carbon Steel Seamless Pipes
Pipes and fittings shall be fully killed and fine grained and shall be supplied in the
normalized, normalized and tempered or quench and tempered finished condition. The
chemical analysis shall be in accordance with the applicable product standard and in
addition the following limitations shall be applied for product chemical composition:




Carbon ≤ 0.18%
Sulfur ≤ 0.010%
Phosphorus ≤ 0.020%
Carbon Equivalent CE ≤ 0.41%
The maximum hardness of wrought fittings shall not exceed 197 BHN (208 HV10).
HIC test is not required for seamless Pipes with Sulfur<0.01 %.
SSC qualification testing shall be carried out as specified in data sheets and as per 10.2 of
this specification.
For Barred Tees, in addition to the above requirements, bars shall be welded in place with
unalloyed low-hydrogen consumables. Attachment welds shall be full penetration type and
MT examined after final heat treatment.
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12.3 Carbon Steel Welded Pipes
Spiral welded SAW pipe is not acceptable. LSAW pipes can also be supplied in thermomechanically rolled condition.
The chemical analysis shall be in accordance with the applicable product standard and in
addition the following limitations shall be applied for product chemical composition:




Carbon ≤ 0.10%
Sulfur ≤ 0.003 %
Phosphorus ≤ 0.012%
Carbon Equivalent CE ≤ 0.38%
Repair welding of parent plate is not permitted. The welded seam may be repaired up to a
maximum of three repairs per pipe provided that the total length of weld repairs does not
exceed 5% of the total weld length of each pipe. The repair of cracks in welds within 200
mm of the ends is not permitted.
Hardness requirement shall be as per Clause 7.3 of NACE MR 0175 / ISO 15156-2.
Weld hardness testing procedure shall be submitted for CONTRACTOR/COMPANY’s
approval.
HIC test shall be performed as per 10.2 of this specification if parent plate does not meeting
the above composition.
SSC qualification testing shall be carried out as specified in data sheets. Procedure shall be
as per 10.2 of this specification.
For Barred Tees, in addition to the above requirements, bars shall be welded in place with
unalloyed low hydrogen consumables. Attachment welds shall be full penetration type and
MT examined after final heat treatment. Barred tees fabricated from the plate shall require
HIC testing of the plate in accordance with this specification.
12.4 Fittings and flanges
All carbon steel fittings and flanges for pressure vessels shall be supplied in accordance
with section 16 of this specification (i.e. "forgings").
13 PLATES
13.1 Requirements for Carbon Steel Plates of Tanks
Carbon steel plates shall be fully killed, fine grained (grain size shall be 7 or finer as defined
in ASTM E 112) and shall be produced by a low sulfur and low phosphorus refining process.
The steel shall be vacuum degassed or argon bubbled and shall be supplied in the
normalized condition in line with the requirements of NACE MR 0175 / ISO 15156 - 2.
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13.1.1 Chemical Composition
The chemical analysis shall be in accordance with the applicable product standard and in
addition the following limitation shall be applied for product chemical composition:






Carbon ≤ 0.21%
Manganese ≤ 1.30%
Sulfur ≤ 0.003%
Phosphorus ≤ 0.012%
Nickel ≤ 1.0%
Boron ≤ 0.0005%
13.1.2 Carbon Equivalent
The carbon equivalent CE shall not exceed 0.43, where CE is:
13.1.3 H2S Corrosion Tests
SSC testing is not required if plates fulfill the requirements as specified in section 7.3 of
NACE MR 0175 / ISO 15156-2
HIC testing is mandatory and shall be performed in accordance with 10.2 of this
specification. Testing for Z quality steel is not required.
13.1.4 Hardness Testing
Parent material shall have a maximum hardness of 22HRC (248 HV10).
Weld hardness determinations shall be performed in accordance with Clause 7.3.3 of NACE
MR0175/ISO 15156-2. Welds and HAZ shall have a maximum hardness of 22HRC (248
HV10).
13.2 Requirements for Carbon Steel Plates for Pressure Vessels
13.2.1 Manufacturing process
Primary steel supply shall be from a basic oxygen furnace rather than an electric arc furnace
used to re-melt scrap (automobile bodies plus wiring, etc.) is preferred. Steel made using a
direct reduction process followed by electric arc furnace (with controlled scrap) can also
result in a superior product.
Ladle refining should be used to remove impurities and to make alloying additions at the
secondary steel making process
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Vacuum degassing in the ladle is desirable.
Calcium treatment for sulphide shape control after de-sulfurizing for flat-rolled products such
as plate and strip for welded pipe, etc.
Plates shall be supplied in the normalized condition in line with the requirements of NACE
MR 0175 / ISO 15156. Controlled rolled or quenched and tempered plates are not
acceptable except by special arrangement (acceptance based on HIC test results).
Carbon steel plates shall be fully killed, fine grained (grain size shall be 7 or finer as defined
in ASTM E 112).
13.2.2 Inclusion Shape Control
Plate materials shall receive an appropriate inclusion shape control treatment by addition of
Calcium. Specific treatment by rare earth metals is not permitted.
13.2.3 Carbon Equivalent
The carbon equivalent CE shall not exceed 0.43, where CE is:
13.2.4 Micro-examination
The plates shall be checked for microstructure from the full thickness, at the center, quarter
width, and at each edge, for confirmation of effectiveness of shape control of the inclusions.
The sample shall be typical of normal production material.
Plates rolled from continuous cast material shall be checked at one end of each plate. Plates
rolled from ingots shall be checked at both ends of each plate. The examination method
shall conform to the ASTM E 45 standard (microscopical method, method D, with [A + B +
C + D] ≤ 20).
13.2.5 Ultrasonic examination
Ultrasonic tests shall be performed according to EN 10160 or ASTM A 578 level B, with
supplementary requirement S1.
13.2.6 H2S Corrosion Tests
HIC tests are required in accordance with 10.2 of this specification. HIC testing is not
required for plates which are fully clad.
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13.2.7 Hardness Testing
Weld hardness determinations shall be performed in accordance with Clause 7.3.3 of NACE
MR0175/ISO 15156-2. For equipment like vessel, tank, drum, etc., additional or more
stringent requirements may be required by applicable Data Sheet.
13.2.8 Plate Material certificate
Material certificates shall be of the EN 10204 3.2 type and shall give the following
information:







Full chemical analysis
Mechanical properties (as required in the material specification)
Steel making process, desulfurization technique, and method of monitoring inclusion
& its shape Control.
Casting method and size of ingots/slabs
Rolling procedures
Results of ultrasonic inspection
Results of micro-examination.
13.2.9 Clad Plates
Cladding shall be integrally and continuously bonded onto base metal and shall be obtained
either by roll bonding or explosive cladding and rolling. However for Pressure vessels only
roll bonded plates are recommended and cladded surface shall be ultrasonically examined
to check the integrity of bonding in accordance to ASTM A578 Level B, with a supplementary
requirement of (ADNOC Doc 30.9924.0651). Clad plates shall confirm to specifications:
ASTM A264 or A265; Nickel and Nickel base Alloy Clad Plate sheet.
14 VALVES
14.1 General
Unless more stringent requirements are provided by valve applicable Design Code, Material
Standard, Project Data Sheets, following shall be applied:

Body, bonnet, disc/ball, bonnet bolts/studs, nuts, stem shall have a maximum
hardness of 235 BHN (248 HV10) or as required in applicable product specification
or as required in NACE MR0175/ISO 15156, whichever is stringent.

Visual inspection and Magnetic Particle Examination shall be carried out for all the
pressure parts. Critical section of pressure containing castings shall be radiographed
whilst critical section of pressure containing forging shall be Ultrasonic tested as
defined in Clause 8.3 of ASME B16.34.
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
All valves in sour service shall be subject to hydrostatic shell test, seat test, backseat test and air seat test to API 598 or API 6D. No leakage shall be permitted in
these tests, (as per API 598).

External bolting on items that shall be insulated or buried shall comply with ASTM
A193 grade B7M, 559 MPa min. Yield strength and 22 HRC (248 HV10) max
hardness. Nuts shall comply with ASTM A194 Grade 2HM (22 HRC Max.) (248 HV10)
Internal bolting shall comply with NACE MR0175/ ISO 15156 requirements.

When “M” grade bolting and nuts are used for bonnets on valves, and flanges stud
bolts shall be tightened with torque wrenches or bolt tensioned so that installed
stress shall not be greater than 276 MPa. The actual torque used shall be
documented for reference.
14.1.1 Plain carbon steels
The materials listed in Table1 of NACE MR 0175 / ISO15156 are acceptable for use as
processed at hardness levels below HRC 22. Subsequent to any cold working or welding,
the whole part shall be heat treated by tempering at 620°C minimum to a hardness level
below HRC 22. Internal valve parts made from these steels shall be normalized or quenched
followed by tempering at 620°C minimum to HRC 22 maximum (248 HV10).
14.1.2 Alloy steels
The materials listed in Table1 of NACE MR 0175 / ISO15156 Part-2 shall be fully annealed,
quenched or normalized followed by tempering at 620°C minimum to a hardness level below
HRC 22 when used for valve bodies. Subsequent to any cold working or welding, the whole
part shall be heat treated by tempering at 620°C minimum to a hardness level below HRC
22. Internal valve parts made from these steels shall be normalized or quenched followed
by tempering at 620°C minimum to HRC 22 maximum.
14.1.3 Stainless steels
The 300 series austenitic stainless steels wrought or cast shall be in the solution annealed
condition, free of cold work, hardness HRC 22 maximum (248 HV10)..
The 400 series stainless steels shall be heat treated by quenching and double tempering at
620°C minimum to give a hardness level below HRC 22 (248 HV10)..
14.1.4 Precipitation hardened steels
Alloy steels or stainless steels, precipitation hardened, shall be given a final heat treatment
to reduce hardness to the levels specified in the NACE MR 0175 / ISO15156. In this case,
heat treatment procedures and heat treatment chart records shall be supplied for every part
of related material. Full material traceability shall be ensured, and detailed material
certificates must also be submitted for information.
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14.2 Special materials

Monel is satisfactory as processed by the MANUFACTURER.

Cold drawn Inconel is satisfactory for springs and other valve parts as processed by
the MANUFACTURER.

Inconel X at hardness level below Rc 35 (345 HV10).is satisfactory for springs and
other valve parts as processed by MANUFACTURER.

Hastalloy B is satisfactory as processed.

Stellite is satisfactory as trim material coating. After application, the trim shall be heat
treated by tempering at 620°C minimum to restore harnesses at values below HRC
22 (this particularly applies to the heat affected zones of the trim).

Cemented Carbides: For valves parts coating, cemented carbides are considered
satisfactory as processed by the MANUFACTURER. When used at trim materials
and applied by a fusion or welding process, the trim shall be subsequently tempered
at 620°C minimum, to restore hardness levels below HRC 22 (248 HV10). in both
base material and heat affected zones.

Tungsten Carbide: Tungsten carbine coatings are considered satisfactory as
processed by the MANUFACTURER at hardness of minimum 1050 Vickers and
thickness of tungsten carbide coating must be a minimum of 400 microns as finished.
14.3 Natural, synthetic, plastic and/or fabric materials
The packing, bonnet seals, seat rings, and seals and/or any other synthetic or fabric
materials and parts shall be those regularly supplied and suitable for this service, i.e.
fluorocarbon materials, Buna N, Nylon, Viton A, etc., as permitted within Shell DEP
30.10.02.13; Non Metallic Material selection & applications specification for valves.
14.4 Valve parts
The SUPPLIER shall provide a complete list of materials used in the valve for approval by
CONTRACTOR/COMPANY. The list shall include material specification numbers and type,
hardness level and heat treatment requirements.
Any material substitution shall be specified by type, hardness level, and heat treatment and
shall be submitted to CONTRACTOR/COMPANY for prior approval.
14.4.1 Flanges
Flanges shall be integrally cast or forged with the body.
Security Code: 5 – Public
DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 29 of 34
14.4.2 Gates, discs, ball, plugs, clappers and seats
These items may be fabricated from any of the materials in section 11 or 12 above and shall
be processed according to the requirements of this specification.
14.4.3 Springs
Springs shall be made of Inconel, Inconel X, Hastalloy B or K Monel, and shall be processed
according to section12 of this specification.
14.4.4 Glands and bushings
Glands and bushings which have close tolerances with moving parts and where build-up of
corrosion products could cause faulty operation by seizure, etc., shall be made of
precipitation hardened copper alloys to maximum hardness or plain carbon steels with
Stellite coating.
14.4.5 Bonnet Seal Rings
Seal Rings shall be made from plain carbon steels or AISI 300 series austenitic stainless
steels with hardness levels below 180 BHN (189 HV10).
14.4.6 Bearings
Valves with bearings located above the packing or valve stems etc., may be made of
standard bearing materials but shall have vent holes located below the bearing to prevent
the sour gas escaping through the bearing.
14.4.7 Bolting materials
Bolting materials exposed to hydrogen sulphide shall comply with ES 30-99-00-0102;
Corrosion and Material Selection Philosophy.
14.4.8 Miscellaneous items
Items not listed in section 11 & 12 shall be fabricated from materials detailed in
accordance to NACE0175 / ISO15156.
15 FORGINGS
All carbon steel flanges and tube sheets shall be supplied in accordance with this section.
Forged valves, flanges, fittings, etc. are preferred to cast items.
Security Code: 5 – Public
DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 30 of 34
15.1 Carbon Steel Forgings
Forgings shall be of the fully killed (deoxidized) type made to fine grain low and shall be
supplied in the normalized condition. Steel shall be vacuum and calcium treated where
commercially available. Alloying elements such as Titanium (Ti) and Boron (B) shall not be
intentionally added to the steel.
Forging shall be to the ADNOC Onshore spec ES-30-99-12-3209; Specification for piping
valves, ES 30-99-23-0123; Specification for Pipeline Flanges & MESC SPE reference as
follows
MESC SPE 76/210: Carbon Steel
MESC SPE 76/211: Low Temperature Carbon Steels
For flanges & forged fittings, that involve pressure containing welding in sour service, the
following limitations shall be applied for product chemical composition in addition to
the applicable product standard of ISO 15590-3:2004.
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Carbon ≤ 0.18%
Sulfur ≤ 0.003%
Phosphorus ≤ 0.020%
Carbon Equivalent CE ≤ 0.43%
Additionally amendment as per Shell DEP 31.40.21.34-Gen clause 9.3 is applicable on the
following Nitrogen and Phosphorous elements, as well as for V+ Nb + Ti combination and
Cr + Mo + Cu combination.
Hardness requirement as per NACE MR0175/ISO15156. SSC test are not required with the
maximum hardness of wrought fittings shall not exceed 197 BHN (208 HV10), while the
forged material shall have a maximum hardness of 187 BHN (195 HV10).
HIC testing is not required if composition of sulfur is <0.01%.
15.2 CRA Forgings
Forging shall be to the ADNOC Onshore spec ES-30-99-12-3209 & MESC SPE reference
as follows
MESC SPE 76/212: Stainless Steels & Super Duplex SS
MESC SPE 76/213: Nickel Alloys
15.3 Process of Manufacture
Forgings shall be of ASTM A105/A105M, ASTM A350/A350M LF2 or ASTM A694/A694M
F60. Cold work (Cold Forging) is not permitted unless otherwise approved in writing by
CONTRACTOR/COMPANY. Hot Forging shall be performed in accordance with ASTM
A788/A788M and shall be forged to shape such that the finishing may be achieved with the
minimum machining.
Hot work operations must be followed by an appropriate heat treatment with the following
decreasing order to preference:

Quenching and tempering
Security Code: 5 – Public
DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 31 of 34


Normalization and tempering
Normalization.
Cold work or machining from bars is not permitted and repair by welding is not allowed.
15.4 Chemical composition
The full chemical analysis (ladle) of forgings shall be within the following limits (all values in
percent, by weight):
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C < 0.18
Mn < 1.30
P < 0.020
S < 0.003
Nb <0.05
V <0.05
Nb +V <0.08
CE <0.43 as established below :
(However, the limitation on carbon equivalent values does not apply if items are not welded
and are not supposed to be welded in the future).
15.5 Hardness Evaluation
CLAS forgings shall be certified to NACE MR 0175/ISO 15156-2 by the manufacturer.
Maximum hardness value shall not exceed 248 HV10 except for ASTM A105/A105M where
the maximum hardness shall not exceed 187 HBW (195 HV10).
15.6 Fittings
Fittings shall be made according to ASTM A105/A105M, ASTM A234/A234M WPB, ASTM
A420/A420M WPL6 or WPL6W or ASTM A860/A860M WPHY standards.
Fittings to ASTM A234/A234M WPB are acceptable if hardness does not exceed 197 HBW
(208 HV10).
The final fitting product shall meet the chemical composition as para 16.4.
15.6.1 Manufacturing Process
Fittings shall be manufactured by a hot forging process in accordance with ASTM
A788/A788M and shall be forged to shape in such that finishing may be achieved with
minimum machining.
Security Code: 5 – Public
DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 32 of 34
Cold work (Cold Forging, Forming, and Bending) is not permitted unless otherwise approved
in writing by CONTRACTOR/COMPANY.
Machining from round bars is allowed only for small fittings items (≤ 2”) provided that the
round bars meet all the requirements of this section.
Hot work operations must be followed by an appropriate heat treatment with the following
decreasing order to preference:



Quenching and tempering
Normalization and tempering
Normalization.
Repair by welding is not allowed.
15.6.2 Hardness Evaluation
Fittings shall be certified NACE MR 0175/ISO 15156-2 by the manufacturer. Maximum
hardness value shall not exceed 248 HV10.
16 CASTINGS
16.1 General
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Casting by bottom pouring from the ladle is preferred.
Continuous casting to the appropriate shape for the final product (flat plate or round billets
for bar or pipe) is preferable to ingot casting.
Using an argon-shrouded tundish over the continuous caster to avoid oxidation of the
aluminum used to kill the steel.
Electromagnetic stirring during continuous casting to help avoid segregation of impurities.
Forged valves, flanges, fittings, etc. are preferred to cast items.
16.2 Steel Castings
1) Steel castings are acceptable provided t h a t the hardness of the material for casted
equipment does not exceed 200 BHN (210 HV10).. The method of heat treatment and
the time/temperature thermal cycle shall be shown on the mill certificate.
2) The chemical composition of carbon and low alloyed castings shall satisfy the
requirements of ASTM A216/A 216M or ASTM A352/A 352M for carbon steels and
carbon-manganese steels, as applicable. Total unspecified elements shall not exceed
0.10 percent. The carbon equivalent of butt welding castings shall not exceed 0.43.
16.3 Cast Iron
Grey, austenitic and white cast irons shall not be used for pressure-containing parts; these
materials may be used for internal components with Company approval.
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DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 33 of 34
Ferritic ductile iron in accordance with ASTM A395 is acceptable for equipment unless
otherwise specified by equipment standard.
16.4 Carbon and Alloy steel Castings
For pressure containing parts, CLAS Casting materials may be proposed as substitute to
forged materials if agreed in writing by CONTRACTOR/COMPANY.
CLAS Castings shall be certified NACE MR 0175/ISO 15156-2 by the manufacturer.
Parts shall be made from ASTM A216/A216M Grade WCB and ASTM A352/A352M Grade
LCC. Other grades are subject to CONTRACTOR/COMPANY agreement.
Casting shall be fully killed and shall be supplied in the normalized, normalized and
tempered or quenched and tempered condition.
For items that involve pressure containing welding, the following limitations shall be applied
for product chemical composition in addition to the applicable product standard:
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Carbon ≤ 0.23%
Mn < 1.35
Sulfur ≤ 0.02%
Phosphorus ≤ 0.030%
Carbon Equivalent CE ≤ 0.38%.
(However, the limitation on carbon equivalent values does not apply if items are not welded
and are not supposed to be welded in the future).
Hardness requirement is as per NACE MR0175/ISO15156. SSC & HIC test are not required.
All castings shall be suitably heat treated after any welding operation has been performed,
and this requirement also applies to the weld repair of defects, irrespective of size.
16.5 Steel Making Process
All castings shall be fully killed and fine-grained steel. Steel shall be produced by Electric
Arc or Basic Oxygen processes, followed by a secondary refining.
16.6 For pressure containing parts
Cast manufacturing process shall be assessed and approved by the Company for all its
extent. Mechanical Test sampling or previous qualification test records shall also be
approved by the Company.
Castings shall comply with the general and supplemental requirements of ASTM
A703/A703M and shall be certified as following by the manufacturer:
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The steel shall be produced in an electric furnace or by the basic oxygen process.
Weld repairs shall be documented as soon as they come under section S20
of ASTM A703/A703M
Security Code: 5 – Public
DOCUMENT TITLE
Project No.: P11570
ADNOC Onshore Doc. No.: 11-99-37-1609
SPECIFICATION FOR PIPING, FORGING,PLATES Rev.: 1
Date: 17-May-2018
& CASTINGS FOR SOUR SERVICE
Page 34 of 34
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Heat treatment condition shall be normalized or quenched and tempered.
For Quenched and Tempered condition, Temperatures of austenitization, tempering
and quenching medium shall be stated in the certificate.
All castings shall be proved sound by radiography and shall be stress relieved at
620°C to 670°C.
All castings repair welds irrespective of size shall be heat treated. PWHT details shall
be mentioned in the certificate.
16.7 Hardness Evaluation
CLAS castings shall be a certified NACE MR 0175/ISO 15156-2 by the manufacturer.
Maximum hardness value shall not exceed 248 HV10.
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