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Duplex Stainless SteelSource: API 938C, Use of DSS in Oil Refinery IndustrySTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Stainless SteelsAdd Fe50 Cr50NiAlloyAlloy 601Add Cr, lower Cfor resisting acidsAdd Cr, Al forresistance toOxidation acidsAlloy 690Add Mo, Cr forresistance,chlorides, andhigh TempenvironmentAdd Fe for economy and Cr forcarburization, oxidationresistanceAlloy600Ni-15Cr-8FeAdd Ti, Al forStrengtheningAlloyX-750Add Co, M,B, Zr, W, CbFor gas turbinerequirementsSource: ASM Corrosion of WeldmentsASM Stress Corrosion CrackingSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYSuperalloysAdd Mo, Cu for Resistance toChlorides, reducing acidsAlloy 800, 800H, 802Add Cr, lowerC for resistingacidsAlloys625, C-276C-4, XAlloys825, GAlloysB, B-2Add Cr got highTemp strengthresistanceto oxidizing mediaAdd Mo forResistance toreducingacids,halogensAdd CuNickel200NickelAlloysAdd CuResistance RATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Materials Application – Carbon SteelCarbon Steel is widely used in oil and gas industry mainly due to its cost, availabilityand easy fabrication and welding.Limitations:Low corrosion resistance in many applicationsVery low temperature -29 C .CS loose toughnessHigh Temperature: 425 C . CS low creep strength, high oxidation rate, andsusceptibility to carburizationSusceptible to FAC in condensate serviceSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Materials Application – Low Alloy Cr-Mo SteelLow alloy Chromium Molybdenum (Cr-Mo) Steels are replacing the Carbon steels as acandidate material where:- Temperature is higher than the maximum limits of carbon steels- In application where Hydrogen is present at relative high temperature and partialpressure to resist High Temperature Hydrogen Attack (HTHA)Common Grades:P11 (1.25 Cr- 0.5 Mo)P22 (2.5 Cr – 0.5 Mo)P5 (5 Cr- 0.5 Mo)P91 (9 Cr- 1 Mo)Note: Cr-Mo steel is usually require application of Post Weld Heat Treatment (PWHT)during fabrication or repair, which sometimes are difficult to apply at siteSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARSteam Pipetemperature 600 C,pressure 30MPaBAHER ELSHEIKH – JULY 2020

Materials Application – Stainless SteelStainless steels is a material of Cr 11 % where Cr formed the distinguishingsurface oxide layer of the stainless steels.Austenitic stainless steels is applied widely where:- Higher Corrosion resistance is required- Temperature is higher than the maximum limits of Cr-Mo Steels- Temperature is lower than the lower limit of CS to avoid brittle fracture andtoughness lossA main concern of austenitic SS is the susceptibility to pitting and cracking in Clservices, Where DSS is preferred for this aspectDuplex stainless steels limited for Temp. 316 C to avoid 475 embrittlementSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Materials Application – Nickel Based AlloysNi Based alloys (Incoloy, Inconel, Monel, .) are replacing Stainless steels when:- Higher Corrosion resistance is required- Temperature is higher than the maximum limits of stainless Steels (oxidation, metal dusting, Nitriding,carburization,.)Ni Alloys are of much higher cost compared to stainless steels which limits its application.Alloys with Ni 42% is almost immune for chloride SCC. Alloy 825 (42% Ni) is often specified for applicationsrequiring resistance to chloride SCC.STATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Materials Application – Refractory LinedRefractory lining is applied where the metals cannot withstand the operating temperature and / or toreduce the cost of the equipment by using lower design temperature and hence lower material gradeSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Materials Application – Non Metallic Piping and VesselsNon metallic materials include wide range of different materials like: FRP, PVC, PE, Cement, lined equipmentUsually applied where corrosion resistance is requiredLimited in temperature applicationSpecial precautions ( Protection from UV, vent holes for PTFE lined, .)Preferred application for underground piping to have good corrosion resistance without need of CathodicProtectionSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

RecommendedReadings forSS and Ni C EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

HeatTreatmentSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Iron-Carbide Phase DiagramArea of FocusSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Heat TreatmentAnnealing980Heat treatment with furnacecooling from Austenitizing rangeFor Hypoeutectoid steels (C 0.80%), full annealing consists ofheating to 90 to 180 C A3 temp.For Hypereutectoid steels (C 0.80%), heating above the A1temperature, followed by veryslow cooling.900Temperature, CAnnealing is used to reducehardness, obtain a relativelynear-stable microstructure,refine grain size, improvemachinability, and facilitate 740723 CA166058000.20.40.60.811.21.41.6Composition (wt, C)Reference: Heat Treating, Vol 4, ASM Handbook, ASM InternationalSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Heat re, CSteelnormalizedby furnaceheatingHeatistreatmentwith160to 200 C intothe austenitecoolingfromAustenitizingrangephase field at temperaturessomewhatthoseAnnealing higheris usedthanto reduceusedby annealing,hardness,obtain afollowedrelativelybycoolingat a mediumrate (Airnear-stablemicrostructure,Coolingfor CS).refine grainsize, improvemachinability, and facilitate coldSteelsare normalized to establishworking.a uniform microstructure andrefinegrain size. steels (C For HypoeutectoidThefasterfullcoolingrate consistsresults inofa0.80%),annealingmuchfinerheatingto microstructure,90 to 180 C A3 whichtemp.is harder and stronger than thecoarsermicrostructureproducedFor Hypereutectoidsteels(C byfull annealing.0.80%),heating above the A1temperature, followed by veryslow 3740723 CA166058000.20.40.60.811.21.41.6Composition (wt, C)Reference: Heat Treating, Vol 4, ASM Handbook, ASM InternationalSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Heat e900Temperature, CSteelnormalizedby furnaceheatingHeatistreatmentwithToproducea steelin itssoftest160to 200 ibleconditionwith minimumphasefieldat rthanthoseAnnealingandis usedto reduceithardness,canbybeannealing,spheroidizedby heatingusedbyobtain afollowedrelativelyjustabovejust belowcoolingat tectoidand thenCoolingfortemperatureCS).refine grainsize, improveholdingat that temperaturemachinability,and facilitate forcoldanextendedperiod oftotime.Steelsare normalizedestablishworking.a uniform microstructure andrefinegrain size. steels (C For HypoeutectoidThefasterfullcoolingrate consistsresults inofa0.80%),annealingmuchfinerheatingto microstructure,90 to 180 C A3 whichtemp.Ref.:Heat TreatingSubjectthanGuideisharderand strongertheASMcoarsermicrostructureproducedFor InternationalHypereutectoidsteels(C byfull annealing.0.80%),heating above the A1temperature, followed by veryslow 3740723 CA1SpheroidizationandStress Relief66058000.20.40.60.811.21.41.6Composition (wt, C)Reference: Heat Treating, Vol 4, ASM Handbook, ASM InternationalSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Post Weld Heat Treatment When weld is applied it is molten metaland thermally expanded when filling agroove.Weld Metal HotBase Metal When weld metal cools, it will shrink alot. Yield Strength is low for much of thecooling range. Surrounding metal that was not heated tomolten temperatures will constrain orkeep the weld from shrinking as it cools.RestraintRestraint Post Weld Heat Treatment is a procedureto reduce residual stress, temper theHAZ, and remove hydrogen from the weldregion after a seam weld is made.STATIC EQUIPMENT IN OIL AND GAS INDUSTRYBase MetalOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARWeld Metal underTensionBAHER ELSHEIKH – JULY 2020

Post Weld Heat Treatment Weld and HAZ heated below the transition temperature for several hours and thengradually allowed to cool. Can Global (entire vessel) Can be Local (weld seam and surrounding metalQ6Recommended Readings: WRC 452STATIC EQUIPMENT IN OIL AND GAS INDUSTRYThink and AnswerWhat are the main pros and cons of each PWHTtechnique Global / LocalOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

CorrosionSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

CorrosionCorrosion a chemical or electrochemical reaction between a materialand its environment that produces a deterioration (change) of thematerial and its propertiesWhy do metals corrode?Most metals are found in nature as ores. The manufacturing process of converting theseores into metals involves the input of energy.During the corrosion reaction the energy added in manufacturing is released, and themetal is returned to its oxide state.Metal OreReduction (add Electron)MetalOxidation (strip electron)Corrosion ProductsCorrosion Consequence:1. Downtime2. Product Loss 3. Efficiency LossSTATIC EQUIPMENT IN OIL AND GAS INDUSTRY4. ContaminationOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINAR5. OverdesignBAHER ELSHEIKH – JULY 2020

Corrosion Forms – Classic Fontana & Green FormsUniformCorrosionCorrosion attack that is more or less distributed over the entire exposed surface of a metal.GalvanicCorrosionaccelerated corrosion of a metal because of contact with a more noble metal in an itting CorrosionLocalized attack at and adjacent to grain boundaries, with relatively little corrosion of the grains, isintergranular corrosion. The alloy disintegrates (grains fall out) and/or loses its strength.a localized attack on a metal adjacent to a crevice between two joining surfaces (two metals or metalnonmetal crevices)a localized phenomenon confined to smaller areas. Pitting corrosion are normally found on passive metalsand alloysSelectiveLeachingRemoval of one element from a solid alloy by corrosion processes Examples are dezincification in on of metals and alloys due to relative movement between metal surfaces and corrosive fluids.Depending on the rate of this movement, abrasion takes place.Stress CorrosionCracking(SCC) refers to failure under simultaneous presence of a corrosive medium and a tensile stress.STATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Uniform CorrosionUniform Corrosion is also called general corrosion. Thesurface effect produced by most direct chemical attacks(e.g., as by an acid) is a uniform etching of the metalControl Selection of a more corrosion resistant alloy (i.e.higher alloy content or more inert alloy) Utilize coatings to act as a barrier between metal andenvironment. Modify the environment or add chemical inhibitors toreduce corrosion rate. Apply cathodic protection. Replace with corrosion resistant non-metallicmaterial.Reference: Inspector Knowledge – Corrosion Basics, By Mok Check MinSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Galvanic CorrosionGalvanic Corrosion is anelectrochemical action of twodissimilar metals in the presenceof an electrolyte and an electronconductive path.It occurs when dissimilar metalsare in contact.Control Use of galvanically compatiblematerials Avoid unfavorable area effectsof a small anode and largecathode Use of electrical insulationbetween dissimilar materialsSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Intergranular CorrosionIntergranular corrosion is an attack on or adjacent to the grainboundaries of a metal or alloy. A highly magnified cross sectionof most commercial alloys will show its granular structure.This structure consists of quantities of individual grains, andeach of these tiny grains has a clearly defined boundary thatchemically differs from the metal within the grain center.Control Heat treatment of alloy to remove phases from grainboundary regions which reduce corrosion resistance (i.e.solution annealing). Use modified alloys which have eliminated such grainboundary phases through stabilizing elements or reducedlevels of impuritiesSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Crevice CorrosionCrevice Corrosion is an intense localized corrosion frequentlyoccurs within crevices and other shielded areas on metal surfacesexposed to corrosives. This type of attack is usually associatedwith small volumes of stagnant solution caused by holes, gasketsurfaces, lap joints, surface deposits, and crevices under bolt andrivet headsControl Redesign of equipment to eliminate crevices. Close crevices with non-absorbent materials or incorporate abarrier to prevent of moisture penetration into crevice. Prevent or remove builds-up of scale or solids on surface. Use of one-piece or welded construction versus bolting orriveting. Select more corrosion resistant or inert alloyReference: NALCO Guide to Cooling Water System Failure AnalysisSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Pitting CorrosionPitting is a form of extremely localized attack that results in holes inthe metal. These holes may be small or large in diameter, but in mostcases they are relatively small. Pits are sometimes isolated or so closetogether that they look like a rough surface.For stainless steels, pitting resistance equivalent number (PREN) is equalto:PREN Cr 3.3 (Mo 0.5 W) 16NControl Choose the material most appropriate for the service conditions Avoid stagnant zones and deposits Reduce the aggressivity of the medium (using inhibitors) Maintain the protective film of the material Use cathodic protection.STATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Selective LeachingSelective Leaching is the removal of one element from a solid alloy bycorrosion processes. The most common example is the selective removal ofzinc in brass alloys (dezincification). Similar processes occur in other alloysystems in which aluminum; iron, cobalt, chromium, and other elementsare removedControl Select “inhibited” versions of copper alloys. Use alternative materials that are not susceptible to dealloying in theenvironment(s) Reduce severity of environment through environmental control oraddition of effective chemical inhibitors Cathodic protection Use of coating to act as a barrier between the environment and thealloySTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Erosion-CorrosionErosion-corrosion is a description for the damage that occurs whenparticle erosion and/or high flow velocity contributes to corrosion byremoving protective films or scales or otherwise accelerating thecorrosion rate.Control Changes in shape, geometry, and materials can help mitigate erosionand erosion-corrosion. Examples include increasing the pipediameter to reduce velocity Improved resistance to mechanical erosion is usually achieved byincreasing component hardness Heat exchangers utilize impingement plates and occasionally tubeferrules Ensure proper operation to avoid water droplets in the steamsystem. Use abrasion resistance coatingSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GROUP – FREE WEBINARBAHER ELSHEIKH – JULY 2020

Stress Corrosion CrackingSCC is Cracking caused by the simultaneous presence of tensile stressand a specific corrosive medium. Usually lead to unexpected suddenfailure.Examples: (Chloride SCC, Carbonate SCC, Caustic SCC, Ethanol SCC,HF SCC and Polythionic acid SCC)Control Use resistant materialProperly apply coating if applicableResidual stress release application when applicableDesign to avoid stagnant conditions of species causing SCCProper application of NDE and inspection techniques for earlydetection of cracksSTATIC EQUIPMENT IN OIL AND GAS INDUSTRYOPERATIONS OIL AND GAS FACEBOOK GRO

Fired Boiler . Reformed Gas / Waste Heat Boiler. ST AT I C EQ U I P MENT I N O I L AND G AS I NDU ST R Y O P ER AT I O NS O I L AND G AS FACEBO O K G R O U P - FR EE WEBI NAR BAHER ELSHEI KH - J U LY 2020. HRSG. How RGB differs from Fired Boiler and what are the common aspects . Q 3