QATAR TECHNICAL PETROLEUM CENTER, P.O. Box 9955, Salwa Road, Doha, Qatar.Tel: +974 4458 1440. Fax: +974 4458 0414 Email: antonymgr@qtpc.qa URL: www.qtpc.qa

MATERIAL SELECTION

Course Duration : 5 Days Training

Daily Schedule : 7:30am - 3:30pm

Training Date : Upon Request

Training Venue : Doha

Traning Fees : TBI

Course Outl ine

What is problem with present metallurgy ? The metallurgy of carbon steel, the material widely used.-The wrong concepts held so far. Metals are not for ever-Desirable physical properties of metals.-The alterability of physical properties

• Crystal structure & grain boundaries• Carbon –the good and bad about it• Types of carbon steel• Physical Properties of metals• Addition of Cr Ni etc and effects –stainless steels • Heat treatment and welding- how it affects physical properties

2

QATAR TECHNICAL PETROLEUM CENTERQTPC - AN ISO 9001:2008 Regd.

Day 1 Aladdin’s lamp - changing new one for old

Grain boundary and the basics of TTT diagram

Elements of nature vs man made giants –the clash of the TitansEnvironment to which metals normally are exposed-Failures that are normally reported-Aggressive conditions in oil and gas process-Chemical reaction that take place-Corrosion an irreversible process

Eight types of corrosion- micro and macro-Uniform or Localized Loss of Thickness - Galvanic Corrosion - Atmospheric Corrosion- corrosion in water – velocity and factors- cavitation- erosion-selective leaching-pitting- filliform- Galvanic corrosion-Factors that enhance corrosion

Special alarming situations- Corrosion Under Insulation (CUI)- Cooling Water Corrosion - Boiler Water Condensate Corrosion. CO2 Corrosion -Flue Gas Dew Point Corrosion- Caustic Corrosion- Dealloying- Graphitic Corrosion-High Temperature Corrosion [400oF (204oC)]- Sulfidation -Carburization – Decarburization- Metal Dusting- Fuel Ash Corrosion - Nitriding- Environment

Stress Assisted Cracking - Chloride Stress Corrosion Cracking (CI–SCC)- Corrosion Fatigue - Caustic Stress Corrosion Cracking (Caustic Embrittlement)- Ammonia Stress Corrosion Cracking- Liquid Metal Embrittlement (LME) - Hydrogen Embrittlement (HE) --Bacterial and microbe induced corrosion

Day 2 The unforeseen forces at play - study of environment

QATAR TECHNICAL PETROLEUM CENTER, P.O. Box 9955, Salwa Road, Doha, Qatar.Tel: +974 4458 1440. Fax: +974 4458 0414 Email: antonymgr@qtpc.qa URL: www.qtpc.qa

MATERIAL SELECTION

Course Outl ine

Some key processing stages and problems failures and case studiesDesalters-chloride acid corrosionCrude towers overhead top trays-cat. reformers-HCl corrosion- SS 300,400 seriesCrude towers, FCC, hydrogen reforming, hydro-processing, tail gas units-Amine corrosionCrude vc heater tubes –transfer- naphthenic acid corrosion-SS317 L and high Mo contentDesulphurizers, hydro-treaters- High Temp Corrosion of CS, 400 series FCC gas plants, coker, Strippers-sour water corrosion of 300 Series and Duplex Stainless steel Boilers and heaters-high temperature and H2/H2s CorrosionHigh heat exchangers- amine stress corrosion cracking- Cu alloys- 400 series St SteelsHydro-processing unit- sour water service – HF alkylation units- Cr/Mo alloys- Hydrogen embrittlementCarbon steel tanks and piping of refrigeration units- ammonia stress corrosion crackingProcess piping- alkylation unit-alloy400 Waste water management units and piping- mercury LME

2

QATAR TECHNICAL PETROLEUM CENTERQTPC - AN ISO 9001:2008 Regd.

Day 3Gas and oil processing units-process Metallurgy

General- Uniform or Localized Loss in Thickness Phenomena - Amine corrosion-Ammonium Bisulfide Corrosion (Alkaline Sour Water)-Ammonium Chloride Corrosion- Hydrochloric Acid (HCl) Corrosion High Temp H2/H2S Corrosion - Hydrofluoric (HF) Acid Corrosion- Naphthenic Acid Corrosion (NAC)

Phenol (Carbonic Acid) Corrosion- Phosphoric Acid Corrosion.-Sour Water Corrosion (Acidic)-Sulfuric Acid Corrosion-Cracking failures -Environment–Assisted Cracking- Polythionic Acid Stress Corrosion Cracking (PASCC)- Amine Stress Corrosion Cracking - Wet H2S Damage (Blistering / HIC / SOHIC / SCC -SWC

Hydrogen Stress Cracking – HF- Carbonate Stress Corrosion Cracking - Other Mechanisms- High Temperature Hydrogen Attack (HTHA)- Titanium Hydriding

Day 4

Day 5

Specific refining industry damage mechanisms

Properties of stainless steel contrasted with carbon steelEvolution of a super metal- four major grouping and propertiesSpecific failure patterns and situations of stainless steelMartensitic stainless steel and its application in flow lines, manifolds etc

Stainless steel for H2S, CO2 ChlorideWet gas metallurgy

Stainless steel – a misnomer

Coating- organic, metallic, plating and anodizing Selection, cost and economicsCathodic protection its advantages and limitationsInhibitors types, application, cost and limitationsDesign changesApplication of lining and claddingFiberglass polymers as piping and storage tanks-applicationsThree causes of failuresApplication of rubber, CPVC UPVC in piping Non ferrous metallurgy and other alloys

Protection measures for carbon steel and other material selection options

QATAR TECHNICAL PETROLEUM CENTER, P.O. Box 9955, Salwa Road, Doha, Qatar.Tel: +974 4458 1440. Fax: +974 4458 0414 Email: antonymgr@qtpc.qa URL: www.qtpc.qa

MATERIAL SELECTIONQATAR TECHNICAL PETROLEUM CENTER

Introduction

QTPC - AN ISO 9001:2008 Regd.

Most of the refineries in the Middle East are more than 30 years old and some even have crossed fifty. It has given a false impression that the plants would continue to run for ever without any problem as before although it is forgotten that many input variables have taken place and stringent quality control on output has warranted several process changes and this has deviated from design parameters and conditions. All the years failures were attributed to mechanical wear out and normal ageing but recent findings and theories of corrosion tell us that materials are also subjected to stress and fatigue and may fail like human beings anytime without warning. Recent devastations in many refineries in spite of Risk Based Inspection tell us that our understanding of material limitation is still very poor and running the plant without such vital information is a question on plant reliability and safety. This course is designed to take a break and learn why problems persist in different parts and plants and machinery and how to address them By Proper Material Selection.

ScopeIn the wake of declining global economy the need for careful asset management is gaining much importance as health and safety. Particularly where old pipelines and equipment need repair alteration, re-rating.the question of an economic approach and a calculated risk in utilizing new material is warranted.

The word material does not restrict itself only to metals and alloys but includes nonmetallic chemicals, and devices that help to improve plant reliability. Days are gone when one department designs or orders and someone uses them. Material selection is becoming a corporate responsibility including process engineers, maintenance staff, laboratory personnel, inspection and safety department and not forgetting the Corrosion engineer- each of them have something say about problems and prospects of closing alternatives in the case of failures. The finance controller and the supplier work out the best solution. Thus a decision tree is evolved to arrive at a right choice. Material selection is thus a challenging task that works to the safety and benefit of all concerned.

Who should attend?Excellent course specially designed for process engineers, maintenance staff, laboratory personnel, those involved in design and material selection. This is a course that embracs all API standards such as 510, 570, 571 and introduction to ISO 15156

PresentationAll the lectures are presented in colourful power point slides with ever so many photographs collected over years.

Student will get only the course material in hard copy or CD

Optional: There will be pre-test and post test questions to evaluate the benefit of the course

There will be a video presentation on Corrosion and its impact

About the InstructorThe author holds a doctorate degree from the Chemical Engineering University of Veszprem in Hungary. He is instructor for NACE International USA and other organizations.He worked as Corrosion Specialist and head of Dept of Inspection and Corrosion in Government of Abu Dhabi Water Electricity for twenty years from 1982 to 2001. Since then he is teaching in seminars on various oil and gas industry subjects’ especially Material selection and Material failure/ corrosion etc. in Middle East countries’He has presented this topic several times and this is totally revised edition