Norsok_M-001_0

This NORSOK standard is developed with broad petroleum industry participation by interested parties in the Norwegian petroleum industry and is owned by the Norwegian petroleum industry represented by The Norwegian Oil Industry Association (OLF) and Federation of Norwegian Manufacturing Industries (TBL). Please note that whilst every effort has been made to ensure the accuracy of this NORSOK standard, neither OLF nor TBL or any of their members will assume liability for any use thereof. Standards Norway is responsible for the administration and publication of this NORSOK standard. Standards Norway Telephone: + 47 67 83 86 00 Strandveien 18, P.O. Box 242 Fax: + 47 67 83 86 01 N-1326 Lysaker Email: petroleum@standard.no NORWAY Website: www.standard.no/petroleum Copyrights reserved NORSOK STANDARD M-001 Rev. 4, August 2004 Materials selection NORSOK standard M-001 Rev. 4, August 2004 NORSOK standard Page 1 of 30 Foreword 2 Introduction 2 1 Scope 3 2 Normative and informative references 3 2.1 Normative references 3 2.2 Informative references 4 3 Terms, definitions and abbreviations 4 3.1 Terms and definitions 5 3.2 Abbreviations 7 4 General principles for materials selection and corrosion protection 7 4.1 Philosophy 7 4.2 Materials selection requirements 7 4.3 Corrosivity evaluation and corrosion protection 8 4.4 Weld overlay 12 4.5 Chemical treatment 12 4.6 Corrosion monitoring 13 5 Materials selection for specific applications/systems 13 5.1 Introduction 13 5.2 Drilling equipment 13 5.3 Well completion 14 5.4 Structural materials 15 5.5 Process facilities 15 5.6 Bolting materials for pressure equipment and structural use 19 5.7 Sub-sea production and flowline systems 20 5.8 Pipeline systems 23 5.9 Chains and mooring lines for floating units 23 6 Design limitations for candidate materials 23 6.1 General 23 6.2 Materials for structural purposes 24 6.3 Materials for pressure retaining purposes 24 6.4 Polymeric materials 28 7 Qualification of materials and manufacturers 29 7.1 Material qualification 29 7.2 Manufacturer qualification 29 7.3 Familiarisation programmes for fabrication contractors 30 NORSOK standard M-001 Rev. 4, August 2004 NORSOK standard Page 2 of 30 Foreword The NORSOK standards are developed by the Norwegian petroleum industry to ensure adequate safety, value adding and cost effectiveness for petroleum industry developments and operations. Furthermore, NORSOK standards are as far as possible intended to replace oil company specifications and serve as references in the authorities’ regulations. The NORSOK standards are normally based on recognised international standards, adding the provisions deemed necessary to fill the broad needs of the Norwegian petroleum industry. Where relevant, NORSOK standards will be used to provide the Norwegian industry input to the international standardisation process. Subject to development and publication of international standards, the relevant NORSOK standard will be withdrawn. The NORSOK standards are developed according to the consensus principle generally applicable standards work and according to established procedures defined in NORSOK A-001. The NORSOK standards are prepared and published with support by The Norwegian Oil Industry Association (OLF) and Federation of Norwegian Manufacturing Industries (TBL). NORSOK standards are administered and published by Standards Norway. Introduction This NORSOK standard gives recommendations, requirements and guidelines for materials use in oil and gas production. This revision 4 includes requirements from NORSOK M-CR-505 "Corrosion monitoring design", which is withdrawn. The evaluation of internal corrosivity in hydrocarbon systems is rewritten and considers corrosion inhibitor availability instead of efficiency, and the maximum hardness and yield strength requirements of materials to be cathodically protected have been lowered. This NORSOK standard is intended to comply with the requirements of the ”Pressure Equipment Directive” (PED) and the Norwegian implementation regulation ”Forskrift for trykkpåkjent utstyr” issued 9 June 1999. The requirements given for materials by PED, Annex I ”Essential Safety Requirements”, section 4.1, are fulfilled provided the principles of materials selection of this NORSOK standard are followed and documented. The documentation requirement in PED, Annex I ”Essential Safety Requirements”, section 4.3, of the materials used in main pressure retaining parts of equipment in PED categories II, III and IV, shall take the form of a certificate of specific product control. This is fulfilled by the certification requirement given by the material data sheets compiled in NORSOK M-630. The PED requires that the manufacturer provides documentation of elements relating to compliance with the material specifications of the PED in one of the following forms: ! by using materials which comply with a harmonised European standard; ! by using materials covered by a European approval of materials; ! by a PMA.. A particular appraisal has to be made to confirm compliance to PED for each particular installation. NORSOK standard M-001 Rev. 4, August 2004 NORSOK standard Page 3 of 30 1 Scope This NORSOK standard provides general principles, engineering guidance and requirements for materials selection and corrosion protection for hydrocarbon production and processing facilities and supporting systems for fixed offshore installations. This NORSOK standard also applies for onshore terminals, except for structural and civil works. This NORSOK standard gives guidance and requirements for ! corrosion and materials selection evaluations, ! specific materials selection where appropriate, ! corrosion protection, ! design limitations for specific materials, ! qualification requirements for new materials or new applications. 2 Normative and informative references The following standards include provisions and guidelines which, through reference in this text, constitute provisions and guidelines of this NORSOK standard. Latest issue of the references shall be used unless otherwise agreed. Other recognized standards may be used provided it can be shown that they meet or exceed the requirements and guidelines of the standards referenced below. 2.1 Normative references API Spec 15 HR, High Pressure Fiberglass Line Pipe. API Spec 15 LR, Low Pressure Fiberglass Line Pipe. API Spec 17J, Unbonded Flexible Pipe. ASME B 31.3, Process Piping. ASTM A153, Standard Specification for Zinc Coating (Hot Dip) on Iron and Steel Hardware. ASTM A 193, Specification for Alloy - Steel and Stainless Steel Bolting Materials for High - Temperature Service. ASTM A 194, Specification for Carbon and Alloy Steel Nuts for Bolts for High - Pressure and High- Temperature Service. ASTM A 320, Specification for Alloy Steel Bolting Materials for Low - Temperature Service. ASTM D 2992, Practice for Obtaining Hydrostatic or Pressure Design Basis for Fibreglass Pipe and Fittings. BS 4994, Specification for design and construction of vessels and tanks in reinforced plastics. BS MA 18, Salt Water Piping in Ships. DIN 16965-2, Wound glass fibre reinforced polyester resin (UP-GF) pipes, Type B pipes, dimensions. DIN 16966-1, Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joint assemblies; Fittings; general quality requirements and testing. DIN 16966-2, Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joints; Elbows; Dimensions. DIN 16966-4, Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joints; Tees, Nozzles; Dimensions. DIN 16966-5, Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joints; Reducers; Dimensions. DIN 16966-6, Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joint assemblies; Collars, flanges, joint rings; Dimensions. DIN 16966-7, Pipe joints and their elements of glass fibre reinforced polyester resins – Part 7: Bushings, flanges, flanged and butt joints; general quality requirements and test methods. DIN 16966-8, Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joints; Laminated joints; Dimensions. DNV RP B201, Metallic Materials in Drilling, Production and Process Systems. DNV OS C501, Composite components. DNV OS F101, Submarine Pipeline Systems. DNV RP F201, Dynamic risers. PED, Pressure Equipment Directive, 97/23/EC. EN 10204, Metallic products – Types of inspection documents. NORSOK standard M-001 Rev. 4, August 2004 NORSOK standard Page 4 of 30 ISO 898, Mechanical properties of fasteners. ISO 3506-1, Mechanical properties of corrosion resistant stainless steel fasteners – Part 1: Bolts, screws and studs. ISO 3506-2, Mechanical properties of corrosion resistant stainless steel fasteners – Part 2: Nuts. ISO 13623, Petroleum and natural gas industries. Pipeline transportations systems. ISO 13628-2, Petroleum and natural gas industries – Design and operation of subsea production systems – Part 2: Unbonded flexible pipe systems for subsea and marine applications. ISO 13628-5, Petroleum and natural gas industries – Design and operation of subsea production systems – Part 5: Subsea control umbilicals. ISO/DIS 13628-7, Petroleum and natural gas industries – Design and operation of subsea production systems – Part 7: Work over/completion riser systems. ISO 14692-1, Petroleum and natural gas industries - Glass reinforced plastics (GRP) piping – Part 1: Vocabulary, symbols, applications and materials. ISO 14692-2, Petroleum and natural gas industries - Glass reinforced plastics (GRP) piping – Part 2: Qualification and manufacture. ISO 14692-3, Petroleum and natural gas industries - Glass reinforced plastics (GRP) piping – Part 3: System design. ISO 14692-4, Petroleum and natural gas industries - Glass reinforced plastics (GRP) piping – Part 4: Fabrication, installation and operation. ISO 15156-1, Petroleum and natural gas industries – Materials for use in H2S-containing environments in oil and gas production – Part 1: General principles for selection of cracking-resistant materials. ISO 15156-2, Petroleum and natural gas industries – Materials for use in H2S-containing environments in oil and gas production – Part 2: Cracking-resistant carbon and low alloy steels, and the use of cast irons. ISO 15156-3, Petroleum and natural gas industries – Materials for use in H2S-containing environments in oil and gas production – Part 3: Cracking-resistant CRAs (corrosion resistant alloys) and other alloys. NS 3420, Beskrivelsestekster for bygg og anlegg (Specification texts for building and construction). NS 3472, Prosjektering av stålkonstruksjoner. Beregnings og konstruksjonsregler. NS 3473, Concrete Structures. Design Rules. NORSOK L-001, Piping and Valves. NORSOK N-004, Design of steel structures. NORSOK M-101, Structural steel fabrication. NORSOK M-102, Structural aluminium fabrication. NORSOK M-120, Material data sheets for structural steel. NORSOK M-121, Aluminium structural materials. NORSOK M-122, Cast structural steel. NORSOK M-123, Forged structural steel. NORSOK M-501, Surface preparation and protective coating. NORSOK M-503, Cathodic protection. NORSOK M-601, Welding and inspection of piping. NORSOK M-622, Fabrication and installation of GRP piping systems (draft standard). NORSOK M-630, Material data sheets for piping. NORSOK M-710, Qualification of non-metallic sealing materials and manufacturers. NORSOK R-004, Piping and Equipment Insulation. 2.2 Informative references DNV RP O501, Erosive wear in piping systems. ISO 12944-3, Paints and Varnishes – Corrosion protection of steel structures by protective paint systems - Part 3: Design considerations. ISO/DIS 13628-11, Petroleum and natural gas industries – Design and operation of subsea production systems – Part 11: Flexible pipe systems for subsae and marine applications. MTI Manual No. 3, Guideline Information on Newer Wrought Iron and Nickel-base Corrosion Resistant Alloys, Phase 1, Corrosion Test Methods. (Appendix B, Method MTI-2). NORSOK M-506, CO2 Corrosion rate calculation model. 3 Terms, definitions and abbreviations For the purposes of this NORSOK standard, the following terms, definitions and abbreviations apply. NORSOK standard M-001 Rev. 4, August 2004 NORSOK standard Page 5 of 30 3.1 Terms and definitions 3.1.1 C-glass special fibre type that is used for its chemical stability in corrosive environments 3.1.2 can verbal form used for statements of possibility and capability, whether material, physical or casual 3.1.3 CAPEX capital expenditure 3.1.4 corrosion resistant alloy alloy which in a given environment shows negligible weight loss corrosion and no significant localised corrosion nor cracking problems NOTE In this NORSOK standard it includes all metallic materials except carbon and low alloy steels and 3,5 % Ni. 3.1.5 E-glass general purpose fibre that is most used in reinforced plastics 3.1.6 ECR-glass modified E-glass fibre type with improved corrosion resistance against acids 3.1.7 free machining steel steel to which elements such as sulphur, selenium or lead, have been added intentionally to improve machinability 3.1.8 glass fibre reinforced plastic GRP composite material made of thermosetting resin and reinforced with glass fibres as defined in ISO 14692-1 3.1.9 maximum operating temperature maximum temperature predicted including deviations from normal operations, like start-up/shutdown, process flexibility, control requirements and process upsets 3.1.10 may verbal form used to indicate a course of action permissible within the limits of the standard 3.1.11 operating temperature temperature in the equipment when the plant operates at steady state condition, subject to normal variation in operating parameters 3.1.12 OPEX operational expenditure 3.1.13 oxygen equivalent mg/m3 oxygen + 0,3 mg/m3 free chlorine NORSOK standard M-001 Rev. 4, August 2004 NORSOK standard Page 6 of 30 3.1.14 pH stabilisation increase in bulk pH to reduce corrosion in condensing water systems 3.1.15 pitting resistance equivalent PRE PRE = % Chromium + 3,3 x % Molybdenum + 16 x % Nitrogen 3.1.16 shall verbal form used to indicate requirements strictly to be followed in order to conform to the standard and from which no deviation is permitted, unless accepted by all involved parties 3.1.17 should verbal form used to indicate that among several possibilities one is recommended as particularly suitable, without mentioning or excluding others, or that a certain action is preferred but not necessarily required 3.1.18 descriptors used for metallic materials Definitions of descriptors used for metallic materials in this NORSOK standard are given below. Observe that non-inclusion in the table below does not imply that a material may not be used. Generic type UNS Typical alloy composition % Cr % Ni % Mo others Carbon and low alloy steels 235a 235LT 360LT 3,5 % Ni 3,5 Martensitic stainless steels 13Cr 13 13Cr 4Ni 13 4 SM13Cr 12 6 2 C < 0,015 % S13Cr 12 6 2 17 - 4 PH S17400 17 4 Cu=4 Austenitic stainless steels 310 S31000 25 20 316 S31600 17 12 2,5 C < 0,035 6Mo (PRE " 40) S31254 N08926 N08367 20 20 21 18 25 24 6 6 6 N = 0,2 N min. 0,15 N = 0,2 904 N08904 21 25 4,5 Cu = 1,5 Superaustenite (PRE " 40) S34565S31 266 S32654 24 17 4 to 5 Mn = 6 N = 0,40 to 0,60 Duplex stainless steels 22Cr S32205 S31803 22 5,5 3 N 25Cr (PRE " 40) S32550 S32750 S32760 25 25 25 5,5 7 7 3,5 3,5 3,5 N N N Nickel base alloys Alloy C22 N26022 21 rem. 14 W = 3 Alloy C276 N10276 16 rem. 16 W = 4 Alloy 625 N06625 22 rem. 9 Nb = 4 Alloy 718 N07718 19 53 3 Nb = 5 Alloy 800H/Alloy 800HT N08810/ 21 33 - Al + Ti NORSOK standard M-001 Rev. 4, August 2004 NORSOK standard Page 7 of 30 Generic type UNS Typical alloy composition % Cr % Ni % Mo others N08811 Alloy 825 N08825 21 42 3 Ti Co-base alloys Elgiloy R30003 20 16 7 Co = 40 MP-35-N R30035 20 35 10 Ti, Co rem. Copper base alloys Cu-Ni 90-10 C70600 - 10 - Fe, Cu rem. Cu-Ni 70-30 C71500 - 31 - Fe, Cu rem. NiAl bronze C95800 - 4,5 - 9Al, Fe, Mn, Cu rem. Gun metal C90500 - - - 10Sn, Zn, Cu rem. Titanium Ti grade 2 R50400 - - - C max. 0,10 Fe max. 0,30 H max. 0,015 N max. 0,03 O max. 0,25 Ti rem. a This material does not comply with PED-requirements concerning documentation of impact toughness if specified according to NORSOK M-630. 3.2 Abbreviations AFFF aqueous film forming foams AWS American Welding Society CRA corrosion resistant alloy CSCC chloride induced stress corrosion cracking CTOD crack tip opening displacement EAM European approval of materials EC European Commission GRP glass fibre reinforced plastic HAZ heat affected zone HB Brinell hardness HRC Rockwell hardness HV Vickers hardness HVAC heating-ventilation-air conditioning MDS material data sheets MTI Materials Technology Institute of the Chemical Process Industries PED Pressure Equipment Directive PMA Particular material appraisal. PRE pitting resistance equivalent SSC sulphide stress cracking SMYS specified minimum yield strength UNS unified numbering system 4 General principles for materials selection and corrosion protection 4.1 Philosophy The materials selection process shall reflect the overall philosophy regarding design life time, cost profile (CAPEX/OPEX), inspection and maintenance philosophy, safety and environmental profile, failure risk evaluations and other specific project requirements. 4.2 Materials selection requirements Materials selection shall be optimised and provide acceptable safety and reliability. As a minimum, the following shall be considered: NORSOK standard M-001 Rev. 4, August 2004 NORSOK standard Page 8 of 30 ! corrosivity, taking into account specified operating conditions including start up and shut-down conditions; ! design life and system availability requirements; ! failure probabilities, failure modes and failure consequences for human health, environment, safety and material assets; ! resistance to brittle fracture; ! inspection and corrosion monitoring; ! access for maintenance and repair. For the final materials selection the following additional factors shall be included in the evaluation: ! priority shall be given to materials with good market availability and documented fabrication and service performance; ! the number of different materials shall be minimised considering stock, costs, interchangeability and availability of relevant spare parts. Deviations from materials selections specified in this NORSOK standard may be implemented if an overall cost, safety and reliability evaluation shows the alternative to be more beneficial. 4.3 Corrosivity evaluation and corrosion protection 4.3.1 Internal corrosion allowance A corrosion allowance of 3 mm is generally recommended for carbon steel piping, unless higher corrosion allowances are required. However, each system should be evaluated and the selected corrosion allowance be supported by corrosion evaluations. All piping classes in carbon steel grades in NORSOK L-001 have a corrosion allowance of 3 mm for standardization reasons. For submarine pipeline systems a maximum corrosion allowance of 10 mm is recommended as a general upper limit for use of carbon steel. Carbon steel can be used in pipelines where calculated inhibited annual corrosion rate is less than 10 mm divided by design life