petrobras plants conception and their material requirements · petrobras plants conception and...

DILLINGER PRESSURE VESSEL COLLOQUIUM - 2009

PETROBRAS PLANTS CONCEPTION AND THEIR

MATERIAL REQUIREMENTS

Carlos Bruno Eckstein, DSc.

PETROBRAS - RESEARCH CENTER

Basic Engineering - Equipment Design - Material Selection

PETROBRAS STRUCTURE RESUME

RESEARCH CENTER

R & D DOWNSTREAM

R & D GAS, ENERGY AND SUSTAINABLE DEVELOPMENT

R & D EXPLORATION

R & D PRODUCTION

BASIC DESIGN UPSTREAM

BASIC DESIGN DOWNSTREAM

GAS AND ENERGY

TECHNOLOGY MANAGEMENT

PRESIDENT

SERVICE DIRECTOR

ENGINEERING MATERIALSINFORMATION TECHNOLOGY

BASIC DESIGN FOR DOWNSTREAM

PETROCHEMICAL, FCCs AND

FERTILIZERS

GAS AND RENEWABLE

ENERGY

COKE AND SEPARATION PROCESSES

HYDROREFINING AND TREATMENT

PROCESSES

AUTOMATION

BASIC DESIGN for DOWNSTREAM,

GAS AND ENERGY

EQUIPMENT ENGINEERING

Thermal Design Furnaces & HE

MechanicalDesign of Furnaces

MechanicalDesign of

Pressure Vessels

MechanicalDesign of

Pipes

Material Selection

PETROBRAS REFINERIES

12 in Brazil

2 in Argentine

1 in USA

1 in Japan

REFINING CAPACITY

PROCESS CAPACITY

– 2.100.000 Barrels/day

CONSUMING NOWADAYS

– 1.800.000 Barrels/day

NEW REFINERIES IN BRAZIL

RNESTNortheast Refinery

COMPERJRio de Janeiro Petrochemical

Complex

PREMIUM 1

PREMIUM 2

PROCESS CAPACITY

2014300.000PREMIUM 2

2014600.000PREMIUM 1

2012150.000COMPERJ

2010300.000RNEST

Start OperationCapacityBarrels/day

New Refinery

PETROBRAS INVESTMENTS 2008-2012

Offshore Investments– US$ 65.1 billions

• Exploration: US$ 11.6 billions• Production: US$ 53.5 billions

Onshore Investments– US$ 42.1 billions

• Downstream: US$ 29.6 billions• Gas & Energy: US$ 6.7 billions• Petrochemical: US$ 4.3 billions• Biofuels: US$ 1.5 billions

INVESTMENTS IN DOWNSTREAM

INVESTMENTS IN DOWNSTREAM – US$ 29.6 billions

Fuel Quality

Conversion

Expansion

SMS

Ships

Pipelines

Others

US$ Millions

FUTURE CHALLENGES FOR PROCESS

AND EQUIPMENT INTEGRITY

New crudes coming:– Heavier crudes

• Tendency for higher pressure and temperature– More acid crudes

• Increase corrosion– More crudes coming from the sea

• More difficulty to remove Clorides– More crudes with high sulphur content

• Increase corrosion and H2S productionPetrobras needs to produce fuels with:– 50ppm of Sulfur until 2010.– 10ppm of Sulfur till 2014.

• For this it will be necessary to increase temperature andpressure.

• With limit in temperature because of the process.

PLANTS CONCEPTION

AtmosfericDistillation

VacuumDistillation

CokeFCCHCC

HDS / HDT

DEA DEADEA

HDS / HDT

CRUDE

DEA

H2 Gen.

CCR

SOUR WATER

INCINERATOR

SULFUR RECOVERY

Conversion

SulfurRemoval

Treatment {Special Fuel

Green Units

EQUIPMENTS FOR NOW AND NEAR FUTURE

Summary– Nowadays Petrobras is buying

equipments for:• Produce fuels with 50ppm of Sulfur;• Petrochemical Complex of Rio de Janeiro,

and• Northeast Refinery.

– For near future:• Refinery Premium 1;• Refinery Premium 2;• Fuels with 10ppm of Sulfur.

DOCUMENTATION

PETROBRAS uses three main specifications for special material application:

– I-ET-5000.00-0000-500-PPC-001 Rev. E, “Additional Requirements for CrMo and CrMoVLow Alloy Steels”.

– N-1704, “Supplementary Requirements for Pressure Vessels for Hydrogen Service ”.

– N-1706, “Design of Pressure Vessel for H2SService”.

TECHNICAL DOCUMENTATION HIERARCHY

INTERNATIONAL TECHNICAL SPECIFICATION ISSUED BY DESIGNER (CENPES)

PETROBRAS INTERNATIONAL STANDARDS

DESIGN CODES

Ex: I-ET-5000.00-0000-500-PPC-001

INTERNATIONAL MATERIAL REQUISITION ISSUED BY PETROBRAS (ENGENHARIA)

EQUIPMENT DRAWINGS ISSUED BY DESIGNER (CENPES)

Ex: I-RM-5285.00-2313-570-PEI-001

Ex: I-DE-5285.00-2313-570-PPC-001

Ex: N-1704, N1706 etc...

Ex: ASME, AD Merkblat etc...

HIGHLIGHTS FROM N-1706

NI-1706 - Design of Pressure Vessel for H2S Service

– This PETROBRAS Standard deals with minimumrequirements for design, fabrication andassembling of pressure vessels fabricated in carbonsteel subject to H2S service, to prevent:

• “Sulfide Stress Cracking” - SSC and• “Hydrogen-Induced Cracking” – HIC.

IT IS UNDER REVISION RIGHT NOW


The basic change proposal is in the “Class” for plate steels, trying to fit with the typesnormally produced by the main steelmakers.

(2) Not applicable.

(1) In accordance with NACE TM-0284.

NANANANANANANA (2)D

<2.2%≤2%<5.5%≤5%<18%≤15A - pH=3C

<1.2%≤1%<3.5%≤3%<13%≤10%A - pH=3B

<0.7%≤0.5%<2%≤1.5%<8%≤5%A - pH=3A

singlemeansinglemeansinglemean

CSRCTRCLR

Acceptance CriteriaTest solution

(1)Class

Material Class Characterization Proposal

Hardness shall be 200 HBmax., at base metal, HAZ and Weld Metal.


It will be controled too:– Carbon Equivalent for all Classes;– Sulfur 0.003% max. for Class A and 0.005% max. for

Classes B and C;– Phosphorus 0.010% max. for Class A and 0.020%

max. for Classes B and C;– Steel shall be vacuum degassed, treated to

globulization of the inclusions and Plates shallbe supplied in fully killed and normalizedcondition;

– UT examination ASTM A578;– Simulated PWHT for steels with toughness

requirement and welding procedurequalification, checking mechanical propertiesafter simulation;

– Welding Procedure Qualification shall present in all welding joint hardness < 200HB.


NI-1704 – Supplementary Requirements for Pressure Vessels for Hydrogen Service.

– This PETROBRAS Standard establishessupplementary requirements for the design, fabrication and assembly of pressure vessels for hydrogen services.

• By “hydrogen service” it is meant any service in whichthe partial pressure of hydrogen is equal to or higherthan 0.45 MPa (4.49 kgf/cm2), regardless of thetemperature.

IT IS ENTERING IN REVISION NEXT MONTHS


CLASSES OF EQUIPMENT IN HYDROGEN SERVICE

Carbon steel with less stringentrequirementsMINIMUMDH

Carbon steel with special requirementsCH

Low alloy Cr-Mo steel

⇓BH

High and low alloy Cr-Mo steel oraustenitic stainless steelMAXIMUMAH

MAIN BASE MATERIAL SUGGESTEDSEVERITYCLASS


NI-1704 MATERIAL CLASSIFICATION


Because of difficulties to update the NI-1704, it was decided to use for Cr-Mo and Cr-Mo-V steels the I-ET-5000.00-0000-500-PPC-001 “Additional Requirements for CrMo and CrMoV Low Alloy Steels”.

However, all content of NI-1704 that is not covered by I-ET-5000.00-0000-500-PPC-001, is still valid.

Nevertheless, for Carbon Steel in Hydrogen Service, all content of NI-1704 is valid.

HIGHLIGHTS FROM I-ET-5000

SCOPE– This specification covers general requirements for the

material, fabrication, welding, inspection and testingof pressurized equipments (drums, towers, reactors and heat exchangers) made of 1.25Cr-0.5Mo, 2.25Cr-1Mo and 2.25Cr-1Mo-V low alloy steel with additional requirements for:

• Equipment submitted to H2 service and temper embrittlement risk.

• Equipment submitted to H2 service without temper embrittlement risk

• Equipment submitted to temper embrittlement risk without H2 service

• Equipment submitted to creep conditions


SCOPE cont.– “Together with the requirements in this Technical

Specification, all project and construction details from PETROBRAS standard N-1704 are valid for low alloy steels. In case of conflict, this specification shall prevail over standard N-1704.”

– “Any conflict among this specification, drawings, codes etc., shall be brought to the attention of PETROBRAS in writing for clarification, prior to any action by the Manufacturer. The most rigorous (stringent) requirements shall govern until written resolution is provided by PETROBRAS.”


BASE MATERIAL (Plates, Forgings, Tubes ...)– All base materials shall comply with the same

chemical composition limits.

0.001%B0.012%P + Sn

0.003%Sb0.008%Sn

0.012%As0.007%P

0.005%S0.030%Al

0.020%Nb + Ti + V0.09-0.16%C

0.020%Nb0.60%Si

0.007%Ti0.20%Cu

0.010%V0.30%Ni

Maximum value

Maximum value

1.25Cr- ½ Mo


BASE MATERIAL (Plates, Forgings, Tubes ...)

2.25Cr-1Mo & 2.25Cr-1Mo-V

0.001%B(****)0.012%P + Sn

0.003%Sb0.010%Sn

0.010%As0.007%P

0.005%S0.025%Al

0.025%Nb+Ti+V(***)0.11-0.16%C

0.006%Nb(**)0.22%Si

0.015%Ti0. 20%Cu

0.007%V(*)0.30%Ni

Maximum value

Maximum value

(*) Except for 2.25Cr-1Mo-V follows proper ASTM limits.

(**) Except for 2.25Cr-1Mo-V value shall be 0.040 max.

(***) Except for 2.25Cr-1Mo-V, Nb +Ti value shall be 0.060 max.

(****) For 2.25Cr-1Mo-V follow value shall be 0.0015 maximum.


For equipments under Temper Embrittlementrisk, shall be controled too:– Grade 11

• J-factor: – J = (Si + Mn)×(P + Sn)×104 ≤ 150 (elem. in %wt)

• Bruscato Parameter (X): – X = (10P + 4Sn + 5Sb + As)/100 ≤ 15 ppm (elem. in ppm)

– Grade 22• J-factor:

– J = (Si + Mn)×(P + Sn)×104 ≤ 100 (elem. in %wt) • Bruscato Parameter (X):

– X = (10P + 4Sn + 5Sb + As)/100 ≤ 12 ppm (elem. in ppm)


Mechanical Properties– In addition to the provisions of the applicable

ASTM specification material tests shall beperformed in coupons submitted to heattreatments as follows:

Minimum SFPWHT

Minimum SFPWHT

Minimum and Maximum SFPWHT

Minimum* and

Maximum SFPWHT

SFPWHT Condition

Step CoolingHardnessTension TestImpact TestTest

* May be evaluated on step cooling test


Tension Test– ½ thickness. Additional ¼ thickness test for materials over

100mm thick.– Tests shall be at room and design temperature.

Creep Properties– Steelmaker shall provide creep strength curve for its own

ASTM the base material.Hardness– Shall be performed at 2mm and ¼ t with:

248Gr 22V

240Gr 22

230Gr 11

HV max.Material


Impact Test– At same locations of tensile test, at temperatures

of -18oC for Gr 11 and -30oC for Gr 22 and 22V.– Shall comply with mean value of 55J and

minimum of 47J.

Step Cooling Test– Step cooling test shall be performed on each heat.– For 2.25Cr-1Mo and 2.25Cr-1Mo-V steels, with a

sequence of three specimen impact test at –62oC, without step cooling, if the mean value 55J with individual minimum of 47J is achieved, the step cooling treatment may be waived. The impact test at -62ºC shall be witnessed by PETROBRAS representative.

– For 1.25Cr-0.5Mo with a J-Factor less or equal to 120, step cooling testing may be waived.


Extra Material Length from Steelmakers

– It is required for plates and shell forgings to be used on:• Production Test Coupons.• One coupon of the thickest shell plate (dimensions 600 x

800mm) of each equipment to be delivered to refinery with respective CMTR. In case of a group of equipment manufactured with the same heat of steel, only one coupon per heat has to be supplied.

• Corrosion gauge blocks only for reactors, at least 3 (three) representatives corrosion test coupons 300 x 300 mm x t(shell thickness).

• Welding Procedure Qualification Coupons.

Nondestructive Examination– All plates shall be ultrasonically tested in accordance with

BS EN 10160, with the Acceptance Standard for: body –class S2 and edge – class E4. UT examination on plates at steelmaker shall be performed by conventional method. Reports shall be issued and attached to CMTR.


WELDING– Manufacturer brand name of all welding consumables

and fluxes are essential variables and shall be specified in the welding procedure.

– Materials properties shall be the same as the base material and the test condition are the same.

– Screening Test• A sample of 20% of purchased WCL’s per consumable

specification, but at least one WCL, from each process shall be tested, by the pressure vessel manufacturer prior to fabrication using the parameters of the WPS (including heat treatment) intended for assembly of longitudinal or circumferential welds of main shell.

• If any test of one WCL fails, the WCL is rejected and 100% of respective remaining purchased consumable WCLs shall be tested.


WELDING– Screening Test shall include:

• Chemical composition, including X-factor;• Tensile test of all weld metal at room

temperature as per ASTM A370;• Tensile test at design temperature;• Hardness;• Charpy tests;• Acceptance criteria shall be according to

paragraphs 3.2.2.1 and 3.2.2.2.


BASE MATERIAL WELDING QUALIFICATION– WPS and PQR shall represent exactly the

combination (sequence and thickness of deposit of each process) of welding processes to be used in fabrication for different weld joints.

– Separate use of welding processes qualified in same one qualification test coupon is not allowed, as well as change in welding sequence.


BASE MATERIAL WELDING QUALIFICATION– The procedure qualification test plate shall

receive a SFPWHT (Simulated Fabrication PWHT) according to followed Table before performing mechanical testing.

Minimum SFPWHT

Minimum SFPWHT

Min and Max SFPWHT

Min and Max SFPWHT

Min and Max SFPWHT

Min and Max SFPWHT

SFPWHT Condition

Step CoolingHardnessMacro/MicroBendingTension

TestImpact Test


Tests Required– Deposited Weld Metal Chemical Analysis– Tensile properties (room and design

temperature)– Hardness test


Tests Required cont.– Macro / Micro examination – Step Cooling Test– Impact Test

The specimens shall be taken from ½ thickness of the test coupon for each process.For base metal over 100mm thick, it is required additional test specimens at ¼ and ¾ thickness.


WELD OVERLAY

– Stainless Steel TP347• Non stressed areas:

– Single pass of SS 347 deposited by ESSC or SAW, for shell and heads.

– Multi-passes of SS 347 deposited by SMAW, GTAW and FCAW, for nozzles.

– The minimum effective thickness of undiluted SS 347 deposit shall be 3mm, and maximum not exceed 6mm.


WELD OVERLAY– Stainless Steel TP347

• At high stressed areas:– First chemistry layer with SS 309L (3mm

minimum of total thickness).– PWHT;– Subsequent SS 347 chemistry layer(s)

must be deposited only after final PWHT.– The minimum effective thickness of

undiluted SS 347 deposit shall be 3mm, and maximum (309L+347) not exceed 10mm.


WELD OVERLAY– Stainless Steel TP317L, 316L or 304L

• Shall be applied in a double weld layer respecting the sequence for high stressed areas.

– Ferritic Stainless Steels• The minimum effective thickness of undiluted

ferritic stainless steel deposits shall be 3mm.• The maximum thickness of weld overlay shall

not exceed 10mm.

– Nickel and nickel base alloys• Same as Ferritic SS.


Weld Overlay Procedure Qualification– The base material to be used for qualification

shall be of the same type/grade of production material and taken from a plate, forging, piping or fitting which fulfill all requirements of this specification.

– Welding materials, overlay thickness, preheating, PWHT, and all welding parameters shall be strictly the same as those to be used on fabrication. Trademark and brand name of welding consumables are considered essential variables.

– Qualification test coupon shall be representative of weld overlay to be performed during fabrication (in particular for thickness of base material and weld position).


Weld Overlay Procedure Qualification– Ferrite Number

• Shall be within the range of FN 3 minimum (5 minimum for SS 347) to 8 (WRC Ferrite Number) based upon the certified chemical analysis and De Long Constitution Diagram for Stainless Steel Weld Metals.

– Chemical analysis• Shall be done by taking chips at two different

locations randomly selected. The chips must be taken from 1.5 and 3.0 mm below machined surfaces.

– Micro examination• Less than 4% of sigma phase after minimum

SFPWHT.


Weld Overlay Procedure Qualification– Macro examination / Hardness test survey

– Disbonding Test– Intergranular Corrosion Test– Ultrasonic Test (UT according to ASTM A578

S1 and S7)


CLADDED PLATES

– Explosion bonded cladding is not permitted.– the minimum effective thickness of clad,

without dilution, shall be 3 mm.– The base material of cladded plates shall fulfill

the requirements of chemical analysis after clad production, plus the following required tests:• Ferrite Number• Disbonding test• Shear Test and Bond Strength• Ultrasonic Test• Microstructure


PRODUCTION TESTS

– For each purchase order, Manufacturer shall prepare a Production Test Coupon Procedure.

– SHELL COURSES AND HEADS• Test Coupons for Hot Formed Plate

Material• Production Weld Coupons

– Production Weld Coupons for Shell and Heads (plate or forged)» For each reactor» For heat exchangers and other

equipment


PRODUCTION TESTS– All production weld coupons shall be cut in

three parts:• the first part shall receive a simulated heat

treatment corresponding to the maximum SFPWHT condition and shall be tested before final assembling of shell courses and heads.

• the second part shall follow the component of which it is representative during all heat treatment stages, and undergo the FPWHT with the completed equipment or of equipment section. All testing results shall be submitted for PETROBRAS before shipment of the equipment.

• the third part, shall be identical to the second part, and shall be sent to PETROBRAS together with the equipment. Manufacturer will not perform tests with this third part of test coupon.


RETEST– RETEST OF BASE MATERIALS

• According to base material manufacturer Quality Assurance System.

• In case of tests performed by equipment manufacturer, no retest is permitted.

– RETEST OF WELD CONSUMABLES• Weld Consumable Manufacturer

– Same as Base Materials.• Screening Test

– NOT ACCEPTABLE• RETEST OF WELD QUALIFICATION

– NOT ACCEPTABLE


RETEST OF WELD PRODUCTION TESTS (under discussion)

– Impact tests• When the requirements of impact tests are not met due to:

– Average value below limit without any individual specimen value failure, one retest, constituted by two sets of three samples each, may be performed;

– One individual specimen with value below the minimum individual value, one retest, constituted by two sets of three samples each, may be performed;

– Two specimens with value below the minimum individual value, one retest, constituted by three sets of three samples each, may be performed

– Three specimens with value below the minimum individual value, retests are not acceptable.

• On retesting, each individual value of the new specimens shall equal or exceed the minimum specified average value. Retest specimens shall be removed from the original test coupons. Only one retest may be performed (Retest of the retest is not acceptable).

– Tension Test• When the requirements of tension tests are not met, one retest,

constituted by two sets of two samples, may be performed. Retestspecimens shall be removed from the original test coupons. Only one retest may be performed (Retest of the retest is not acceptable).

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