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TABLE OF CONTENTS
1. INTRODUCTION ......................................................................................................................... 3
1.1 PROJECT BACKGROUND ......................................................................................... 3
2. ABBREVIATIONS AND DEFINITIONS ...................................................................................... 5
3. SCOPE OF DOCUMENT ............................................................................................................ 6
4. CORROSION MECHANISM ....................................................................................................... 7
4.1 CO2 CORROSION ....................................................................................................... 7
4.2 CORROSION AND CRACKING IN SOUR SERVICE ................................................. 8
4.2.1 H2S weight loss corrosion of carbon steel ....................................................... 8
4.2.2 Sulphide Stress Cracking (SSC) ...................................................................... 8
4.2.3 Hydrogen Induced Cracking (HIC) ................................................................... 9
4.2.4 Stress Corrosion Cracking (SCC) .................................................................... 9
4.3 NACE REQUIREMENT FOR SOUR SERVICE ......................................................... 10
4.3.1 Cracking-resistant Carbon & Low Alloy Steels as per NACE MR0175/ISO
15156-2....................................................................................................................... 11
4.4 MICROBIOLOGICALLY INFLUENCED CORROSION (MIC)................................... 13
4.5 DISSIMILAR METALS ............................................................................................... 14
4.6 CORROSION UNDER INSULATION (CUI) ............................................................... 15
5. CORROSION MONITORING .................................................................................................... 16
5.1 MONITORING AND TESTING FACILITIES .............................................................. 16

5.1.1 Monitoring Methods ...................................................................................... 17
5.1.2 Corrosion Monitoring Techniques and Equipment ..................................... 17
5.1.3 Process Monitoring ....................................................................................... 17
5.1.4 Location of Corrosion Probes and Coupons .................................................. 18
6. EXTERNAL COATING REQUIREMENT .................................................................................. 20

7. INPUT DATA AND ASSUMPTION ........................................................................................... 21
7.1 INPUT DATA .............................................................................................................. 21
7.2 GENERAL ASSUMPTIONS AND HYPOTHESIS: .................................................... 21
8. MATERIAL SELECTION .......................................................................................................... 22
8.1 MATERIAL SELECTION CRITERIA ......................................................................... 22
8.2 MATHEMATICAL MODEL USED FOR CO2 CORROSION RATE ESTIMATION ... 22
9. APPENDIX ................................................................................................................................ 24
9.1 MATERIAL SELECTION TABLE – TOPSIDES PROCESS EQUIPMENT ............... 24
9.2 MATERIAL SELECTION TABLE – TOPSIDES PROCESS PIPING ........................ 24
9.3 MATERIAL SELECTION DIAGRAMS – TOPSIDES PROCESS FACILITIES ......... 24
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1. INTRODUCTION
1.1 PROJECT BACKGROUND
Husky CNOOC Madura Ltd. (HCML hereinafter called COMPANY) plans to develop the Madura
Strait Block BD gas reserves for sales gas to buyers in Java Island. This field is located offshore
in the Madura Strait East Java, about 65 km east of Surabaya and about 16 km south of Madura
Island. The project envisages development of a wellhead platform; an offshore spread moored
converted tanker based Floating, Production, Storage and Offloading (FPSO) with gas processing
facilities and self-sufficient offsite and utility systems; Gas metering Station (GMS) at onshore; 10”
Multiphase flexible riser connecting wellhead platform to FPSO, 16” gas export flexible riser
connecting FPSO to wellhead platform (WHP) and 16” export gas pipeline from WHP to GMS.
The FPSO will provide electrical power via 6.6 KV subsea power cable and communication via
fiber optic cable to WHP.
The facility is designed for 110 MMscfd sales gas. An unmanned wellhead platform with four well
slots and two slots for future expansion would be set in 182 feet of water. The FPSO will be
located at a distance of 125 m from WHP. The well fluids would be delivered from WHP to FPSO
via a 10” multiphase flexible riser.
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At FPSO, the main process components of the gas processing facilities would include: fluids inlet
separation, gas sweetening, gas dehydration and hydrocarbon dew point control equipment,
condensate stabilization, condensate storage and export, produced water treating and disposal,
and sulfur recovery with molten sulfur export. The gas is separated from the liquids through three
stage of separation. The sour gas is treated with an amine solution to remove all H2S and some
of CO2. The sweet gas is then dehydrated to 7 lbs/mmscf to meet water dew point specifications
and enter the Dew Point Control System unit for controlling the hydrocarbon dew point. The
treated gas is then transported through a 16” flexible riser to WHP. From WHP treated gas flows
through 52 kilometer long carbon steel pipeline to a gas metering at onshore and distribution
system in East Java near Pasuruan.
The condensate from the separators is stabilized to meet sales specification and stored in tanks
integral with the FPSO Barge which will total 370 kbbls. The condensate is loaded onto shuttle
tanker for shipment to market.
Acid gas from the amine unit is processed in sulfur recovery unit to recover the sulfur in molten
form to export to molten sulfur tanker by offload hose. Molten sulfur is stored in 2 x 1500m³ tanks.
The gas exiting the LP, MP separators and Condensate Stabilization Unit is routed to the Gas
Recompression Package. The recompressed gas is then routed to the HP Separator before being
routed to the Gas Treating Unit.
The produced water coming from the HP and MP separators is de-oiled through two liquid/liquid
Hydro-cyclones, then is conveyed into the degassers together with the produced water of the
others topside facilities. After the water is de-oiled, the treated water will go to the sour water
stripper where the dissolved H2S is removed from the water using stripping column before being
disposed to the sea
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2. ABBREVIATIONS AND DEFINITIONS
Within the body of this document, the following definitions apply:
 COMPANY – BUMI ARMADA OFFSHORE HOLDING LIMITED (BAOHL)
 CLIENT – HUSKY CNOOC MADURA LIMITED
 CONTRACTOR – Direct contractors or their assigns

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3. SCOPE OF DOCUMENT
This study is to evaluate the material selection for each piece of equipment, pipes and valves of
the process topsides on Company’s Floating Production Storage and Offloading (FPSO) facilities.
The evaluation of sour service conditions and the consequent selection of the materials have
been carried out in accordance with ISO 15156 part 1, 2 and 3 2009 Ed. as described in the
following sections.
Materials selected have been reported in tables 6.1 and 6.2 attached in Appendix 9.
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4. CORROSION MECHANISM
The most likely degradation mechanisms that can cause internal damage to hydrocarbon systems
are related to:
Corrosive Agent Type of Damage

CO2 Localised & general corrosion
H2S SSC/HIC/SOHIC/SWC Cracking
SRB Localised corrosion (MIC)
In some cases, the presence of sand may cause erosion. Other factors, such as organic acids in
the fluids, affect the above mechanisms indirectly, e.g. in terms of pH.
Materials selection for the hydrocarbon systems is based on more detailed evaluation of the fluid
properties, as explained in this report.
4.1 CO2 CORROSION
CO2 is usually present in produced fluids and although it does not in itself cause the catastrophic failure
mode of cracking associated with H2S, its presence in contact with an aqueous phase nevertheless
can result in very high corrosion rates, especially where the mode of attack is localized (e.g. mesa
corrosion).
In general, carbon dioxide dissolves in water and form weak carbonic acid which causes
corrosion on carbon steels. The carbonic acid may lower the pH and sufficient quantities may promote
general corrosion and/or pitting corrosion of carbon steel. Higher partial pressures of CO2 imply
more dissolved CO2 and hence higher corrosion rates. Although it is a week acid, carbonic acid is
highly corrosive because it involves direct reduction of un-dissociated acid in the cathodic reaction and
does not need H+ as with normal acid corrosion.
CO2 corrosion occurs primarily in the form of general corrosion and three variants of localized
corrosion, i.e. pitting, mesa attack and flow-induced localized corrosion.
CO2 corrosion is influenced by a number of parameters including environmental, physical and

metallurgical variables. Notable parameters affecting CO2 corrosion include:
 Water chemistry, organic acids, pH, water wetting, hydrocarbon characteristics and phase
ratios
 CO2 and H2S content (and possible oxygen contaminants)
 Temperature & pressure
 Steel surface including corrosion film morphology, presence of wax and asphaltene
 Fluid dynamics
 Steel chemistry
All parameters are interdependent and can interact in many ways to influence CO2 corrosion.
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CO2 corrosion assessment for the applicable streams and equipments for this project was done using
De Waard and Milliams model, where partial pressure of CO2 is high and high corrosion rate are
expected, while using M-605 corrosion model tool, from Norsok, where corrosion rate is expected to
be low and to take into account the inhibition effect of glycol on corrosion rate of carbon steel.
4.2 CORROSION AND CRACKING IN SOUR SERVICE
The presence of hydrogen sulphide (H2S) influences the corrosion rate and can cause hydrogen
embrittlement, sulphide stress cracking, or other hydrogen related damage mechanisms.
4.2.1 H2S weight loss corrosion of carbon steel

Like CO2, hydrogen sulphide dissolves in water forming weak acid. It affects carbon steel in a similar
manner to that of CO2 with all influential parameters outlined earlier for CO2 corrosion affecting its
process and mechanism. The type of damage caused by H2S appears in the form of localized corrosion
or general corrosion, depending upon the type and nature of corrosion product formed.
Compared with CO2, H2S rarely causes severe weight loss corrosion in production equipment
because the corrosion reaction often leads to the formation of highly protective iron sulfide scales
on the steel surface under certain condition. However, if the film is imperfect or breakdown, it
can lead to very severe localized corrosion (pitting). The exact conditions that give rise to a protective
film and those that cause pitting are not understood well enough to accurately predict corrosion
rates in H2S-containing systems. Sour weight loss corrosion due to H2S is generally less damaging
than sweet corrosion (CO2) and can even be fully negligible.
Corrosion is further complicated in the mixed H 2S / CO 2 containing system. H 2S can either increase
CO2 corrosion by acting as a promoter of anodic dissolution through sulfide adsorption and affecting
the pH of the water or decrease sweet corrosion through the formation of a protective sulfide scale.
The exact interaction of H2S on the anodic dissolution reactions in the presence of CO2 is not fully
understood.
4.2.2 Sulphide Stress Cracking (SSC)

SSC is the cracking of a metal under the combined effect of tensile stress and corrosion in the
presence of water and hydrogen sulfide. Corrosion of the steel by the hydrogen sulfide liberates atomic
hydrogen at the metal surface which normally will combine to form molecular hydrogen and
discharge from the surface. However, hydrogen sulfide poisons the recombination steps and thus
promoting the absorption of atomic hydrogen by the steel. The atomic hydrogen then diffuses through
the steel and tends to accumulate at areas of high metal hardness and high tensile stress (either
applied or residual) and embrittles the steel. These high metal hardnesses are primarily found in the
weld deposit and weld heat-affected zones in the adjacent base metal. High metal stresses are
primarily localized stresses from residual welding stresses and poor weld joint fit-up. Therefore,
SSC can be minimized by limiting weldment hardness and by applying proper PWHT. Assessment
of the risk of SSC is based upon the NACE MR0175/ISO 15156 criteria
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4.2.3 Hydrogen Induced Cracking (HIC)
HIC happened when atomic hydrogen generated by the corrosion of steel surface enters the steel
and diffuses to voids, laminations and other internal discontinuities (such as non-metallic inclusions),
and collects as molecular hydrogen. This particularly happened to rolled steel. When more hydrogen
enters the steel, pressure rises, deforming the surrounding steel and cause blister on the surface.
The high stresses at the circumference of the blister may interact to cause linking of adjacent cracks to
form stepped cracks (step-wise cracking) or induce further cracks to form in the surrounding stress
field.
HIC can be minimized by selecting a higher quality steel (clean steel) with low inclusion content.
Increased resistance to HIC is usually achieved by lowering the sulfur content of the steel and
controlling the sulfide inclusion morphology by calcium or rare earth metal additions to produce
spheroidal sulfide shape. Base metal heat treatments such as normalizing or quenching, and
tempering above 593°C (1100°F), will increase resistance to HIC.
4.2.4 Stress Corrosion Cracking (SCC)
SCC is a brittle failure mode caused by the effect of tensile stress and a corrosive environment. SCC
can result from two different species, specifically chlorides ions and H2S, and involves an anodic
reaction in which a crack is initiated and propagated in stressed metal by dissolution of metal ions.
Metal loss continues at the leading edge of the crack until brittle fracture occurs.
This form of cracking usually occurs on passive material such as stainless steel or CRA, which known
as chloride stress corrosion cracking (CSCC). Susceptibility of CRA to CSCC increases with
increasing temperature, decreasing pH and the presence of H2S. Selection of appropriate CRAs, thus
requires consideration of the maximum temperatures, H2S content, pH and chloride content in the fluid.
Typically more severe combinations require more highly alloyed materials. NACE MR0175/ISO
15156-3:2009 gives guidance on the limitation of pH 2 S, chloride, temperature and pH for CRA
in low H2S condition. Limitation of austenitic stainless steel in H2S is shown as follow (Table A.2 of
NACE MR0175/ISO 15156-3:2009):
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However, there is also a risk of external CSCC of stainless steel components in marine
environments. With salt accumulation, stainless steel materials like 316/316L are susceptible to external
CSCC at temperature above 60°C. For more highly alloyed, the maximum operating temperature may
be increased. Typical limit for 22Cr and 25Cr duplex stainless steel are about 100°C and 110°C. CRA
shall be externally protected with suitable coating system to prevent CSCC at operating temperature
>60°C for SS316L & 100°C for 22%Cr DSS.
4.3 NACE REQUIREMENT FOR SOUR SERVICE
The requirements outlined in the ISO 15156 shall be followed if the particular streams are
categorized in “Sour Service”. The following covers some of the important requirements for the
carbon & low alloys steels and CRA that are resistant to the particular environmental cracking
mode in sour service (SCC, SWC, HIC & etc) according to ISO 15156.
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4.3.1 Cracking-resistant Carbon & Low Alloy Steels as per NACE MR0175/ISO 15156-2
The severity of the sour environment with respect to SSC of a carbon or low alloy steel can be
determined in accordance with Figure 1 in above mentioned ISO document as follow. Materials
which used in the respective region shall meet the requirements outlined in the ISO 15156-2. This
document shall be referred for more detail classification of the region of environment severity with
regard to SSC of carbon steel.
Region 0: “Sweet Service” (only negligible traces of H2S): the domain within which no specific
metallurgical precautions are needed. This Region applies to all metallic components.
Region 1: “Mild Sour Service” The domain within which minor and inexpensive precautions is
required.
Region 2: “Intermediate Sour Service” The domain within which increasing precautions is required.
Similarly, resistance to HIC and SOHIC can be achieved by the use of moderately low sulphur, clean
and micro structurally homogeneous steels.
Region 3: “Severe Sour Service" The domain within which the most stringent precautions are
necessary. Examples include materials taken from the ISO 15156 reference list. Similarly,
resistance to SWC requires steels with very low sulphur and other impurity contents, and/or calcium
treatment, and qualified by laboratory testing in the expected service conditions.
The main concerns on the CRA in H2S service are SSC, SCC and HIC. The requirements of chemical
composition, heat treatment, mechanical property, hardness, environmental & materials limits of
the particular CRA or alloys are defined in ISO 15156-3.
Material selection in H2S service shall be performed following table A.14 and A.24 of ISO 15156-3:
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Note: Pitting Resistant Equivalent (PREN) is a measurement of the localized corrosion resistance for
stainless steel containing Ni. The mathematical expression generally used is PREN= %Cr + 3.3 x %Mo +
16 x %N (w/w)
4.4 MICROBIOLOGICALLY INFLUENCED CORROSION (MIC)
Microbiologically Influenced Corrosion (MIC) is caused by various types of bacteria in the fluids, SRB
(Sulfate Reducing Bacteria) or TRB (Thiosulfate Reducing Bacteria). It is typically occurring in the
well when water injection is used, or from natural infections. From the operation feedback, the most
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likely causes/sources of MIC are as follow: drilling campaign, well service activities,
precommissioning/hydrotest activities, sump caisson and drains, vessel cleanings/topside
maintenance operations. MIC also preferable in stagnant or low flow velocity fluids; therefore a
typical guidance is to avoid fluid flow below 4m/s. Similarly, it may occur under deposits. Attack by
MIC is “severe” in that corrosion rates may be in excess of 5mm/year in carbon steels, leaving
randomly distributed local rounded pits in the surface. In order to detect and quantify the propensity for
microbial corrosion, it is necessary to quantify both the floating (planktonic) bacteria and surface-
adhering (sessile) bacteria. The API and NACE documents covering this area are:
- API RP 38: Recommended practice for biological analysis of subsurface oilfield waters
- NACE TM0194-2014: Field monitoring of bacteria growth in oilfield systems.
As good practice, it is recommended that due consideration should be given to include bacteria
sampling in the future corrosion monitoring. If bacteria are identified then chemical biocides
should be used for treatment in order to kill the bacteria infection. A sump and drain
management program should be included as part of the facilities operations. It is important that all
activities that allow ingress of water into the equipment, piping, pipeline etc, only use properly treated
(sea) water, typically hydrotesting and vessel cleaning.
4.5 DISSIMILAR METALS
Galvanic corrosion is possible in any system where dissimilar materials are joined and filled with a
conductive fluid. To overcome these problems a number of options exist;
 Install insulating gasket kits. This is appropriate where the pipework / vessels either side
of the joint are not electrically continuous via pipe supports or plant earthing, particularly
drains lines or other connections to buried lines that will require cathodic protection.
 The more noble (e.g. stainless steel) material should be coated to increase the anode to
cathode surface area ratio.
Where either of the above cannot occur, the two materials should be separated by a distance piece
of lined carbon steel for process or non metallic material for utilities.
In pipework the length of the distance piece or the depth to which the more noble section of
pipework should be coated is a minimum of 10 pipe diameters. Each dissimilar metal joint shall be
recorded on a register during detailed design and reviewed by the corrosion engineer to confirm
adequate corrosion management either through coatings, insulating joints or distance spools.
This will not apply to the majority of instrument tappings tying into carbon steel lines as only those
lines with a bulk electrolyte flow and no inhibition require consideration. Joints that operate above 80
°
C will remain dry and are unlikely to require isolation. Other dried gas service flanges should be
reviewed on a case by case basis taking account of the gas humidity and the temperature.
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4.6 CORROSION UNDER INSULATION (CUI)
Corrosion under insulation (CUI) is a severe form of localized external corrosion that occurs in
carbon and low alloy steel equipment/piping that has been insulated. This form of corrosion occurs
when water is absorbed by or collected in the insulation.
NACE SP0198-2010. provides current technology and industry practices for mitigating corrosion under
thermal insulation and fireproofing materials.
Insulated carbon steel corrodes due to:

 Infiltration of water under insulation (rain, process liquids, fire water, etc.)
 Condensation water
 Ingress of external contaminants
The insulation material may also contribute to CUI:
 Creates a crevice for water retention
 May absorb water
 May leach contaminants that increase corrosion rate
The mechanism of corrosion is the following: Water will penetrate the insulation cover, and due to the
high temperature, the water tends to evaporate, with a consequential increase in the chloride
concentration. High chloride concentrations combined with relatively high temperature from fluid in the
pipe/equipment or from heat tracing may cause a very corrosive environment and thus high corrosion
rates.
API 570, Piping Inspection Code - Inspection, Repair, Alteration, and Rerating of In-Service Piping
Systems provides guidance on how to determine which piping systems are most susceptible to CUI
(section 5.3.3.1). Additionally, the code also provides guidance on the most common locations to find CUI
(section 5.3.3.2) on those systems that are determined to be susceptible to CUI.
In order to prevent CUI, a correct selection and design of insulation material is needed, to avoid moisture
entering in contact with the insulated pipe/equipment. Application of corrosion protection, like external
coating or thermal spray aluminum represents a mitigation measure against CUI, as indicated in NACE
SP0198-2010.
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5. CORROSION MONITORING
A corrosion monitoring plan is established for all facilities likely to be subjected to corrosion failure
over their planned service life the monitoring plan is established to fulfill the main following
objectives:
 Controlling/verifying the corrosive behavior of produced fluids, when no preventive

action is implemented such as corrosion inhibition, biocide treatment, pH stabilization.
 Verifying the practical application and efficiency of preventive treatments, when they are applied.
The monitoring plan shall consist of selection of monitoring methods with regard to the
objectives indicated here above, and according to:
 The nature and severity of expected corrosion
 The areas of high risk

 The selected corrosion prevention methods
 The operating conditions
In oil and gas production, none of the available corrosion monitoring method alone can supply all
the data needed to achieve the aims cited above. The corrosion monitoring plan shall include a
combination of several methods:
 Corrosion samples: corrosion coupons (CC), bioprobes and spool piece.

 Corrosion probes: coneventional electrical resistance probes (ER), linear polarization resistance
probes (LPR), hydrogen probes (HP).
 Bacterial activity (bioprobes).
 Sampling points (SP) chemical analysis.
 Ultrasonic method, UT measurements.
5.1 MONITORING AND TESTING FACILITIES
Systems potentially at risk of corrosion will require corrosion monitoring facilities, such as corrosion
coupons or corrosion probes. Where monitoring is required, two access fittings should always be
installed for the purpose of monitoring with electrical resistance (ER) probes and corrosion coupons.
The probes and coupons shall be of a type and dimension such that the sensitive element shall be in
the water phase.
The following points shall also be taken into consideration:

 Some systems will also need sampling points for chemical analysis.
 Systems at risk of bacteria contamination will require bioprobes and/or sample points.
Other testing facilities relevant to corrosion and integrity management will be necessary in the
appropriate system.
 All carbon steel systems will require Non Destructive Testing at some point in their service
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life.
5.1.1 Monitoring Methods
Corrosion monitoring should not rely on just one method and should use any method that enables
an operator to estimate or measure the corrosion rate occurring in service of equipment, or the
corrosivity of a process stream. The main methods fall into the following categories:
a. On-line corrosion monitoring techniques to assess corrosion rates and changes
in corrosivity with time, such as electrical resistance probes, electrochemical
probes, field signature monitoring (FSM), flexible ultrasonic transducer mats
(Fleximats), bio-probes and corrosion coupons.
b. Analysis of process streams for pressure, temperature, production rates, fluid

chemistry, CO2 and H2S gas concentrations, water content, dew point, dissolved
oxygen, pH, corrosion product (Fe and/or Mn) concentrations, bio-activity, chemical
treatments (e.g. dose rate, frequency and residual levels).
Monitoring and inspection are overlapping tasks that need to be put in place to confirm:
 Actual versus predicted corrosion rates
 Process parameters are within design limits
 Correct operation of control measures
Inspection techniques include ultrasonics (UT), radiography, thermography, visual examination, dye-
penetrant and magnetic particle inspection, but detailing of inspection requirements is outside the
scope of this document.
5.1.2 Corrosion Monitoring Techniques and Equipment
The following monitoring techniques shall be used. Where corrosion monitoring is to be

performed at an identified location, access fittings should be provided for the use of both ER probe
and a corrosion coupon as a minimum.
All types of probes shall be installed at 6 o’clock position by standard 2” access fittings.
Sensitive elements shall be in the water phase and preferably flushed mounted.
The exact locations will be dependent on the space constraints on the existing facilities
5.1.3 Process Monitoring
Process monitoring for the production system should comprise:

 Flow rate (oil/water/gas)
 Temperature and pressure
 CO2 (and H2S for sour systems) in the gas phase from upstream vessels
 Water chemistry and iron/manganese counts in the water from the main pipeline
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 Solids production and sand monitoring

 Production chemical additions (rate and type) and periodic measurement of inhibitor
residuals
 Planktonic and sessile bacteria monitoring in the water from the main pipeline
 Corrosion product examination and bacteria analysis after cleaning pig runs
5.1.4 Location of Corrosion Probes and Coupons
An ER probe and a corrosion coupon should be located downstream of the HP separator water outlet to
verify adequate inhibitor injection and adequate protection of the individual CS piping. Preferably,
access fittings for corrosion probes and coupons should be mounted 1m apart in horizontal pipe, a
minimum distance of 7 pipe diameters downstream of bends/T’s, and a minimum of 10 pipe
diameters downstream of any inhibitor injection point, with the ER probe located upstream of the
coupon.
Care must be taken to ensure that there is sufficient space around the pipe for unhindered access
to install and retrieve the probe/coupon safely and reliably using a retrieval tool (typically 2-3m). The
location should also be accessible from the floor level or from adjacent walkways, or special provision
for access should be made such that scaffolding is not required.
Prior to operation, the Operator in conjunction with the Chemical Services Provider should develop
a Corrosion Monitoring Manual that comprises:
 Documentation on the locations and methods of monitoring
 Operating and maintenance instructions
 Methods of sampling and chemical analysis
 Frequency of monitoring, sampling and analysis
 Results interpretation guide
 Key performance indicators (KPIs) for each system where monitoring is performed
Recommended Locations for Corrosion Monitoring
Fluid Monitoring Location Comments

Produced water CC + ERP + SP Water outlet
To monitor the corrosiveness of
header from
produced water to the effluent treating
separator
facilities. In case corrosion occurs out of
the expectation, CI to be provided at
the inlet of HP separator.
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Piping header of
To monitor the corrosiveness of
collected liquids
produced water to the effluent treating
from condensate
facilities. In case corrosion occurs out of
stabilization
the expectation, CI to be provided at
the inlet of stabilization section
Dry gas CC + ERP Dry gas outlet

To ensure that the gas flow coming from
of glycol
the contactor is dry and to provide
contactor
indication of corrosion downstream.
Lean amines CC + ERP GTU outlet of

To monitor the corrosiveness of lean
regenerator
amines
Gas export CC + ERP Inlet export line

To monitor the delivery gas corrosivity
Lean amines CC + ERP AGE outlet of

To monitor the corrosiveness of lean
regenerator
amines
Sour water CC + ERP Sulfur recovery

Monitor the corrosiveness of sour
unit
water
Sour water CC + ERP Sour water stripper

Monitor the corrosiveness of water after
stripping
Drain water SP + Drain sumps,

To monitor the development of
Bacteria open drain
bacterial activity
countin tanks
All types of probes shall be installed at 6 o’clock position preferable, through standard 2” access
fittings.
Bacterial sampling: the counting of the bacteria development will be done by sampling the water in
the sump drum and drain tanks and numeration through a standard serial dilution test kit.
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6. EXTERNAL COATING REQUIREMENT
External coating is required when risk of CSCC of stainless steel piping and equipment is envisaged if
exposed to chlorinated atmosphere. With salt accumulation, stainless steel materials like 316/361L, DSS,
and SDSS are susceptible to external CSCC at the following operating temperature:
- Above 60°C for 316/316L as per table A2 of ISO 15156-3
- Above 232°C for Duplex and Super Duplex as per table A24 of ISO 15156-3.
In order to prevent CSCC corrosion due to marine environment, external coating is required for:
- Insulated and un-insulated austenitic materials with operating temperatures higher than 60°C
- Insulated duplex and Super Duplex SS materials with operating temperature higher than 232°C
- Insulated Super Austenitic materials with operating temperature higher than 121°C
Coating can be either high temperature resistant epoxy (Thermaline 450, Hempadur 85671, Intertherm
228HS, Tank guard storage, Epo-phen, Sigma Phenguard 930 or equal) or thermally sprayed aluminium
(TSA).
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7. INPUT DATA AND ASSUMPTION
7.1 INPUT DATA
The following input data have been considered for the selection of the materials for the equipment
and piping of the process topsides:
1. Design life: 20 years
2. Temperature, Pressure, H2S and CO2 molar fraction as per H&MB. For liquid streams,
the partial pressure of CO2 and H2S have been evaluated at the bubble point pressure of
the stream at the operating temperature, following the procedure described in ISO 15156
for the evaluation of H2S partial pressure
3. Produced Water Chemical Composition:
mg/l mg/l
Na+ 475,7 Cl- 733,7 (note 1)
Ca2+ 47 SO42- 103,7
Mg2+ 68 HCO3 - 324,6
Ba2+ 0,5 CO32- 36
Fe2+ 4 OH- 0
Note1. The chloride content of produced water has been changed from the one listed in
table 6.6 of Process Design Basis 21022-BAE-70000-PR-RP-0001, in order to balance
the ion equivalents.
7.2 GENERAL ASSUMPTIONS AND HYPOTHESIS:
1. This material selection study is based on the operating conditions (temperature, pressure
and composition) as shown on the Heat & Material Balance of reference case Year 1 –
2000BPD.
2. The effect of corrosion inhibitors has not been considered in the analysis
3. Gas phase chloride content is assumed to be less than 50 ppm (since it is assumed all
the chlorides are dissolved in the free produced water phase)
4. Gas downstream compressor unit is not corrosive because is above water dew point
5. Gas downstream TEG unit is not corrosive because dehydrated
6. Specific assumptions and hypothesis are reported in column note in the material
selection table
Doc. No : 21022-BAE-70000-PR-RP-0012
Rev No : B0
8. MATERIAL SELECTION
8.1 MATERIAL SELECTION CRITERIA
Material selection for process lines and equipment is based on the following criteria:
1. For expected corrosion allowance up to 6 mm, Carbon Steel material shall be used,
otherwise a proper CRA material shall be selected
2. For expected corrosion allowance > 6 mm, a suitable Corrosion Resistant Alloy shall be
used. Where sour service condition is verified (evaluation of sour service conditions has
been made according to ISO 15156), materials for process equipment and piping, in dry
or wet services, shall be selected according to ISO 15156 (part 1, 2 and 3) which is to
say:
 Carbon Steel material should be specified as suitable for sour service conditions
(ISO 15156 Part 2)
 CRA materials shall be chosen in accordance with ISO 15156 Part 3
CRA Materials do not require corrosion allowance. In case carbon steel clad CRA is
selected, min thickness of CRA material shall be 3 mm.
3. All carbon steel is intended as killed carbon steel (KCS). KCS is a de-oxidized carbon
steel, characterized by a high degree of chemical homogeneity and freedom from gas
porosity. Carbon content level is 0.25% (maximum)
4. Stainless steel materials shall be selected in accordance with Table A.2 of ISO 15156
Part 3. When operating temperature is higher than 60°C, external coating shall be applied
due to possible corrosion of marine environment (external chloride content higher than 50
mg/l).
5. Solid 625 is preferable to solid 825 for piping in view of alloy 625 higher mechanical
properties.
In the following tables are reported materials selected for piping and equipment of process
topsides. Material indicated in column “Material Selected” and those indicated as alternative
materials in column “Notes” shall be considered equivalent from corrosion point of view.
8.2 MATHEMATICAL MODEL USED FOR CO2 CORROSION RATE ESTIMATION
The evaluation of corrosion rate of carbon steel in CO2 saturated waters has been done
according to De Waard and Milliams formula, in the form of nomogram, where the corrosion rate
is an exponential function of CO2 partial pressure and temperature.
Doc. No : 21022-BAE-70000-PR-RP-0012
Rev No : B0
Figure 5.1 Corrosion Nomograph for carbon steel in contact with wet CO2 (De Waard - Milliams)
The nomogram has been used to evaluate the corrosion rate at the given operating temperature
and CO2 partial pressure for each equipment/piping section.
Results obtained following this approach shall be considered as “conservative case corrosion”,
and have been applied to streams and equipment where high corrosion rate is expected.
Where a more sensible analysis is required (e.g. low corrosion rate), the corrosion rate has been
evaluated considering the M-605 model tool, from Norsok, This model has been used also for
evaluation of CO2 corrosion rate of Gas dehydration Unit, to take into account the inhibition effect
of glycol (TEG) on corrosion rate of carbon steel.
Doc. No : 21022-BAE-70000-PR-RP-0012
Rev No : B0
9. APPENDIX
9.1 MATERIAL SELECTION TABLE – TOPSIDES PROCESS EQUIPMENT
The material selected for the process equipment is given in table 6.1 below. Equipment installed in Sulfur
Removal Unit is not included in this report.
9.2 MATERIAL SELECTION TABLE – TOPSIDES PROCESS PIPING
The material selected for the process piping is given in table 6.2 below. Piping installed in Sulfur Removal
Unit is not included in this report.
9.3 MATERIAL SELECTION DIAGRAMS – TOPSIDES PROCESS FACILITIES
The material selection diagram for topsides is enclosed below.

TABLE 6.1 ‐ MATERIAL SELECTION TABLE ‐ TOPSIDES PROCESS EQUIPMENT
1ST STAGE 2ND STAGE
STABILIZER 1ST STAGE COMPRESSOR 2ND STAGE COMPRESSOR AFTER 1ST STAGE 2ND STAGE
Equipment HP SEPARATOR MP SEPARATOR LP SEPARATOR COMPRESSOR COMPRESSOR CONDENSATE PREHEATER O/H STABILIZER COOLER RUNDOWN COOLER STABILIZER REBOILER
COLUMN INTERSTAGE COOLER COOLER COMPRESSOR COMPRESSOR
SCRUBBER SCRUBBER
TAG NUMBER 30‐VS‐1110 30‐VS‐1120 30‐VS‐1130 30‐CS‐1220 30‐VC‐3711 30‐VC‐3712 30‐HE‐1210A/B 30‐HE‐1230 30‐HE‐1260 30‐HR‐1240 30‐HP‐3711 30‐HE‐3712 30‐KC‐3711A/B 30‐KC‐3712A/B
SHELL SIDE TUBE SIDE SHELL SIDE TUBE SIDE SHELL SIDE TUBE SIDE SHELL SIDE TUBE SIDE HOT SIDE COLD SIDE TUBE SIDE SHELL SIDE
Phase: Liquid (L), Gas (G) L/G L/G L/G L/G L/G L/G L L/G WATER L/G WATER L L/G STEAM G/L L L/G WATER G G
Operating Temperature °C 71.6 63.5 61.6 195 40.65 44.44 195 61.60 65 45.00 65 71.92 196 204 45.00 65 45.00 41 40.65 41.07
Operating Pressure bar 83.75 27.21 9.97 6.50 6.13 23.32 6.50 9.98 HOLD 6.41 HOLD 6.32 7.01 117 24.32 HOLD 84.32 HOLD 6.613 23.32
Possible Free Water YES YES YES NO YES YES NO YES YES YES YES NO NO YES YES YES YES YES YES YES
Sour Service YES YES YES YES YES YES NO YES NO YES NO YES NO NO YES NO YES NO YES YES
CO2 Partial Pressure bar 5.6 2.4 1 0.22 0.62 2.21 0 1.1 ‐ 0.66 ‐ 0 0 ‐ 2.7 ‐ 8 ‐ 0.61 2.24
Carbon Steel CO2 Corrosion Rate mm/y > 20 10 4.8 1.8 4 4.8 ‐ 2 ‐ 0 ‐ 5 ‐ 11 ‐ 1.8 4
H2S Partial Pressure kPa 38.5 18.2 11.8 6.3 10.7 25.6 0.39 12.2 ‐ 15.4 ‐ 0,44 0.42 ‐ 43.3 ‐ 93.7 ‐ 10.6 27.5
Chloride Content mg/l >50 >50 >50 >50 <50 <50 <50 >50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50
KCS + Alloy 625 KCS + Alloy 625 KCS + Alloy 625 KCS + 3 mm CA KCS + SS316 CLAD KCS + SS316 CLAD KCS + 3 mm CA Duplex with 40 < KCS + 3 mm CA SS316 according SHELL: KCS + 3 mm CA TUBE:SA179 SHELL: KCS + 3 mm CA PLATES:Duplex with 40 < FPREN ≤ 45, TOO HIGH KCS + 3 mm SS316 according SS316 according
CLAD , according CLAD , according CLAD , according according to table according to table FPREN ≤ 45, to table A.2 of ISO TUBE:SA179 PANELS:KCS + SUPERDUPLEX LINING PRESSURE FOR to table A.2 of ISO to table A.2 of ISO
to table A.14 of to table A.14 of to table A.14 of A.2 of ISO 15156‐3 A.2 of ISO 15156‐3 according to table 15156‐3 according to table A.24 of ISO 15156‐ SS316 ‐ 600#. 15156‐3 15156‐3
ISO 15156‐3 ISO 15156‐3 ISO 15156‐3 A.24 of ISO 15156‐ 3 ALTERNATIVE
Material Selected
3 MATERIAL: SS316 ‐
900#
ALTERNATIVE ALTERNATIVE Assumed no free TUBES: TO BE TO BE

MATERIAL: Duplex MATERIAL: Duplex water and SUPERDUPLEX 25 CONFIRMED BY CONFIRMED BY
with 40 < FPREN ≤ with 40 < FPREN ≤ chloride content Cr COMPRESSOR COMPRESSOR
45, according to 45, according to >50 mg/l VENDOR VENDOR
table A.24 of ISO table A.24 of ISO dissolved in
15156‐3 15156‐3 condensate. CA to
NOTES
accomodate
condensation
corrosion during
shut downs.
DEGASSER
HP LIQUID MP LIQUID 1ST STAGE 2ND STAGE DEGASSING SOUR WATER SWS INLET GTU INLET FILTER AMINE FLASH
Equipment CONDENSATE SWS FEED PUMPS SWS COOLER ACID GAS COOLER ABSORBER LEAN/RICH AMINE EXCHANGER REGENERATOR REGENERATOR CONDENSER
HYDROCYCLONE HYDROCYCLONE DEGASSER DEGASSER VESSEL STRIPPER FILTERS SEPARATOR DRUM
PUMPS
TAG NUMBER 35‐PC‐3120 35‐VJ‐1610 35‐VJ‐1620 35‐VH‐1630 35‐VH‐1640 35‐VH‐3110 35‐CZ‐1670 35‐PC‐1650 A/B 35‐HP‐1680 35‐FF‐1660 A/B 45‐FF‐3320 A/B 45‐HE‐3310 45‐CZ‐3330 45‐VH‐3340 45‐HP‐3350 45‐CZ‐3360 45‐HP‐3370
HOT SIDE HOT SIDE COLD SIDE HOT SIDE COLD SIDE HOT SIDE COLD SIDE
Phase: Liquid (L), Gas (G) L L L L/G L/G L/G L/G L L L L/G G WATER L/G L/G L L L/G L/G L
Operating Temperature °C 65.00 71.60 63.50 71.90 71.90 65 71.90 71.90 71.50 71.90 37.78 71.60 65 37.64 57.80 128.00 57.80 99.50 99.50 65
Operating Pressure bar 2.05 83.75 27.21 4.12 2.05 2.04 2.289 3.77 2.37 3.08 83.06 83.75 HOLD 82.65 5.16 2.03 5.16 2.20 2.20 HOLD
Possible Free Water YES YES V YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES
Sour Service YES YES YES YES YES YES YES YES YES YES YES YES NO YES YES YES YES YES YES NO
CO2 Partial Pressure bar 1.1 5.6 2.3 3.2 1.51 1.1 0.22 0 1.5 5.57 5.58 ‐ 5.5 0.48 0.0012 0.48 0.88 0.88 ‐
Carbon Steel CO2 Corrosion Rate mm/y 6 > 20 10 18 10 6 2.5 9 6.5 > 20 ‐ 6.5 2.6 0.4 2.6 14.9 14.9 ‐
H2S Partial Pressure kPa 10.7 38.4 17.6 22.8 17.2 10.7 6.04 0.023 17.5 38.2 38.4 ‐ 38 3.7 0.11 3.7 14.8 14.8 ‐
Chloride Content mg/l <50 >50 >50 >50 >50 <50 >50 >50 >50 <50 <50 <50 <50 <50 <50 <50 <50 <50
CASE: KCS, SHELL: KCS + 3 SHELL: KCS + 3 KCS + Alloy 625 KCS + Alloy 625 KCS + SS316 CLAD Duplex with 30 < IMPELLER: SS316 PLATES: SS316L, CASE: CS+3mm KCS + SS316L CLAD TUBES: SS316 ‐ KCS+3mm CA KCS + SS316 CLAD SS316 + EXTERNAL SS316 PLATES AND PANELS FROM KCS + SS316 CLAD. SS316 PLATES AND PANELS FROM
IMPELLER: SS316L mm CA, WET mm CA, WET CLAD, INTERNALS: CLAD, INTERNALS: according to table FPREN ≤ 40 PANELS: KCS CA; INTERNALS: INTERNALS: SS316L 900# according to table COATING; KCS+316L LINING according to table INTERNALS: KCS+316L LINING according to table
PARTS: Alloy 625 PARTS: Alloy 625 Alloy 625, Alloy 625, A.2 of ISO 15156‐3 according to table +SS316L LINING SUPERDUPLEX according to table A.2 of ISO 15156‐3 INTERNALS: A.2 of ISO 15156‐3 SS316L A.2 of ISO 15156‐3
according to table according to table according to table A.24 of ISO 15156‐ (40<PREN<45) A.2 of ISO 15156‐3 INTERNALS: SS316L according according to table
Material Selected
A.14 of ISO 15156‐ A.14 of ISO 15156‐ A.14 of ISO 15156‐ 3 SS316L to table A.2 of ISO A.2 of ISO 15156‐3
3 3 3 15156‐3.
ALTERNATIVE ALTERNATIVE T > 60°C but PH2S < ALTERNATIVE FLAG FOR

MATERIAL: Duplex MATERIAL: Duplex 100kPa MATERIAL: REGULAR
with 40 < FPREN ≤ with 40 < FPREN ≤ SUPERDUPLEX 25 INSPECTION
45, according to 45, according to Cr‐ 600#
table A.24 of ISO table A.24 of ISO
NOTES 15156‐3 15156‐3
COMPANY CONTRACTOR DOC CLIENT PROJECT NAME FACILITY NAME LOCATION SCALE SHEET NO. PAPER SIZE
21022-BAE--70000-PR-RP-0012 MADURA FPSO TOPSIDE N.A. 25 OF 31 A3
JOB NO. DOCUMENT TITLE SUPERSEDED N.

BAB 002 1022
B0 1/7/2015 APPROVED FOR DESIGN RVK SS SRN KCG MADURA STRAIT BD MATERIAL SELECTION TABLE
CONSULTANTS
FIELD DEVELOPMENT SUPERSEDED BY N.
A1 12/12/2014 ISSUED FOR REVIEW HMS SS SRN KCG TOPSIDES PROCESS EQUIPMENT
PLANT AREA PLANT UNIT
REV DATE DESCRIPTION PREP. CHK. ENGR. APPR. N.A. N.A.

TEG TEG
CONDENSATE RECYCLE REGENERATOR REFLUX REGENERATOR LEAN AMINE BOOSTER LEAN AMINE LEAN AMINE LEAN AMINE AFTER REGENERATOR REFLUX LEAN AMINE WASH WATER WASH WATER COLDFINGER/TEG TEG REFLUX TEG STILL
Equipment LEAN AMINE COOLER TEG FEED COOLER CONTACTOR/INLE REBOILER/SURGE
PUMPS DRUM REBOILER PUMPS FILTER CARBON BED FILTER PUMPS MAIN PUMPS PUMPS MAKE UP PUMPS SURGE DRUM CONDENSER COLUMN
T KO DRUM DRUM
55‐CA‐3220/55‐ 55‐HZ‐3230/55‐VA‐ 55‐HR‐3235/55‐

TAG NUMBER 30‐PC‐3710A/B 45‐VC‐3380 45‐HR‐3390 45‐PC‐3335A/B 45‐HP‐3345 45‐FF‐3355 45‐VX‐3365 45‐FF‐3375 45‐PC‐3385 A/B 45‐PP‐3385 45‐PC‐3325A/B 45‐PP‐3315A/B 55‐HE‐3210A/B 55‐HE‐3235 55‐CS‐3235
VN‐3220 3235 VA‐3235
HOT SIDE COLD SIDE HOT SIDE COLD SIDE
Phase: Liquid (L), Gas (G) L L/G L/G L L L L L L L L L L G WATER L/G L/G L/G L/G L/G
Operating Temperature °C 40.65 45.00 128.00 84 84 65 43 43 43 45.00 45 HOLD HOLD 46.10 45 37.78 38.5 44 161 204
Operating Pressure bar 85.01 2.10 2.21 5.6 14.7 HOLD 14 13.313 12.613 2.10 11.913 HOLD HOLD 82.51 HOLD 81.82 7.013 6.513 1.313 1.313
Possible Free Water YES YES YES YES YES YES YES YES YES YES YES HOLD HOLD YES YES YES YES YES YES YES
Sour Service YES YES YES YES YES NO YES YES YES YES YES HOLD HOLD NO NO NO NO NO NO NO
CO2 Partial Pressure bar 0.64 1.7 0.0036 0 0 HOLD 0 0 0 1.7 0 HOLD HOLD 3.5 HOLD 3.5 1.38 1.35 0.03 0
Carbon Steel CO2 Corrosion Rate mm/y 1.5 3.8 0.8 HOLD 3.8 9 5 0.082 0.082
H2S Partial Pressure kPa 11.3 30.6 0.19 0.004 0.02 HOLD 0.03 0.03 0.03 30.6 0.03 HOLD HOLD 0.07 HOLD 0.07 0.03 0.03 0 0
Chloride Content mg/l <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50
CASE: KCS+3mm CA, SS316Laccording to table SHELL: KCS + 3 mm CASING: KCS IMPELLER:SS316 SS316 PLATES AND PANELS FROM KCS + 3 mmCA KCS + 3 mmCA KCS + 3 mmCA CASING: KCS CASING: KCS CASING: KCS SS316 WETTED TUBES: SS316L ‐ SHELL: KCS + 3mm KCS+ SS316 CLAD KCS+3mm CA SS316L + SS316L + KCS+3 mm CA
IMPELLER: SS316L A.2 of ISO 15156‐3. CA, TUBES: SA179 AS PER A8 MATERIAL CLASS KCS+316L LINING according to table IMPELLER:SS316 AS PER A8 WETTED IMPELLER:SS316 AS PART 900# CA UP TO 1/3 HEIGHT INTERNALS:SS316L EXTERNAL EXTERNAL INTERNALS:
INTERNALS: SS316L OF API610 A.2 of ISO 15156‐3 MATERIAL CLASS OF API610 PARTS:SS316 PER A8 MATERIAL FROM BOTTOM COATING COATING SS316L
CLASS OF API610 OF PACKING. KCS + according to table according to table
Material Selected
3mm CA ON A.2 of ISO 15156‐ A.2 of ISO 15156‐
UNCLADDED 3; TUBES: SS316L 3; INTERNALS:
SECTION SS316L
ALTERNATIVE
MATERIAL:
SUPERDUPLEX 25
Cr‐ 600#
NOTES
ANTIFOAM ANTIFOAM
GAS/GAS/LIQUID DEW POINT KO FUEL GAS FUEL GAS KO FILTER HP FLARE KO HP FLARE KO LP/ACID GAS LP/ACID GAS
Equipment STRIPPING COLUMN TEG FLASH DRUM TEG SOCK FILTERS TEG CHARCOAL FILTER TEG LEAN/RICH EXCHANGER STAND PIPE TEG PUMPS LEAN TEG COOLER CHEMICAL CHEMICAL
EXCHANGER DRUM PREHEATER DRUM SEPARATOR DRUM PUMP FLARE KO DRUM FLARE KO PUMP
STORAGE TANK INJECTION PUMP
TAG NUMBER 55‐CS‐3245 55‐VH‐3240 55‐FF‐3250 A/B 55‐FA‐3255 55‐HP‐3260 55‐VA‐3270 55‐PP‐3280 55‐HE‐3290 55‐HQ‐3310 55‐VN‐3320 55‐HS‐6110 55‐VN‐6120 55‐FF‐6130 20‐VN‐1710 20‐PC‐1720A/B 20‐VN‐1810 20‐PC‐1820A/B 45‐TA‐3310 45‐PD‐3310A/B
COLD SIDE HOT SIDE
Phase: Liquid (L), Gas (G) L/G L/G L L L/G L L L L L/G L/G G L/G G G/L L G/L L L L
Operating Temperature °C 38.5 56.10 56.10 56.142202 56.18375 201.959124 76 76 78.504567 38.63 4.17 33.51 32.50 32.50 HOLD HOLD HOLD HOLD AMB AMB
Operating Pressure bar 7.013 6.00 6.00 5.513 5.013 1.313 1.313 1.313 82.553 81.56 62.72 62.03 15.84 15.84 HOLD HOLD HOLD HOLD ATM 6.00
Possible Free Water NO YES YES YES YES YES YES YES YES NO NO NO NO NO HOLD HOLD HOLD HOLD NO NO
Sour Service NO YES YES YES YES YES YES YES YES NO NO NO NO NO HOLD HOLD HOLD HOLD NO NO
CO2 Partial Pressure bar HOLD 1.3 1.3 1.4 1.3 0.0007 0 0.0005 0.0005 3.5 2.7 2.6 0.68 0.68 HOLD HOLD HOLD HOLD 0.00 0.00
Carbon Steel CO2 Corrosion Rate mm/y 4.8 0.087 0.087 4.8 1.8 0.031 0.031 HOLD HOLD HOLD HOLD
H2S Partial Pressure kPa HOLD 0.04 0.04 0.03 0.04 0 0 0 0 0.07 0.05 0.05 0.01 0.01 HOLD HOLD HOLD HOLD 0.00 0.00
Chloride Content mg/l <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 HOLD HOLD HOLD HOLD <50 <50
KCS+3 mm CA SS316L integral or CS + KCS+3mm CA KCS+3mm CA SS316 PLATES AND PANELS FROM KCS+3mm CA SS316L SHELL: KCS + 3 mm SS316L KCS+3mm KCS+3mm CA KCS+3mm CA KCS+3mm CA KCS+ SS316L CLAD CASE: KCS, CS+ SS316L CLAD CASE: KCS, SS316L SS316L
INTERNALS: SS316 SS316L clad according to KCS+316L LINING according to table CA; TUBES:SA179 CA+EPOXY IMPELLER: SS316L IMPELLER: SS316L
table A.2 of ISO 15156‐3 A.2 of ISO 15156‐3 COATING
INTERNALS: SS316L
Material Selected
COATING NON
ESSENTIAL.
CONSIDERED ONLY
TO ACCOMODATE
MINOR
NOTES CORROSION
RESULTING FROM
DEHYDRATION
UPSET.

BAB 002 1022
CONSULTANTS

REVERSE
ANTIFOAM ANTIFOAM pH NEUTRALIZER REVERSE FLOCCULANT FLOCCULANT POUR POINT POUR POINT CORROSION CORROSION COOLING WATER COOLING WATER
pH NEUTRALIZER DEMULSIFIER SEA WATER BLOWDOWN
Equipment CHEMICAL CHEMICAL INJECTION DEMULSIFIER CHEMICAL INJECTION DEPRESSANT DEPRESSANT INHIBITOR TOTE INHIBITOR MEG TOTE TANK MEG PUMPS EXPANSION COOLING WATER COOLERS CIRCULATION
STORAGE TANK INJECTION COARSE FILTERS DRUM
STORAGE TANK INJECTION PUMP PUMPS STORAGE TANK STORAGE TANK PUMPS TOTE TANK PUMPS TANK PUMPS VESSEL PUMPS
PUMPS
TAG NUMBER 55‐TA‐3220 55‐PD‐3220A/B 55‐TA‐3210 55‐PD‐3210A/B 35‐TA‐1610 35‐PD‐1610A/B 35‐TA‐1620 35‐PD‐1620A/B 50‐TA‐6810 50‐PD‐6810A/B 50‐TA‐6820 50‐PD‐6820A/B 50‐TA‐6830 50‐PD‐6830A/B XX‐FC‐5320A/B 65‐VB‐6710 65‐HP‐6740A/B/C 65‐PC‐6720A/B/C HOLD
HOT SIDE COLD SIDE
Phase: Liquid (L), Gas (G) L L L L L L L L L L L L L L L L L L L L/G
Operating Temperature °C AMB AMB AMB AMB AMB AMB AMB AMB AMB AMB AMB AMB AMB AMB 30.00 AMB 65.00 32.2 AMB HOLD
Operating Pressure bar ATM 6.00 ATM 6.00 ATM 5.00 ATM 5.00 ATM 14.00 ATM 91.00 ATM 94.00 10.00 ATM 1.50 7.00 6 HOLD
Possible Free Water NO NO NO NO NO NO NO NO NO NO NO NO NO NO YES YES YES YES YES YES
Sour Service NO NO NO NO NO NO NO NO NO NO NO NO NO NO N0 NO NO NO NO YES
CO2 Partial Pressure bar 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 ‐ 0 0 ‐ 0 HOLD
Carbon Steel CO2 Corrosion Rate mm/y HOLD
H2S Partial Pressure kPa 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0 0 0 0 0 HOLD
Chloride Content mg/l <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 >50 <50 <50 >50 <50 <50
SS316L SS316L SS316L SS316L SS316L SS316L SS316L SS316L SS316L SS316L SS316L SS316L SS316L SS316L KCS WITH GLASS Galvanized CS PLATES: Titanium, SS316L KCS + 3mm CA
FLAKE LINING PANELS:KCS + lining
Material Selected
NOTES
STEAM SOUR WATER OFFSPEC

AMINE DRAIN CLOSED DRAIN GLYCOL SUMP HC DRAIN SUMP OPEN DRAIN AMINE DRAIN CLOSED DRAIN OPEN DRAIN SOUR WATER AMINE STORAGE SPENT AMINE
Equipment UA RECEIVER IA RECEIVER HC DRAIN SUMP CONDENSATE DIESEL PUMPS DRAIN SUMP SLOP OIL PUMP CONDENSATE
SUMP SUMP PUMP PUMP SUMP PUMP SUMP PUMP SUMP PUMP SUMP TANK STORAGE TANK TANK TANK
RETURN PUMPS PUMP TANK
TAG NUMBER HOLD 60‐VA‐5680 XX‐VA‐6430 XX‐VA‐6470 XX‐VA‐6490 XX‐YY‐57XXA/B XX‐PC‐8160 XX‐PC‐6410 XX‐PC‐6430A/B XX‐PC‐6450A/B HOLD XX‐PC‐6470A/B XX‐PC‐6490A/B HOLD HOLD HOLD HOLD 45‐TA‐3120 HOLD
Phase: Liquid (L), Gas (G) G G L L L/G L L L L L L L L L L L L L L
Operating Temperature °C 38.00 38.00 32.50 37.70 63.30 HOLD AMB 23.90 32.20 51.10 HOLD HOLD 32.20 HOLD 38.00 38.00 38.00 38.00 38.00
Operating Pressure bar 8.60 8.60 ATM ATM ATM HOLD ATM 6.70 5.80 3.20 HOLD HOLD 2.00 HOLD ATM ATM ATM ATM ATM
Possible Free Water NO NO YES YES YES YES NO YES NO YES YES YES YES YES YES YES YES YES YES
Sour Service YES YES YES YES YES NO NO NO YES YES NO YES YES YES NO YES YES NO NO
CO2 Partial Pressure bar ‐ ‐ HOLD HOLD HOLD ‐ ‐ ‐ HOLD HOLD ‐ HOLD HOLD HOLD ‐ HOLD HOLD ‐ ‐
Carbon Steel CO2 Corrosion Rate mm/y ‐ ‐ HOLD HOLD HOLD ‐ ‐ ‐ HOLD HOLD ‐ HOLD HOLD HOLD ‐ HOLD HOLD ‐ ‐
H2S Partial Pressure kPa ‐ ‐ HOLD HOLD HOLD ‐ ‐ ‐ HOLD HOLD ‐ HOLD HOLD HOLD ‐ HOLD HOLD ‐ ‐
Chloride Content mg/l <50 <50 >50 >50 >50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50
GALVANIZED GALVANIZED KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA + KCS KCS KCS SS316L SS316L SS316; SS316L SS316L KCS KCS + 1.5 mm CA KCS + 1.5 mm CA KCS + 1.5 mm CA KCS + 1.5 mm CA KCS + 1.5 mm CA
CS/KCS + 1.5 mm CS/KCS + 1.5 mm EPOXY COATING IMPELLER:PTFC + EPOXY COATING + EPOXY COATING + EPOXY COATING + EPOXY COATING
CA + INTERNAL CA + INTERNAL DIAPHGRAM/ (bottom & 1m
Material Selected COATING COATING ROTOR‐ tank wall)
STATOR:PEEK
NOTES

BAB 002 1022
CONSULTANTS

TABLE 6.1 ‐ MATERIAL SELECTION TABLE ‐ TOPSIDES PROCESS
DIESEL STORAGE OPEN DRAIN NON OPEN DRAIN HAZ. CLOSED DRAIN

Equipment SLOP OIL TANK
TANK HAZ. TANK TANK DRUM
TAG NUMBER XX‐TA‐8150 HOLD XX‐TA‐6510 XX‐TA‐6550 HOLD
Phase: Liquid (L), Gas (G) L L L L L/G
Operating Temperature °C 38.00 38.00 AMB AMB 20.00
Operating Pressure bar ATM ATM ATM ATM 50.40
Possible Free Water YES YES YES YES YES
Sour Service NO YES NO NO YES
CO2 Partial Pressure bar ‐ HOLD ‐ ‐ HOLD
Carbon Steel CO2 Corrosion Rate mm/y ‐ HOLD ‐ ‐ HOLD
H2S Partial Pressure kPa ‐ HOLD ‐ ‐ HOLD
Chloride Content mg/l <50 <50 <50 <50 <50
KCS + 1.5 mm CA KCS + 1.5 mm CA KCS + 1.5 mm CA KCS + 1.5 mm CA KCS + 3 mm CA +
+ EPOXY COATING + EPOXY COATING + EPOXY COATING + EPOXY COATING EPOXY COATING
(bottom & 1m
Material Selected tank wall)
NOTES
Equipment
TAG NUMBER
Phase: Liquid (L), Gas (G)
Operating Temperature °C
Operating Pressure bar
Possible Free Water
Sour Service
CO2 Partial Pressure bar
Carbon Steel CO2 Corrosion Rate mm/y
H2S Partial Pressure kPa
Chloride Content mg/l
Material Selected
NOTES

BAB 002 1022
CONSULTANTS

TABLE 6.2 ‐ MATERIAL SELECTION TABLE ‐ TOPSIDES PROCESS PIPING
Stream Number P1 G1 G2 G3 G4 G5 G6 G7 G14 G15 G16 G17 G18 G19 G20 G21 G22 G23 G24 G25
PRODUCED
Commodity SOUR GAS SOUR GAS SOUR GAS SOUR GAS SOUR GAS SOUR GAS SOUR GAS SOUR GAS SOUR GAS SOUR GAS SOUR GAS SOUR GAS SOUR GAS SOUR GAS SOUR GAS SOUR GAS SOUR GAS SWEET GAS SWEET GAS
FLUIDS
To 1st stage from 2nd stage
From MP From MP From LP Separator From stabilizer From stabilizer To 1st stage From 1st stage From compressor From compressor from 2nd stage from compressor From acid gas from GTU inlet from GTU From TEG feed
PIPING From well fluid From HP separator From LP separator compressor compressor
separator Separator PCV PCV column cooler compressor compressor after cooler after cooler compressor after cooler cooler filter absorber cooler
scrubber scrubber
Phase: Liquid (L), Gas (G) L/G G G G G G G L/G L/G G G L/G L/G G G L/G L/G G G L/G
Operating Temperature °C 73.05 71.50 63.50 61.50 61.60 60.60 152.00 45.00 40.65 39.95 123.60 45.00 44.44 44.44 146.30 45.00 37.78 37.64 46.16 37.78
Operating Pressure bar 83.75 83.75 27.21 24.51 9.98 8.45 6.41 6.11 6.11 6.61 24.10 23.32 23.32 23.32 85.01 84.32 84.32 82.65 82.51 81.82
Possible Free Water YES YES YES YES YES YES NO YES YES YES NO YES YES YES NO YES YES YES YES YES
Sour Service YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES NO NO
CO2 Partial Pressure bar 5.5 5.58 2.3 2 1 0.9 0.21 0.63 0.61 0.61 2.3 2.7 2.24 2.24 7.8 8 5.6 5.5 3.5 3.5
Carbon Steel CO2 Corrosion Rate mm/y > 20 > 20 10 9 4.8 4 2 1.8 1.8 5 4 4 11 6.5 6.5 9 5
H2S Partial Pressure kPa 37.1 38.5 18.2 15.8 12.2 10 6.2 14.4 10.6 10.6 40.1 43.3 27.5 27.5 96.3 93.7 38.2 38 0.07 0.07
Chloride Content mg/l >50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50
Alloy 625, SS316 + external SS316 + external SS316 + external SS316 + external SS316 + external KCS + 3 mm CA SS316 according SS316 according SS316 according KCS + 3 mm CA SS316 according SS316 according SS316 according KCS + 3 mm CA SS316 according SS316 according SS316 according SS316 + EXTERNAL SS316 according
according to table coating, according coating, according coating, according coating, according coating, according to table A.2 of ISO to table A.2 of ISO to table A.2 of ISO to table A.2 of ISO to table A.2 of ISO to table A.2 of ISO to table A.2 of ISO to table A.2 of ISO to table A.2 of ISO COATING to table A.2 of ISO
A.14 of ISO 15156‐ to table A.2 of ISO to table A.2 of ISO to table A.2 of ISO to table A.2 of ISO to table A.2 of ISO 15156‐3 15156‐3 15156‐3 15156‐3 15156‐3 15156‐3 15156‐3 15156‐3 15156‐3 according to table 15156‐3
Material Selected 3 15156‐3 15156‐3 15156‐3 15156‐3 15156‐3 A.2 of ISO 15156‐3
Piping class CA200 DS100 BS100 BS100 AS100 AS100 AC220 AS100 AS100 AS100 BC220 BS100 BS100 BS100 DC220 DS100 DS100 DS100 DS100 DS100
FLAG FOR ABOVE WATER ABOVE WATER ABOVE WATER EXTERNAL
REGULAR DEW POINT ‐ NO DEW POINT ‐ NO DEW POINT ‐ NO COATING
INSPECTION FREE WATER FREE WATER FREE WATER RECOMMENDED
BY BAB
NOTES
Stream Number G26 G27 G28 G29 G30 G31 AG4 AG5 AG6 AG7 FG1 FG2 FG3 FG4 FG5 FG6 L1 L2 L3 L4
PRODUCED PRODUCED PRODUCED PRODUCED
Commodity DRY GAS DRY GAS DRY GAS DRY GAS SALES GAS SALES GAS ACID GAS ACID GAS ACID GAS ACID GAS FUEL GAS FUEL GAS FUEL GAS FUEL GAS FUEL GAS FUEL GAS
CONDENSATE CONDENSATE CONDENSATE CONDENSATE
From From From From
from TEG To dew point KO From dew point From degassing from degassing From FG filter From FG filter From MP From MP
PIPING gas/gas/liquid gas/gas/liquid gas/gas/liquid From SWS column From SWS column gas/gas/liquid From FG heater From FG heater From FG KO drum From HP separator From HP separator
contactor drum KO drum vessel vessel separator separator spearator spearator
exchanger exchanger exchanger exchanger
Phase: Liquid (L), Gas (G) G L/G L/G G G G G G G G G G G G G G L L/G L L/G
Possible Free Water NO NO NO NO NO NO YES YES YES YES NO NO NO NO NO NO YES YES YES YES
Sour Service NO NO NO NO NO NO YES YES YES YES NO NO NO NO NO NO YES YES YES YES
CO2 Partial Pressure bar 3.5 3.5 2.7 2.7 2.6 2.6 1.1 0.8 0.22 0.15 2.6 2.6 0.68 0.68 0.67 0.67 5.58 2.5 2.3 1.1
Carbon Steel CO2 Corrosion Rate mm/y 6 5 2.3 2 > 20 15 10 5
H2S Partial Pressure kPa 0.07 0.06 0.05 0.05 0.05 0.05 10.7 7.8 6.05 4 0.05 0.05 0.01 0.01 0.01 0.01 38.5 22.8 18.2 12.4
Chloride Content mg/l <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 >50 >50 >50 >50
KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA SS316 + EXTERNAL SS316 + EXTERNAL SS316 + EXTERNAL SS316 + EXTERNAL KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA Alloy 625, Alloy 625, Alloy 625, Alloy 625,
COATING COATING COATING COATING according to table according to table according to table according to table
according to table according to table according to table according to table A.14 of ISO 15156‐ A.14 of ISO 15156‐ A.14 of ISO 15156‐ A.14 of ISO 15156‐
Material Selected A.2 of ISO 15156‐3 A.2 of ISO 15156‐3 A.2 of ISO 15156‐3 A.2 of ISO 15156‐3 3 3 3 3
Piping class CC120 CC120 CC120 CC120 CC120 CC120 AS100 AS100 AS100 AS100 CC120 CC120 AC121 AC121 AC121 AC121 CA200 BA200 BA200 AA200
FLAG FOR ALTERNATIVE ALTERNATIVE
REGULAR MATERIAL: SUPER MATERIAL: SUPER
INSPECTION DUPLEX DUPLEX
40<PREN<45 40<PREN<45
according to table according to table
NOTES A.24 of ISO 15156‐ A.24 of ISO 15156‐
3 3

BAB 002 1022
CONSULTANTS
A1 12/12/2014 ISSUED FOR REVIEW HMS SS SRN KCG PROCESS PIPING

Stream Number L5 L6 L7 L11 L12 L13 L14 L17 L17 after pump L18 L19 L20 L21 L22 L23 L24 L25 L26 L27 L28
PRODUCED PRODUCED PRODUCED STABILIZED STABILIZED STABILIZED STABILIZED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED
Commodity
CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE CONDENSATE
From 1st From condensate From 2nd stage From 2nd stage From degasser From degasser
From condensate From condensate From stabilizer from condensate from rundown from rundown From degassing From GTU inlet From GTU inlet from TEG inlet KO from TEG inlet KO
PIPING From LP separator compressor recycle pumps to From valve compressor compressor condensate condensate From DP KO drum
preheater preheater column preheater cooler cooler vessel filter filter drum drum
scrubber valve scrubber scrubber pumps pumps
Phase: Liquid (L), Gas (G) L L/G L/G L L L L L L L L L/G L L L L L/G L L/G L
Possible Free Water YES NO NO NO NO NO NO YES YES YES YES YES YES YES YES YES YES YES YES NO
Sour Service YES YES YES NO NO NO NO YES YES YES YES YES YES YES YES YES YES NO NO NO
CO2 Partial Pressure bar 1.1 0.6 0.37 0 0 0 0 2.2 0.96 5.5 2.6 3.5 1.8 2
Carbon Steel CO2 Corrosion Rate mm/y 4.8 < 0.1 < 0.1 < 0.1 4 1.6 < 0.1 < 0.1 < 0.1 6.5 3.2 5 3
H2S Partial Pressure kPa 12.2 12.8 8.7 0.14 0.44 0.54 0.45 25.6 16.8 38 22.7 0 0.04 0.05
Chloride Content mg/l >50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50
Alloy 625, KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA SS316L according SS316L according KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA SS316L according SS316L according SS316L according SS316L according KCS+3mm CA
according to table to table A.2 of ISO to table A.2 of ISO to table A.2 of ISO to table A.2 of ISO to table A.2 of ISO to table A.2 of ISO
A.14 of ISO 15156‐ 15156‐3 15156‐3 15156‐3 15156‐3 15156‐3 15156‐3
Material Selected 3
Piping class AA200 AC220 AC220 AC220 AC220 AC220 AC220 AC220 AC220 AC220 BS100 AS100 AC220 AC220 AC220 DS100 BS100 DS100 BS100 CC120
ALTERNATIVE ABOVE WATER ABOVE WATER CORROSION RATE CORROSION RATE CORROSION RATE CORROSION RATE CORROSION RATE CORROSION RATE
MATERIAL: SUPER DEW POINT ‐ NO DEW POINT ‐ NO ESTIMATED WITH ESTIMATED WITH ESTIMATED WITH ESTIMATED WITH ESTIMATED WITH ESTIMATED WITH
DUPLEX FREE WATER. CA FREE WATER. CA H2S PRESENCE H2S PRESENCE H2S PRESENCE H2S PRESENCE H2S PRESENCE H2S PRESENCE
40<PREN<45 TO ACCOMODATE TO ACCOMODATE
according to table CONDENSATION CONDENSATION
A.24 of ISO 15156‐ CORROSION CORROSION
NOTES 3 DURING SHUT DURING SHUT
DOWN. DOWN.
ALTERNATIVE ALTERNATIVE
MATERIALS: MATERIALS:
ALLOY 625 ALLOY 625
Stream Number L29 L30 L31 W1 W2 W3 W4 W11 W12 W13 W14 W15 W16 W17 W18 W19 W20 W21 W22 W23
PRODUCED PRODUCED ACID PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED PRODUCED
Commodity STRIPPED WATER STRIPPED WATER STRIPPED WATER
CONDENSATE CONDENSATE GAS/SKIMMED OIL WATER WATER WATER WATER WATER WATER WATER WATER WATER WATER WATER WATER WATER WATER
From From
From 1st/2nd From MP From HP From HP From MP From MP From 1st Stage From 1st Stage From 2nd Stage
PIPING gas/gas/liquid gas/gas/liquid From HP separator From LP separator From LP separator From SWS pumps From SWS pumps From SWS filter From SWS column From SWS cooler From SWS cooler
stage degassers separator hydrocyclone hydrocyclone hydrocyclone hydrocyclone degasser degasser degasser
exchanger exchanger
Phase: Liquid (L), Gas (G) L L/G G L L L L L L/G L L/G L L/G L L L L L L L
Possible Free Water NO NO YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES
Sour Service NO NO YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES
CO2 Partial Pressure bar 3.4 1.9 1.1 5.6 2.4 1.12 5.6 2.3 0 0 0
Carbon Steel CO2 Corrosion Rate mm/y 6 > 20 10 4.8 <0.1 > 20 8.6 < 0.1 < 0.1 < 0.1 < 0.1
H2S Partial Pressure kPa 0.07 0.05 10.6 38.5 18.2 12.1 29.8 18.1 0.023 0.02 0.016
Chloride Content mg/l <50 <50 <50 >50 >50 >50 >50 >50 >50 >50 >50 >50 >50 >50 >50 >50 >50 >50 >50 >50
KCS+3mm CA KCS +3 mm CA SS316L+EXTERNAL Alloy 625, Alloy 625, Alloy 625, CS + 3 mm CA Alloy 625, KCS + 3 mm CA Alloy 625, KCS + 3 mm CA KCS + 6 mm CA KCS + 6 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA
COATING according to table according to table according to table according to table according to table
according to table A.14 of ISO 15156‐ A.14 of ISO 15156‐ A.14 of ISO 15156‐ A.14 of ISO 15156‐ A.14 of ISO 15156‐
Material Selected A.2 of ISO 15156‐3 3 3 3 3 3
Piping class CC120 BC110 AS100 CA200 BA200 AA200 AC220 CA200 AC220 BA200 AC220 AC231 AC231 AC220 AC220 AC220 AC220 AC220 AC220 AC220
ALTERNATIVE ALTERNATIVE CORROSION RATE CORROSION RATE CORROSION RATE CORROSION RATE CORROSION RATE CORROSION RATE CORROSION RATE CORROSION RATE CORROSION RATE
MATERIAL: SUPER MATERIAL: SUPER ESTIMATED WITH ESTIMATED WITH ESTIMATED WITH ESTIMATED WITH ESTIMATED WITH ESTIMATED WITH ESTIMATED WITH ESTIMATED WITH ESTIMATED WITH
DUPLEX DUPLEX H2S PRESENCE H2S PRESENCE H2S PRESENCE H2S PRESENCE H2S PRESENCE H2S PRESENCE H2S PRESENCE H2S PRESENCE H2S PRESENCE
40<PREN<45 40<PREN<45
according to table according to table
NOTES A.24 of ISO 15156‐ A.24 of ISO 15156‐
3 3

BAB 002 1022
CONSULTANTS

Stream Number AM3 AM4 AM5 AM7 AM1 AM21 AG1 AG3 VG2 T4 VG5 T6 T7 T13 VG3 CW1‐CW23 S1‐S3 ST IA/UA N
STEAM/CONDENS
Commodity RICH AMINE RICH AMINE RICH AMINE LEAN AMINE LEAN AMINE REBOILER BOILOFF ACID GAS ACID GAS ACID GAS RICH TEG VENT GAS RICH TEG RICH TEG LEAN TEG VENT GAS COOLING WATER SEAWATER AIR NITROGEN
ATE
From GTU From TEG Steam
From GTU From GTU flash From GTU From GTU amine From GTU From Regenerator From GTU flash From TEG From TEG Reflux From TEG reflux From TEG flash From TEG flash Closed loop Seawater/cooling Instrument/Utility
PIPING lean/rich From GTU reboiler lean/rich system/condensat Utility Nitrogen
absorber drum regenerator pumps regenerator reflux drum drum contactor Condenser condenser drum drum cooling water water loop air
exchanger exchanger e return
Phase: Liquid (L), Gas (G) L/G L L/G L L G G G G L/G G L/G L L G L L G/L G G
Operating Temperature °C 57.80 57.80 96.00 128.00 45.00 128.00 99.50 45.00 84.60 38.40 106.04 56.10 56.10 76.00 56.10 35‐65 32.2‐55 204 HOLD HOLD
Operating Pressure bar 5.16 5.16 4.41 2.03 84.79 2.21 2.20 2.10 5.16 7.00 1.30 6.00 6.00 1.31 6.00 6 7 17 HOLD HOLD
Possible Free Water YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES HOLD HOLD
Sour Service YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES NO NO NO NO NO
CO2 Partial Pressure bar 0.53 0.48 3.4 0.0012 0 0.0036 0.88 1.7 0.31 1.38 0.03 1.3 1.3 0 1.3 0 HOLD 0
Not evaluated (the
model is not
applicable
Carbon Steel CO2 Corrosion Rate mm/y 2.6 2.6 > 20 0.8 14.9 3.8 4.8 0.078 1.9 0.087 0.087 4.8
because the CO2
partial pressure is
too low)
H2S Partial Pressure kPa 5.1 3.7 16.9 0.11 0.004 0.19 14.8 30.6 0.08 0.03 0.003 0.04 0.04 0 0.04 0 HOLD 0
Chloride Content mg/l <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 >50 <50 <50 <50
SS316 + EXTERNAL SS316 + EXTERNAL SS316 + EXTERNAL KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA SS316 + EXTERNAL SS316 according SS316 + EXTERNAL KCS + 3 mm CA SS316 + EXTERNAL KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA SS316 + EXTERNAL CS (GALVANIZED) CuNi/GRE KCS + 3 mm CA CS (GALVANIZED) KCS + 1.5 mm CA
COATING COATING COATING COATING to table A.2 of ISO COATING COATING COATING + 1.5 mm CA + 1.5 mm CA
according to table according to table according to table according to table 15156‐3 according to table according to table according to table
Material Selected A.2 of ISO 15156‐3 A.2 of ISO 15156‐3 A.2 of ISO 15156‐3 A.2 of ISO 15156‐3 A.2 of ISO 15156‐3 A.2 of ISO 15156‐3 A.2 of ISO 15156‐3
Piping class AS100 AS100 AS100 AC221 DC121 AC221 AS100 AS100 AS100 AC121 AS100 AC121 AC121 AC121 AS100 AC111 AN100 CC122 AC111 AC110
NOTES
Stream Number UTILITIES FLARE HEADER DRAIN DRAIN CHEMICAL CHEMICAL CHEMICAL C1 C2 C3 C4 C5 C6 CHEMICAL CHEMICAL
HC NON AMINE HC AMINE
ANTIFOAM ANTIFOAM POUR POINT POUR POINT CORROSION CORROSION REVERSE
Commodity UTILITIES DRAIN/CLOSE DRAIN/CLOSE pH NEUTRALIZER MEG MEG FLOCCULANT
CHEMICAL CHEMICAL DEPRESSANT DEPRESSANT INHIBITOR INHIBITOR DEMULSIFIER
DRAIN DRAIN
to storage To sales gas dew
HC non amine HC amine drain to Hp separator/to
PIPING Diesel/comb. Air to GTU to GDU to GDU To PPD pumps tanks/downstrea To MEG pumps point control To CI pumps To PWT To PWT
drain header header GTU
m preheater system
Phase: Liquid (L), Gas (G) G/L G/L L L L L L L L L L L L L L
Operating Temperature °C HOLD HOLD HOLD HOLD AMB AMB AMB AMB AMB AMB AMB AMB AMB AMB AMB
Operating Pressure bar HOLD HOLD HOLD HOLD 5.00 5.00 5.00 ATM 14.00 ATM 94.00 ATM 91.00 5.00 5.00
Possible Free Water HOLD HOLD HOLD HOLD NO NO NO NO NO NO NO NO NO NO NO
Sour Service HOLD HOLD HOLD YES NO NO NO NO NO NO NO NO NO NO NO
CO2 Partial Pressure bar
Carbon Steel CO2 Corrosion Rate mm/y
H2S Partial Pressure kPa
Chloride Content mg/l <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50 <50
KCS + 1.5 mm CA KCS + 3mmCA KCS + 3 mm CA KCS + 3 mm CA SS316L SS316L SS316L SS316L SS316L SS316L SS316L SS316L SS316L SS316L SS316L
Material Selected
Piping class AC110 AC220 AC220 AC220 AS100 AS100 AS100 AS100 BS100 AS100 DS100 AS100 DS100 AS100 AS100
NOTES

BAB 002 1022
CONSULTANTS

Appendix - 9.3 Material Selection Diagrams for Topsides
KCS + 3 mm CA
SS316L
SS316L
ALLOY 625
SS316L + COATING
ALLOY 625
KCS + 3 mm CA SS316L
CARBON STEEL
SS316L + COATING
SS316L CuNi/GRE
KCS + ALLOY 625 CLAD
ALLOY 625
KCS + 3 mm CA
SS316L
SS316L
SS316L
ALLOY 625
ALLOY 625
ALLOY 625
KCS + 3 mm CA KCS + 3 mm CA
ALLOY 625
ALLOY 625
CS (GALV.) + 1.5 mm CA
SHELL:KCS + 3
KCS + 3 mm CA mm CA;
TUBES:SS316
CS (GALV.) + 1.5 mm CA ALLOY 625
SS316L
CARBON STEEL
ALLOY 625 KCS + 3 mm CA KCS + 3 mm CA
CuNi/GRE
SHELL:KCS + 3
mm CA;
TUBES:SDSS
KCS + 3 mm CA
KCS + 3 mm CA
KCS + 3 mm CA
SHELL:KCS + 3
mm CA;
TUBE:SA179
KCS + 3 mm CA
KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA
SHELL:KCS + 3
mm CA;
TUBE:SA179
KCS + 3 mm CA
SS316L SS316L
ALLOY 625
SS316L
CARBON STEEL
CuNi/GRE
SS316L SS316L
KCS + 3 mm CA
KCS + 3 mm CA
SS316L + COATING
SS316L
KCS + SS136L SS316L

SS316L SS316L
CLAD PANELS:KCS +
SUPERDUPLEX SHELL:KCS + 3
LINING; mm CA;
PLATES:SUPER TUBES:SS316L
DUPLEX
SS316L + COATING SS316L CS (GALV.) + 1.5 mm CA

KCS + SS136L
CLAD
SS316L
SS316L
KCS + 3 mm CA
KCS + 3 mm CA
SS316L + COATING
SS316L + PANELS:KCS +
COATING SS316L LINING;
PLATES:SS316L
SS316L
ALLOY 625
SS316L
SS316L
SS316 CARBON STEEL
L CuNi/GRE
SS316L
WET PART:
SS136L
KCS + SS136L
KCS + SS136L
CLAD SS316L
CLAD
SS316L
IMPELLER:
SS136L KCS + 3 mm CA IMPELLER:
CS (GALV.) + 1.5 mm CA SS136L
KCS SS316L
SS316L
+ 3 mm CA
SS316L SHELL:KCS + 3 KCS + 3 mm CA

mm CA;
TUBES:SS316L
KCS + SS136L
CLAD
CS (GALV.) + 1.5 mm CA SHELL:KCS + 3

KCS + 3 mm CA
SS316L mm CA;
TUBE:SA179
KCS + 3 mm CA
KCS + SS136L
CLAD PANELS:KCS +
SS316L SS316L LINING;
PLATES:SS316L
SS316L
SS316L
KCS + 3 mm CA
PANELS:KCS +
SS316L LINING;
SS316L PLATES:SS316L
SS316L
KCS + 3 mm CA
KCS + 3 mm CA
WET PART: IMPELLER:

SS136L SS136L
KCS + 3 mm CA
KCS + 3 mm CA
WET PART:
SS136L
KCS + 3 mm CA
KCS + 3 mm CA
SS316L +
CS (GALV.) + 1.5 mm CA COATING
SHELL:KCS + 3
mm CA;
TUBE:SA179
KCS + 3 mm CA
SS316L +
KCS + 3 mm CA
KCS + SS136L COATING
CLAD
ALLOY 625
SS316L
KCS + 3 mm CA
CARBON STEEL
CuNi/GRE
KCS + 3 mm CA
SS316L +
COATING
CS (GALV.) + 1.5 mm CA KCS + 3 mm CA
KCS + 3 mm CA
KCS + 3 mm CA
KCS + 3 mm CA
SS316L SS316
L
KCS
+ 3 mm CA
KCS + 3 mm CA SS316
SHELL:KCS + 3 L
mm CA;
TUBES:SS316L
SS316
L
KCS + 3 mm CA
KCS + 3 mm CA
KCS + 3 mm CA
WET PART:
SS136L
SS316
SS316
L
L SS316
L
PANELS:KCS +
SS316L LINING;
WET PART: PLATES:SS316L
SS136L KCS
SS316 + 3 mm CA
L
KCS + 3 mm CA
SS316
L KCS + 3 mm CA
KCS
+ 3 mm CA
WET PART:
SS136L
KCS + 3 mm CA
SS316
L
SS316
L
KCS + 3 mm CA
ALLOY 625
SS316L
CARBON STEEL
CuNi/GRE
KCS + 3 mm CA
KCS + 3 mm CA
+ EPOXY
COATING
SS316
L
KCS + 3 mm CA KCS + 3 mm CA KCS + 3 mm CA
KCS + 3 mm CA
ALLOY 625
SS316L
CARBON STEEL
CuNi/GRE
KCS + 3 mm CA
KCS + 3 mm CA
KCS + 3 mm CA
KCS + 3 mm CA
KCS + 3 mm CA
KCS + 3 mm CA
KCS + 3 mm CA
ALLOY 625
CASE: KCS ALLOY 625

+ 3 mm CA;
WET PART:
ALLOY 625
ALLOY 625 KCS + 3 mm CA
SS316L +
EXTERNAL
COATING
ALLOY 625
SS316L
ALLOY 625
CARBON STEEL
KCS + 3 mm CA CuNi/GRE
SS316L +
EXTERNAL
ALLOY 625 COATING
CASE: KCS
+ 3 mm CA;
WET PART:
ALLOY 625 SS316L + EXTERNAL
ALLOY 625
COATING
SS316L +
EXTERNAL
SS316L + EXTERNAL
COATING
COATING
SS316
KCS + 3 mm CA
L
KCS +
KCS +
ALLOY 625
SS316
SS316 CLAD
CLAD
L
SS316
L WET PART:
SS136L SS316L + SS316L +
EXTERNAL EXTERNAL
COATING COATING
KCS + 3 mm CA
KCS + 3 mm CA
KCS + 3 mm CA
SS316
KCS + 6 mm CA
L KCS + 6 mm CA
KCS + KCS + 3 mm CA
ALLOY 625 IMPELLER:
SS316 CLAD SS136L
L
SS316
L WET PART:
SS136L
KCS + 3 mm CA
SS316L + EXTERNAL
COATING
SS316L + EXTERNAL
COATING
ALLOY 625
SS316L
CARBON STEEL
KCS + 3 mm CA CuNi/GRE
KCS + 3 mm CA
DUPLEX
KCS + 3 mm CA
IMPELLER:
SS136L
CASE:KCS + 3
mm CA;
INTERNALS:
SUPERDUPLEX
KCS + 3 mm CA
PANELS:KCS + KCS + 3 mm CA
SS316L LINING;
PLATES:SS316L
PANELS:KCS +
KCS + GLASS
LINING;
FLAKING
PLATES:
TITANIUM
CuNi/GRE CS (GALV.) + 1.5 mm CA
CuNi/GRE
CS (GALV.) + 1.5 mm CA CuNi/GRE
ALLOY 625
SS316L
CARBON STEEL
CS (GALV.) + 1.5 mm CA CuNi/GRE
CS (GALV.) + 1.5 mm CA CS (GALV.) + 1.5 mm CA
CS (GALV.)
CS (GALV.) + 1.5 mm CA CS (GALV.) + 1.5 mm CA CS (GALV.) + 1.5 mm CA
IMPELLER:
SS136L
ALLOY 625
SS316L
CARBON STEEL
CuNi/GRE
KCS + 3 mm CA
KCS + 3 mm CA
KCS + 3 mm CA
KCS + SS316L
CLAD
KCS + 3 mm CA
KCS + 3 mm CA
IMPELLER:
SS136L
ALLOY 625
SS316L
CARBON STEEL
CuNi/GRE
KCS + 3 mm CA
KCS + 3 mm CA
KCS + 3 mm CA
KCS + SS316L
CLAD
KCS + 3 mm CA
KCS + 3 mm CA
IMPELLER:
SS136L
ALLOY 625
SS316L
CARBON STEEL
CuNi/GRE
SS316 SS316
L L
WET PART:
SS316 SS136L
L
SS316
L
SS316
L WET PART:
SS316 SS136L
L
SS316 SS316
L L
SS316 WET PART:

L SS136L

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5.1 MONITORING AND TESTING FACILITIES .............................................................. 16

6. EXTERNAL COATING REQUIREMENT .................................................................................. 20

1.1 PROJECT BACKGROUND

2. ABBREVIATIONS AND DEFINITIONS

Within the body of this document, the following definitions apply:

 COMPANY – BUMI ARMADA OFFSHORE HOLDING LIMITED (BAOHL)

 CLIENT – HUSKY CNOOC MADURA LIMITED

 CONTRACTOR – Direct contractors or their assigns

Corrosive Agent Type of Damage

4.1 CO2 CORROSION

CO2 corrosion is influenced by a number of parameters including environmental, physical and

4.2 CORROSION AND CRACKING IN SOUR SERVICE

4.2.1 H2S weight loss corrosion of carbon steel

4.2.2 Sulphide Stress Cracking (SSC)

4.2.3 Hydrogen Induced Cracking (HIC)

4.2.4 Stress Corrosion Cracking (SCC)

4.3 NACE REQUIREMENT FOR SOUR SERVICE

4.4 MICROBIOLOGICALLY INFLUENCED CORROSION (MIC)

4.5 DISSIMILAR METALS

4.6 CORROSION UNDER INSULATION (CUI)

Insulated carbon steel corrodes due to:

 Controlling/verifying the corrosive behavior of produced fluids, when no preventive

 The nature and severity of expected corrosion

 The areas of high risk

 Corrosion samples: corrosion coupons (CC), bioprobes and spool piece.

5.1 MONITORING AND TESTING FACILITIES

The following points shall also be taken into consideration:

5.1.1 Monitoring Methods

b. Analysis of process streams for pressure, temperature, production rates, fluid

5.1.2 Corrosion Monitoring Techniques and Equipment

The following monitoring techniques shall be used. Where corrosion monitoring is to be

5.1.3 Process Monitoring

Process monitoring for the production system should comprise:

 Solids production and sand monitoring

5.1.4 Location of Corrosion Probes and Coupons

Recommended Locations for Corrosion Monitoring

Fluid Monitoring Location Comments

Dry gas CC + ERP Dry gas outlet

Lean amines CC + ERP GTU outlet of

Gas export CC + ERP Inlet export line

Lean amines CC + ERP AGE outlet of

Sour water CC + ERP Sulfur recovery

Sour water CC + ERP Sour water stripper

Drain water SP + Drain sumps,

6. EXTERNAL COATING REQUIREMENT

7. INPUT DATA AND ASSUMPTION

7.1 INPUT DATA

7.2 GENERAL ASSUMPTIONS AND HYPOTHESIS:

8.1 MATERIAL SELECTION CRITERIA

8.2 MATHEMATICAL MODEL USED FOR CO2 CORROSION RATE ESTIMATION

9.1 MATERIAL SELECTION TABLE – TOPSIDES PROCESS EQUIPMENT

9.2 MATERIAL SELECTION TABLE – TOPSIDES PROCESS PIPING

9.3 MATERIAL SELECTION DIAGRAMS – TOPSIDES PROCESS FACILITIES

The material selection diagram for topsides is enclosed below.

ALTERNATIVE ALTERNATIVE Assumed no free TUBES: TO BE TO BE

ALTERNATIVE ALTERNATIVE T > 60°C but PH2S < ALTERNATIVE FLAG FOR

21022-BAE--70000-PR-RP-0012 MADURA FPSO TOPSIDE N.A. 25 OF 31 A3

JOB NO. DOCUMENT TITLE SUPERSEDED N.

REV DATE DESCRIPTION PREP. CHK. ENGR. APPR. N.A. N.A.

55‐CA‐3220/55‐ 55‐HZ‐3230/55‐VA‐ 55‐HR‐3235/55‐

21022-BAE--70000-PR-RP-0012 MADURA FPSO TOPSIDE N.A. 26 OF 31 A3

JOB NO. DOCUMENT TITLE SUPERSEDED N.