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

PRESIDENT
SERVICE DIRECTOR

INFORMATION
TECHNOLOGY

ENGINEERING

R&D
EXPLORATION

RESEARCH CENTER

R&D
PRODUCTION

BASIC DESIGN
UPSTREAM

MATERIALS

R&D
DOWNSTREAM

BASIC DESIGN
DOWNSTREAM
GAS AND
ENERGY

R & D GAS,
ENERGY AND
SUSTAINABLE
DEVELOPMENT

TECHNOLOGY
MANAGEMENT

BASIC DESIGN FOR DOWNSTREAM

BASIC DESIGN for
DOWNSTREAM,
GAS AND ENERGY

COKE AND
SEPARATION
PROCESSES

HYDROREFINING
AND TREATMENT
PROCESSES

AUTOMATION

Thermal Design
Furnaces & HE

Mechanical
Design of
Furnaces

PETROCHEMICAL,
FCCs AND
FERTILIZERS

GAS AND
RENEWABLE
ENERGY

EQUIPMENT ENGINEERING

Mechanical
Design of
Pressure Vessels

Mechanical
Design 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

RNEST
Northeast Refinery
COMPERJ
Rio de Janeiro
Petrochemical
Complex

PREMIUM 1

PREMIUM 2

PROCESS CAPACITY

New Refinery

Capacity
Barrels/day

Start Operation

RNEST

300.000

2010

COMPERJ

150.000

2012

PREMIUM 1

600.000

2014

PREMIUM 2

300.000

2014

PETROBRAS INVESTMENTS 2008-2012

Offshore Investments
US$ 65.1 billions
Exploration:
Production:

US$ 11.6 billions

US$ 53.5 billions

Onshore Investments
US$ 42.1 billions
Downstream:
Gas & Energy:
Petrochemical:
Biofuels:

US$
US$
US$
US$

29.6 billions
6.7 billions
4.3 billions
1.5 billions

INVESTMENTS IN DOWNSTREAM

INVESTMENTS IN DOWNSTREAM US$ 29.6 billions

US$ Millions
Fuel Quality
Conversion
Expansion
SMS
Ships
Pipelines
Others

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 production

Petrobras needs to produce fuels with:

50ppm of Sulfur until 2010.
10ppm of Sulfur till 2014.
For this it will be necessary to increase temperature and
pressure.
With limit in temperature because of the process.

PLANTS CONCEPTION
Atmosferic
Distillation

CRUDE

Conversion

Sulfur
Removal
Treatment

HCC

Special Fuel
Green Units

Vacuum
Distillation

DEA
HDS / HDT

DEA
H2 Gen.

FCC

DEA
HDS / HDT

CCR
SOUR
WATER

SULFUR RECOVERY
INCINERATOR

Coke

DEA

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 CrMoV
Low Alloy Steels.
N-1704, Supplementary Requirements for
Pressure Vessels for Hydrogen Service .
N-1706, Design of Pressure Vessel for H2S
Service.

TECHNICAL DOCUMENTATION HIERARCHY

INTERNATIONAL MATERIAL REQUISITION
ISSUED BY PETROBRAS (ENGENHARIA)
Ex: I-RM-5285.00-2313-570-PEI-001

EQUIPMENT DRAWINGS ISSUED BY DESIGNER

(CENPES)
Ex: I-DE-5285.00-2313-570-PPC-001

INTERNATIONAL TECHNICAL SPECIFICATION

ISSUED BY DESIGNER (CENPES)
Ex: I-ET-5000.00-0000-500-PPC-001

PETROBRAS INTERNATIONAL STANDARDS

Ex: N-1704, N1706 etc...

DESIGN CODES
Ex: ASME, AD Merkblat etc...

HIGHLIGHTS FROM N-1706

NI-1706 - Design of Pressure Vessel for

H2S Service
This PETROBRAS Standard deals with minimum
requirements for design, fabrication and
assembling of pressure vessels fabricated in carbon
steel subject to H2S service, to prevent:
Sulfide Stress Cracking - SSC and
Hydrogen-Induced Cracking HIC.

IT IS UNDER REVISION RIGHT NOW

HIGHLIGHTS FROM N-1706

The basic change proposal is in the Class for

plate steels, trying to fit with the types
normally produced by the main steelmakers.
Material Class Characterization Proposal
Class

Test
solution
(1)

Acceptance Criteria
CLR

CTR

CSR

mean

single

mean

single

mean

single

A - pH=3

5%

<8%

1.5%

<2%

0.5%

<0.7%

A - pH=3

10%

<13%

3%

<3.5%

1%

<1.2%

A - pH=3

15

<18%

5%

<5.5%

2%

<2.2%

NA (2)

NA

NA

NA

NA

NA

NA

(1) In accordance with NACE TM-0284.

(2) Not applicable.

Hardness shall be 200 HBmax., at base metal,

HAZ and Weld Metal.

HIGHLIGHTS FROM N-1706

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 shall
be supplied in fully killed and normalized
condition;
UT examination ASTM A578;
Simulated PWHT for steels with toughness
requirement and welding procedure
qualification, checking mechanical properties
after simulation;
Welding Procedure Qualification shall present in
all welding joint hardness < 200HB.

HIGHLIGHTS FROM N-1704

NI-1704 Supplementary Requirements for

Pressure Vessels for Hydrogen Service.
This PETROBRAS Standard establishes
supplementary requirements for the design,
fabrication and assembly of pressure vessels for
hydrogen services.
By hydrogen service it is meant any service in which
the partial pressure of hydrogen is equal to or higher
than 0.45 MPa (4.49 kgf/cm2), regardless of the
temperature.

IT IS ENTERING IN REVISION
NEXT MONTHS

HIGHLIGHTS FROM N-1704

CLASSES OF EQUIPMENT IN HYDROGEN

SERVICE
CLASS

SEVERITY

AH

MAXIMUM

BH

CH

DH

MINIMUM

MAIN BASE MATERIAL

SUGGESTED
High and low alloy Cr-Mo steel or
austenitic stainless steel
Low alloy Cr-Mo steel
Carbon steel with special
requirements
Carbon steel with less stringent
requirements

HIGHLIGHTS FROM N-1704

NI-1704 MATERIAL CLASSIFICATION

HIGHLIGHTS FROM N-1704

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-PPC001 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-PPC001, 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 testing
of 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

HIGHLIGHTS FROM I-ET-5000

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.

HIGHLIGHTS FROM I-ET-5000

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

All base materials shall comply with the same

chemical composition limits.

1.25Cr- Mo
Maximum
value

Maximum
value

Ni

0.30%

0.010%

Cu

0.20%

Ti

0.007%

Si

0.60%

Nb

0.020%

0.09-0.16%

Nb + Ti + V

0.020%

Al

0.030%

0.005%

0.007%

As

0.012%

Sn

0.008%

Sb

0.003%

P + Sn

0.012%

0.001%

HIGHLIGHTS FROM I-ET-5000

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

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

Maximum
value

Maximum
value

Ni

0.30%

V(*)

0.007%

Cu

0. 20%

Ti

0.015%

Si

0.22%

Nb(**)

0.006%

0.11-0.16%

Nb+Ti+V(***)

0.025%

Al

0.025%

0.005%

0.007%

As

0.010%

Sn

0.010%

Sb

0.003%

P + Sn

0.012%

B(****)

0.001%

(*) Except for 2.25Cr1Mo-V follows proper

ASTM limits.
(**) Except for 2.25Cr1Mo-V value shall be
0.040 max.
(***) Except for 2.25Cr1Mo-V, Nb +Ti value
shall be 0.060 max.
(****) For 2.25Cr-1Mo-V
follow value shall be
0.0015 maximum.

HIGHLIGHTS FROM I-ET-5000

For equipments under Temper Embrittlement

risk, 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)

HIGHLIGHTS FROM I-ET-5000

Mechanical Properties
In addition to the provisions of the applicable
ASTM specification material tests shall be
performed in coupons submitted to heat
treatments as follows:
Test

Impact Test

Tension Test

Hardness

Step Cooling

SFPWHT
Condition

Minimum*
and
Maximum
SFPWHT

Minimum and
Maximum
SFPWHT

Minimum
SFPWHT

Minimum
SFPWHT

* May be evaluated on step cooling test

HIGHLIGHTS FROM I-ET-5000

Tension Test
thickness. Additional 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 t with:
Material

HV max.

Gr 11

230

Gr 22

240

Gr 22V

248

HIGHLIGHTS FROM I-ET-5000

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 -62C 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.

HIGHLIGHTS FROM I-ET-5000

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.

HIGHLIGHTS FROM I-ET-5000

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 WCLs 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.

HIGHLIGHTS FROM I-ET-5000

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.

HIGHLIGHTS FROM I-ET-5000

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.

HIGHLIGHTS FROM I-ET-5000

BASE MATERIAL WELDING

QUALIFICATION
The procedure qualification test plate shall
receive a SFPWHT (Simulated Fabrication
PWHT) according to followed Table before
performing mechanical testing.

SFPWHT
Condition

Impact Test

Tension
Test

Bending

Macro/Micro

Hardness

Step
Cooling

Min and Max

SFPWHT

Min and Max

SFPWHT

Min and Max

SFPWHT

Min and Max

SFPWHT

Minimum
SFPWHT

Minimum
SFPWHT

HIGHLIGHTS FROM I-ET-5000

Tests Required
Deposited Weld Metal Chemical Analysis
Tensile properties (room and design
temperature)
Hardness test

HIGHLIGHTS FROM I-ET-5000

Tests Required cont.

Macro / Micro examination

Step Cooling Test
Impact Test

The specimens shall be taken from thickness

of the test coupon for each process.
For base metal over 100mm thick, it is required
additional test specimens at and thickness.

HIGHLIGHTS FROM I-ET-5000

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.

HIGHLIGHTS FROM I-ET-5000

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.

HIGHLIGHTS FROM I-ET-5000

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.

HIGHLIGHTS FROM I-ET-5000

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).

HIGHLIGHTS FROM I-ET-5000

Weld Overlay Procedure Qualification

Ferrite Number

Chemical analysis

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.
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.

HIGHLIGHTS FROM I-ET-5000

Weld Overlay Procedure Qualification

Macro examination / Hardness test survey

Disbonding Test
Intergranular Corrosion Test
Ultrasonic Test (UT according to ASTM A578
S1 and S7)

HIGHLIGHTS FROM I-ET-5000

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

HIGHLIGHTS FROM I-ET-5000

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

HIGHLIGHTS FROM I-ET-5000

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.

HIGHLIGHTS FROM I-ET-5000

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

HIGHLIGHTS FROM I-ET-5000

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. Retest
specimens shall be removed from the original test coupons. Only one
retest may be performed (Retest of the retest is not acceptable).