Dpvc 09 Petrobras

8/9/2019 Dpvc 09 Petrobras

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DILLINGER PRESSURE VESSEL COLLOQUIUM - 2009

PETROBRAS PLANTS

CONCEPTION AND THEIRMATERIAL REQUIREMENTS

Carlos Bruno Eckstein, DSc.

PETROBRAS - RESEARCH CENTERBasic Engineering - Equipment Design - Material Selection


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PETROBRAS STRUCTURE RESUME

RESEARCH CENTER

R & D

DOWNSTREAM

R & D GAS,

ENERGY AND

SUSTAINABLE

DEVELOPMENT

R & D

EXPLORATION

R & D

PRODUCTION

BASIC DESIGN

UPSTREAM

BASIC DESIGN

DOWNSTREAM

GAS AND

ENERGY

TECHNOLOGY

MANAGEMENT

PRESIDENT

SERVICE DIRECTOR

ENGINEERING MATERIALSINFORMATION

TECHNOLOGY


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BASIC DESIGN FOR DOWNSTREAM

PETROCHEMICAL,FCCs AND

FERTILIZERS

GAS ANDRENEWABLE

ENERGY

COKE ANDSEPARATION

PROCESSES

HYDROREFININGAND TREATMENT

PROCESSES

AUTOMATION

BASIC DESIGN forDOWNSTREAM,

GAS AND ENERGY

EQUIPMENT ENGINEERING

Thermal DesignFurnaces & HE

MechanicalDesign ofFurnaces

MechanicalDesign of

Pressure Vessels

MechanicalDesign of

Pipes

MaterialSelection


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PETROBRAS REFINERIES

12 in Brazil

2 in Argentine

1 in USA

1 in Japan


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REFINING CAPACITY

PROCESS CAPACITY

– 2.100.000 Barrels/day

CONSUMING NOWADAYS

– 1.800.000 Barrels/day


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NEW REFINERIES IN BRAZIL

RNEST

Northeast Refinery

COMPERJ

Rio de JaneiroPetrochemical

Complex

PREMIUM 1

PREMIUM 2


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PROCESS CAPACITY

2014300.000PREMIUM 2

2014600.000PREMIUM 1

2012150.000COMPERJ

2010300.000RNEST

Start OperationCapacity

Barrels/dayNew Refinery


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PETROBRAS INVESTMENTS 2008-2012

Offshore Investments

– US$ 65.1 billions

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

Onshore Investments– US$ 42.1 billions

• Downstream: US$ 29.6 billions

• Gas & Energy: US$ 6.7 billions

• Petrochemical: US$ 4.3 billions

• Biofuels: US$ 1.5 billions


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INVESTMENTS IN DOWNSTREAM

INVESTMENTS IN DOWNSTREAM – US$ 29.6 billions

Fuel Quality

Conversion

Expansion

SMS

Ships

Pipelines

Others

US$ Millions


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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.


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PLANTS CONCEPTION

AtmosfericDistillation VacuumDistillation

CokeFCCHCC

HDS / HDT

DEA DEADEA

HDS / HDT

CRUDE

DEA

H2 Gen.

CCR

SOUR

WATER INCINERATOR

SULFUR RECOVERY

Conversion

Sulfur Removal

Treatment {

Special Fuel

Green Units


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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


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DOCUMENTATION

PETROBRAS uses three main specifications forspecial material application:

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

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

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

TECHNICAL DOCUMENTATION HIERARCHY


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TECHNICAL DOCUMENTATION HIERARCHY

INTERNATIONAL TECHNICAL SPECIFICATIONISSUED BY DESIGNER (CENPES)

PETROBRAS INTERNATIONAL STANDARDS

DESIGN CODES

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

INTERNATIONAL MATERIAL REQUISITIONISSUED BY PETROBRAS (ENGENHARIA)

EQUIPMENT DRAWINGS ISSUED BY DESIGNER(CENPES)

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

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

Ex: N-1704, N1706 etc...

Ex: ASME, AD Merkblat etc...

HIGHLIGHTS FROM N 1706


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HIGHLIGHTS FROM N-1706

NI-1706 - Design of Pressure Vessel forH2S Service

– This PETROBRAS Standard deals with minimum

requirements for design, fabrication and

assembling of pressure vessels fabricated in carbonsteel subject to H2S service, to prevent:

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

IT IS UNDER REVISION RIGHT NOW



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

(2) Not applicable.

(1) In accordance with NACE TM-0284.

NANANANANANANA (2)D


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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 toglobulization of the inclusions and Plates shall

be supplied in fully killed and normalizedcondition;

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

requirement and welding procedurequalification, checking mechanical propertiesafter simulation;

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



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

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

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

IT IS ENTERING IN REVISION

NEXT MONTHS



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CLASSES OF EQUIPMENT IN HYDROGENSERVICE

Carbon steel with less stringent

requirementsMINIMUMDH

Carbon steel with specialrequirements

CH

Low alloy Cr-Mo steel

BH

High and low alloy Cr-Mo steel oraustenitic stainless steel

MAXIMUMAH

MAIN BASE MATERIALSUGGESTEDSEVERITYCLASS



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NI-1704 MATERIAL CLASSIFICATION



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Because of difficulties to update the NI-1704,it was decided to use for Cr-Mo and Cr-Mo-Vsteels the I-ET-5000.00-0000-500-PPC-

001 “Additional Requirements for CrMo andCrMoV Low Alloy Steels”.

However, all content of NI-1704 that is notcovered by I-ET-5000.00-0000-500-PPC-001, is still valid.

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

HIGHLIGHTS FROM I-ET-5000


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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 andheat 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 temperembrittlement risk.

• Equipment submitted to H2 service without temper

embrittlement risk

• Equipment submitted to temper embrittlement risk without

H2 service

• Equipment submitted to creep conditions



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

Specification, all project and construction details

from PETROBRAS standard N-1704 are valid forlow alloy steels. In case of conflict, thisspecification shall prevail over standard N-1704.”

– “Any conflict among this specification, drawings,

codes etc., shall be brought to the attention ofPETROBRAS in writing for clarification, prior toany action by the Manufacturer. The most

rigorous (stringent) requirements shall governuntil written resolution is provided byPETROBRAS.”



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

0.001%B0.012%P + Sn

0.003%Sb0.008%Sn

0.012%As0.007%P

0.005%S0.030%Al

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

0.020%Nb0.60%Si

0.007%Ti0.20%Cu

0.010%V0.30%Ni

Maximumvalue

Maximumvalue

1.25Cr- ½ Mo



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

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

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

0.003%Sb0.010%Sn

0.010%As0.007%P

0.005%S0.025%Al

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

0.006%Nb(**)0.22%Si

0.015%Ti0. 20%Cu

0.007%V(*)0.30%Ni

Maximumvalue

Maximumvalue

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

ASTM limits.

(**) Except for 2.25Cr-

1Mo-V value shall be

0.040 max.

(***) Except for 2.25Cr-

1Mo-V, Nb +Ti valueshall be 0.060 max.

(****) For 2.25Cr-1Mo-V

follow value shall be0.0015 maximum.



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For equipments under Temper Embrittlementrisk, shall be controled too:

– Grade 11

• J-factor:

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

• Bruscato Parameter (X):

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

– Grade 22

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

• Bruscato Parameter (X):

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



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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:

Minimum

SFPWHT

Minimum

SFPWHT

Minimum and

MaximumSFPWHT

Minimum*and

MaximumSFPWHT

SFPWHT

Condition

Step CoolingHardnessTension TestImpact TestTest

* M a y b e e v a l u a t e d o n s t e p c o o l i n g t e s t



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

100mm thick.

– Tests shall be at room and design temperature.Creep Properties

– Steelmaker shall provide creep strength curve for its own

ASTM the base material.Hardness

– Shall be performed at 2mm and ¼ t with:

248Gr 22V

240Gr 22

230Gr 11

HV max.Material



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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 andminimum of 47J.

Step Cooling Test

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

sequence of three specimen impact test at –62oC,

without step cooling, if the mean value 55J with

individual minimum of 47J is achieved, the step cooling

treatment may be waived. The impact test at -62ºC shall

be witnessed by PETROBRAS representative.

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



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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 x800mm) of each equipment to be delivered to refinery withrespective CMTR. In case of a group of equipmentmanufactured with the same heat of steel, only one couponper 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 withBS EN 10160, with the Acceptance Standard for: body –class S2 and edge – class E4. UT examination on plates atsteelmaker shall be performed by conventional method.Reports shall be issued and attached to CMTR.



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WELDING – Manufacturer brand name of all welding consumables

and fluxes are essential variables and shall be specifiedin the welding procedure.

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

– Screening Test

• A sample of 20% of purchased WCL’s per consumablespecification, but at least one WCL, from each processshall be tested, by the pressure vessel manufacturer priorto fabrication using the parameters of the WPS (including

heat treatment) intended for assembly of longitudinal orcircumferential welds of main shell.

• If any test of one WCL fails, the WCL is rejected and100% of respective remaining purchased consumableWCLs shall be tested.



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WELDING– Screening Test shall include:

• Chemical composition, including X-factor;

• Tensile test of all weld metal at roomtemperature as per ASTM A370;

• Tensile test at design temperature;• Hardness;

• Charpy tests;

• Acceptance criteria shall be according toparagraphs 3.2.2.1 and 3.2.2.2.



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BASE MATERIAL WELDINGQUALIFICATION

– WPS and PQR shall represent exactly thecombination (sequence and thickness ofdeposit of each process) of welding

processes to be used in fabrication fordifferent weld joints.

– Separate use of welding processes

qualified in same one qualification testcoupon is not allowed, as well as changein welding sequence.



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BASE MATERIAL WELDINGQUALIFICATION

– The procedure qualification test plate shallreceive a SFPWHT (Simulated Fabrication

PWHT) according to followed Table before

performing mechanical testing.

Minimum

SFPWHT

Minimum

SFPWHT

Min and Max

SFPWHT

Min and Max

SFPWHT

Min and Max

SFPWHT

Min and Max

SFPWHT

SFPWHT

Condition

Step

CoolingHardnessMacro/MicroBending

Tension

TestImpact Test



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Tests Required– Deposited Weld Metal Chemical Analysis

– Tensile properties (room and design

temperature)– Hardness test



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Tests Required cont.

– Macro / Micro examination

– Step Cooling Test

– Impact Test

The specimens shall be taken from ½ thicknessof the test coupon for each process.

For base metal over 100mm thick, it is requiredadditional test specimens at ¼ and ¾ thickness.



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WELD OVERLAY

– Stainless Steel TP347

• Non stressed areas:

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

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

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



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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 ofundiluted SS 347 deposit shall be 3mm,and maximum (309L+347) not exceed10mm.



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

• Shall be applied in a double weld layer

respecting the sequence for high stressedareas.

– Ferritic Stainless Steels

• The minimum effective thickness of undilutedferritic 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.



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

shall be of the same type/grade of productionmaterial and taken from a plate, forging, piping

or fitting which fulfill all requirements of thisspecification.

– Welding materials, overlay thickness, preheating,PWHT, and all welding parameters shall bestrictly the same as those to be used onfabrication. Trademark and brand name ofwelding consumables are considered essentialvariables.

– Qualification test coupon shall be representativeof weld overlay to be performed duringfabrication (in particular for thickness of basematerial and weld position).



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Weld Overlay Procedure Qualification– Ferrite Number

• Shall be within the range of FN 3 minimum (5

minimum for SS 347) to 8 (WRC Ferrite Number)based upon the certified chemical analysis and DeLong Constitution Diagram for Stainless SteelWeld Metals.

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

locations randomly selected. The chips must betaken from 1.5 and 3.0 mm below machined

surfaces.

– Micro examination

• Less than 4% of sigma phase after minimum

SFPWHT.



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Weld Overlay Procedure Qualification– Macro examination / Hardness test survey

– Disbonding Test

– Intergranular Corrosion Test

– Ultrasonic Test (UT according to ASTM A578S1 and S7)



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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 fulfillthe requirements of chemical analysis afterclad production, plus the following requiredtests:

• Ferrite Number

• Disbonding test• Shear Test and Bond Strength

• Ultrasonic Test

• Microstructure



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PRODUCTION TESTS

– For each purchase order, Manufacturer

shall prepare a Production Test CouponProcedure.

– SHELL COURSES AND HEADS

• Test Coupons for Hot Formed PlateMaterial

• Production Weld Coupons

– Production Weld Coupons for Shell andHeads (plate or forged)

» For each reactor

» For heat exchangers and other

equipment



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PRODUCTION TESTS

– All production weld coupons shall be cut inthree parts:

• the first part shall receive a simulated heat

treatment corresponding to the maximum SFPWHTcondition and shall be tested before finalassembling of shell courses and heads.

• the second part shall follow the component ofwhich it is representative during all heat treatmentstages, and undergo the FPWHT with thecompleted equipment or of equipment section. Alltesting results shall be submitted for PETROBRASbefore shipment of the equipment.

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



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RETEST– RETEST OF BASE MATERIALS

• According to base material manufacturerQuality Assurance System.

• In case of tests performed by equipmentmanufacturer, 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



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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, oneretest, constituted by two sets of three samples each, may be performed;

– One individual specimen with value below the minimum individual value, oneretest, 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 arenot acceptable.

• On retesting, each individual value of the new specimens shall equal orexceed the minimum specified average value. Retest specimens shall beremoved from the original test coupons. Only one retest may beperformed (Retest of the retest is not acceptable).

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

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

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