Analysis and Improvement of Material Selection for Process Piping System in Offshore Industry

Abstract

Material failure mainly because of corrosion is a highly dangerous and expensive phenomenon in the offshore sector of the oil and gas industry, associated with severe negative consequences such as loss of asset, loss of production due to plant shutdown, loss of human life, and health, safety, and environment (HSE) problems (e.g. environmental pollution). Additionally, piping systems are produced in large numbers for the topside facilities in the oil and gas plants. Thus, the main aim of this paper is to introduce a novel approach for the piping material selection in the offshore industry to minimize the risk of piping corrosion and weight reduction with an optimum cost. The central focus of the study is to develop a material selection tool based on a systematic material selection approach and the existing literature, standards, and specifications. In this study, the optimal material selection strategy includes three well-known methods of screening: Cambridge material selector, value engineering (VE), and technique for order preference by similarity to ideal solution (TOPSIS). The proposed guideline is a practical reference for material and piping engineers in the offshore industry to select the best choice of material for a specific application. The main finding of this research is that 25% chromium super duplex stainless steel is the best choice of material for processing piping systems in offshore plants for non-sour process (hydrocarbon) services. Super duplex stainless steel provides a high corrosion resistance and mechanical strength with the advantage of weight reduction for the selected facilities. A method of piping cost analysis is introduced to validate super duplex stainless steel as the most economical option.