AS 21457:2022
Petroleum, petrochemical and natural
gas industries — Materials selection and
corrosion control for oil and gas production
systems (ISO 21457:2010, MOD)
AS 21457:2022
This Australian Standard ® was prepared by ME-092, Materials, equipment, structures and
related services for petroleum, petrochemical and natural gas industries. It was approved
on behalf of the Council of Standards Australia on 19 April 2022.
This Standard was published on 13 May 2022.
The following are represented on Committee ME-092:
Australian Industry Group
Australian Organisation for Quality
Australian Petroleum Production and Exploration Association
Australian Pipelines and Gas Association
Department for Energy and Mining, SA
Department of Mines, Industry Regulation and Safety WA
DNV-GL Oil and Gas
Energy Safe Victoria
Engineers Australia
National Energy Resources Australia
Resources Safety & Health Queensland
University of Western Australia
This Standard was issued in draft form for comment as DR AS 21457:2022.
Keeping Standards up-to-date
Ensure you have the latest versions of our publications and keep up-to-date about
Amendments, Rulings, Withdrawals, and new projects by visiting:
www.standards.org.au
ISBN 978 1 76113 728 0
AS 21457:2022
Petroleum, petrochemical
and natural gas industries
— Materials selection and
corrosion control for oil and
gas production systems (ISO
21457:2010, MOD)
First published as AS 21457:2022.
COPYRIGHT
© ISO 2022 — All rights reserved
© Standards Australia Limited 2022
All rights are reserved. No part of this work may be reproduced or copied in any
form or by any means, electronic or mechanical, including photocopying, without the
written permission of the publisher, unless otherwise permitted under the Copyright
Act 1968 (Cth).
AS 21457:2022 ii
Preface
This Standard was prepared by the Standards Australia Committee ME-092, Materials, equipment,
structures and related services for petroleum, petrochemical and natural gas industries.
The objective of this document is to identify the corrosion mechanisms and parameters for evaluation
when performing selection of materials for pipelines, piping and equipment related to transport
and processing of hydrocarbon production, including utility and injection systems. This includes all
equipment from and including the well head, to and including pipelines for stabilized products.
Guidance is given for the following:
(a) Corrosion evaluations.
(b) Materials selection for specific applications, or systems, or both.
(c) Performance limitations for specific materials.
(d) Corrosion control.
This document is not applicable to downhole components. This document does not provide detailed
material requirements or guidelines for manufacturing and testing of equipment.
This document is an adoption with national modifications, and has been reproduced from,
ISO 21457:2010, Petroleum, petrochemical and natural gas industries — Materials selection and corrosion
control for oil and gas production systems. The modifications are additional requirements and are set out
in Appendix ZZ, which has been added at the end of the source text.
Appendix ZZ lists the modifications to ISO 21457:2010, for the application of this document in Australia.
As this document has been reproduced from an International document, the following apply:
(i) In the source text “this International Standard” should read “this document”.
(ii) A full point substitutes for a comma when referring to a decimal marker.
Australian or Australian/New Zealand Standards that are identical adoptions of international
normative references may be used interchangeably. Refer to the online catalogue for information on
specific Standards.
The terms “normative” and “informative” are used in Standards to define the application of the
appendices or annexes to which they apply. A “normative” appendix or annex is an integral part of a
Standard, whereas an “informative” appendix or annex is only for information and guidance.
© Standards Australia Limited 2022
iii AS 21457:2022
Contents
Preface................................................................................................................................................................................................................................................ ii
Foreword...........................................................................................................................................................................................................................................v
Introduction................................................................................................................................................................................................................................. vi
1 Scope........................................................................................................................................................................................................................................... 1
2 Normative references................................................................................................................................................................................................ 1
3 Terms, definitions and abbreviated terms.......................................................................................................................................... 1
3.1 Terms and definitions............................................................................................................................................................................. 1
3.2 Abbreviated terms..................................................................................................................................................................................... 5
4 Design information for materials selection....................................................................................................................................... 6
5 Materials selection report.................................................................................................................................................................................... 6
6 General guidelines for corrosion evaluations and materials selection................................................................ 7
6.1 General................................................................................................................................................................................................................. 7
6.2 Internal corrosion in oil and gas production and processing.............................................................................. 7
6.2.1 Corrosion evaluation........................................................................................................................................................ 7
6.2.2 Corrosion mechanisms................................................................................................................................................... 7
6.2.3 Corrosion parameters...................................................................................................................................................... 9
6.3 Internal corrosion in injection systems............................................................................................................................... 12
6.4 Internal corrosion in utility systems...................................................................................................................................... 12
6.5 Sand erosion................................................................................................................................................................................................ 12
6.6 External corrosion.................................................................................................................................................................................. 13
6.6.1 General....................................................................................................................................................................................... 13
6.6.2 External marine atmospheric environments........................................................................................... 13
6.6.3 External non-marine atmospheric environments................................................................................ 14
6.6.4 Buried and submerged installations................................................................................................................ 14
6.6.5 Corrosion under insulation...................................................................................................................................... 14
6.7 Polymeric materials.............................................................................................................................................................................. 14
6.8 Glass-fibre-reinforced plastic........................................................................................................................................................ 15
6.9 Mechanical properties and material usage limitations.......................................................................................... 15
6.9.1 General....................................................................................................................................................................................... 15
6.9.2 Submerged installations............................................................................................................................................. 16
7 Materials selection for specific applications and systems...............................................................................................16
7.1 General.............................................................................................................................................................................................................. 16
7.2 Oil and gas production and processing systems........................................................................................................... 16
7.2.1 General....................................................................................................................................................................................... 16
7.2.2 Heat exchangers................................................................................................................................................................ 17
7.2.3 Wellhead, production and process systems.............................................................................................. 17
7.2.4 Flare systems........................................................................................................................................................................ 18
7.2.5 Produced water.................................................................................................................................................................. 18
7.3 Injection systems..................................................................................................................................................................................... 19
7.3.1 General....................................................................................................................................................................................... 19
7.3.2 De-aerated seawater...................................................................................................................................................... 19
7.3.3 Aerated seawater.............................................................................................................................................................. 19
7.3.4 Produced water and aquifer water................................................................................................................... 19
7.3.5 Gas injection systems.................................................................................................................................................... 20
7.4 Utility systems............................................................................................................................................................................................ 20
7.4.1 General....................................................................................................................................................................................... 20
7.4.2 Fresh-water systems...................................................................................................................................................... 20
7.4.3 Seawater carrying systems...................................................................................................................................... 21
7.4.4 Other utility systems..................................................................................................................................................... 23
7.5 Pipelines and flowlines....................................................................................................................................................................... 24
8 Corrosion control........................................................................................................................................................................................................25
AS 21457:2022 iv
8.1 Chemical treatment............................................................................................................................................................................... 25
8.2 Internal corrosion allowance........................................................................................................................................................ 26
8.3 Selection of internal and external coatings....................................................................................................................... 27
8.4 External splash zone protection................................................................................................................................................. 27
8.5 Cathodic protection............................................................................................................................................................................... 27
8.5.1 Offshore..................................................................................................................................................................................... 27
8.5.2 Onshore..................................................................................................................................................................................... 28
8.6 Corrosion protection of closed compartments.............................................................................................................. 28
8.7 Connection of dissimilar materials.......................................................................................................................................... 28
8.7.1 Piping systems.................................................................................................................................................................... 28
8.7.2 Submerged installations............................................................................................................................................. 29
8.7.3 Structural installations................................................................................................................................................ 29
8.8 Sealing materials...................................................................................................................................................................................... 29
8.9 Fasteners......................................................................................................................................................................................................... 29
8.10 Weld overlay............................................................................................................................................................................................. 30
8.11 Preferential weld corrosion........................................................................................................................................................ 30
8.12 Corrosion management.................................................................................................................................................................. 30
Annex A (informative) Design basis for hydrocarbon systems............................................................................31
Annex B (informative) Corrosion monitoring........................................................................................................................33
Annex C (informative) Chemical composition of some typical oilfield alloys......................................34
Bibliography.............................................................................................................................................................................................................................. 38
Appendix ZZ (normative) Modifications to ISO 21457:2010 for Australia.........................................................40
v AS 21457:2022
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.
The main task of technical committees is to prepare International Standards. Draft International
Standards adopted by the technical committees are circulated to the member bodies for voting.
Publication as an International Standard requires approval by at least 75 % of the member bodies
casting a vote.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights.
ISO 21457 was prepared by Technical Committee ISO/TC 67, Materials, equipment and offshore structures
for petroleum, petrochemical and natural gas industries.
© Standards Australia Limited 2022
AS 21457:2022 vi
Introduction
The provision of well-established and robust material selection guidelines offers a means of satisfying
long-term materials performance that meet the minimum requirements for a broad range of end users
in the petroleum, petrochemical and natural gas industries. An additional benefit can be to enable
product suppliers to develop, manufacture and provide off-the-shelf equipment that meets these
requirements.
Oil and gas production projects benefit from a structured evaluation of materials used for the different
fluids being handled. Therefore, the main objective of this International Standard is to provide general
requirements with guidelines for the selection of materials for systems and components, with due
consideration to the transported fluids and the external environment.
It is the end user's responsibility to provide a project document with respect to implementation of the
requirements and guidelines of this International Standard, and to specify the design conditions for
material selection. In addition to the end user, the organization responsible for the facility or for the
equipment design, or for both, is regarded as responsible for materials selection.
This International Standard is developed to provide responsible parties with a structured process to
carry out materials selection in a consistent manner as a part of the engineering work, based upon
a design basis for a particular installation. This International Standard is intended for use by oil
companies and engineering contractors.
Users of this International Standard are advised that further or differing requirements might be
needed for individual applications. This International Standard is not intended to inhibit a vendor
from offering, or the purchaser from accepting, alternative equipment or engineering solutions for
the individual application. This can be particularly applicable where there is innovative or developing
technology. Where an alternative is offered, it is advisable that the vendor identify any variations from
this International Standard and provide details.
© Standards Australia Limited 2022
1 AS 21457:2022
Australian Standard®
Petroleum, petrochemical and natural gas industries — Materials
selection and corrosion control for oil and gas production systems (ISO
21457:2010, MOD)
1 Scope
This International Standard identifies the corrosion mechanisms and parameters for evaluation
when performing selection of materials for pipelines, piping and equipment related to transport
and processing of hydrocarbon production, including utility and injection systems. This includes all
equipment from and including the well head, to and including pipelines for stabilized products. This
International Standard is not applicable to downhole components.
Guidance is given for the following:
— corrosion evaluations;
— materials selection for specific applications, or systems, or both;
— performance limitations for specific materials;
— corrosion control.
This International Standard refers to materials that are generally available, with properties that are
known and documented. It also allows other materials to be evaluated and qualified for use.
This International Standard does not provide detailed material requirements or guidelines for
manufacturing and testing of equipment. Such information can be found in particular product and
manufacturing standards.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
ISO 15156-11), Petroleum and natural gas industries — Materials for use in H2S-containing environments
in oil and gas production — Part 1: General principles for selection of cracking-resistant materials
ISO 15156-22), Petroleum and natural gas industries — Materials for use in H2S-containing environments
in oil and gas production — Part 2: Cracking-resistant carbon and low-alloy steels, and the use of cast irons
ISO 15156-33), Petroleum and natural gas industries — Materials for use in H2S-containing environments
in oil and gas production — Part 3: Cracking-resistant CRAs (corrosion-resistant alloys) and other alloys
3 Terms, definitions and abbreviated terms
3.1 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
1) ISO 15156 (all parts) has been adopted by NACE as NACE MR0175/ISO 15156.
2) ISO 15156 (all parts) has been adopted by NACE as NACE MR0175/ISO 15156.
3) ISO 15156 (all parts) has been adopted by NACE as NACE MR0175/ISO 15156.
© Standards Australia Limited 2022
