Technical Report: Comparative Assessment of Carbon Steel, Stainless Steel,
Killed Carbon Steel, and NACE-Compliant Steel
Prepared by: Teimour Neshat – May 12, 2025
1. Overview
Material selection in oil and gas projects is a critical technical decision, directly affecting safety, service
life, integrity, cost, and compliance with industry standards. This report provides a comparative analysis
of four commonly used steel types in the oil, gas, and petrochemical industry:
• Plain Carbon Steel
• Stainless Steel (SS304 / SS316)
• Killed Carbon Steel
• NACE-Compliant Steel
2. Plain Carbon Steel
• Definition: Iron alloyed with a limited amount of carbon and no significant alloying elements.
• Characteristics:
o Economical and widely available.
o Good weldability.
o Susceptible to corrosion in acidic, H₂S-rich, and wet environments.
• Limitations: Not suitable for sour service without additional protection (e.g., internal coatings or
inhibitors).
3. Stainless Steel (SS304 / SS316)
• Definition: Iron-based alloys containing chromium (≥10.5%) and often nickel and molybdenum.
• Advantages:
o Excellent corrosion resistance in most environments.
o SS316 offers better resistance to chlorides and pitting corrosion.
• Limitations:
o Significantly more expensive than carbon steel.
o Susceptible to stress corrosion cracking in chloride or H₂S environments.
• Typical Uses: Instrument tubing, piping for chemical services, low-pressure sour gas applications
(if certified).
4. Killed Carbon Steel
• Definition: Carbon steel deoxidized (typically with aluminum or silicon) to reduce gas porosity.
• Characteristics:
o Homogeneous structure.
o Improved toughness and weldability.
o Reduced tendency for lamellar tearing.
• Common Grades: ASTM A106 Gr. B (killed), A333, API 5L Gr. B (killed)
• Uses: Pressure piping, pipelines, and vessels under moderate conditions.
5. NACE-Compliant Steel
• Definition: Steels meeting NACE MR0175 / ISO 15156 requirements for sour service.
• Background: Hydrogen sulfide (H₂S) causes three main types of damage:
o SSC (Sulfide Stress Cracking)
o HIC (Hydrogen-Induced Cracking)
o SOHIC (Stress-Oriented Hydrogen-Induced Cracking)
• Requirements:
o Strict control of hardness (≤22 HRC)
o Low impurity levels (S, P)
o Microstructure suitability
o Certified material test reports (MTRs)
• Applications: Sour gas lines, separators, wet H₂S service, amine treatment systems
6. Key Considerations
6-1. H₂S Presence:
If partial pressure of H₂S ≥ 0.05 psia and water is present → sour service conditions apply.
6-2. Use of Killed Carbon Steel:
When better toughness, uniformity, and weldability are needed, especially in thicker sections.
6-3. NACE Requirement Criteria:
Mandatory in presence of:
• Wet H₂S environment
• Stress concentration or cyclic loading
• Temperatures below 150°C
• Welding zones or hard spots
6-4. Recommended Actions:
Always assess sour service risk using process data, H₂S concentration, pressure/temperature, and design
life. Over-specifying materials can lead to unnecessary cost; under-specifying can result in catastrophic
failure.
7. Comparative Summary Table
Feature Carbon Steel Stainless Steel Killed CS NACE Steel
Cost Low High Medium High
Corrosion Resistance Low High Medium High
Weldability Good Medium Excellent Medium
Sour Service Suitability Poor Conditional Conditional Excellent
Availability High Medium Medium Medium
8. Final Remarks
Material selection must align with process conditions, design codes, and long-term reliability
expectations. For sour service, NACE-compliant materials are essential, while for dry and low-risk
services, killed carbon steel or internally lined carbon steel may provide a more cost-effective solution.