Case Studies of Material Corrosion Prevention for Oil and Gas Valves

Case Studies of Material Corrosion Prevention for Oil and Gas Valves delivers a critical reference for engineers and corrosion researchers. Packed with nearly 30 real-world case studies, this reference gives engineers standardized knowledge on how to maintain, select and prevent typical corrosion problems in a variety of oil and gas settings. Subsea, offshore, refineries and processing plants are all included, covering a variety of challenges such as chloride stress cracking, how to use Teflon powder to prevent cross contamination, and carbon dioxide corrosion. Organized for quick discovery, this book gives engineers a much-needed tool to safely protect their assets and the environment. Engineers working in oil and gas operations understand that corrosion is a costly expense that increases emissions and damages the environment, but many standards do not provide practical examples with solutions, leaving engineers to learn through experience. This resource provides comprehensive information on topics of interest. Provides solutions to common oil and gas corrosion valve failures with standard case studies Helps readers improve safety and reliability with the addition of references for further training Presents tactics on how to reduce environmental impact and use methods to prevent corrosion across offshore, subsea and refinery activities Front Cover Case Studies of Material Corrosion Prevention for Oil and Gas Valves Copyright Contents Chapter 1: External topside offshore corrosion Case study 1.1. Valve gear box material selection and corrosion prevention in topside offshore oil and gas industry 1. Introduction 1.1. Offshore external corrosion 1.2. Means of valve operation 2. Aim and objective 3. Importance 4. Audiences 5. Case study 6. Expected results and deliverables 7. Conclusions Case study 1.2. Minimizing usage of low-alloy steel bolts and carbon steel nuts for valves in topside offshore oil 1. Introduction 2. Aim and objective 3. Importance 4. Audiences 5. Case study (challenges/solutions) 6. Expected results and deliverables 7. Conclusions Case study 1.3. Material selection for hub and clamp (mechanical joint) connections 1. Introduction 2. Aim and objective 3. Importance and contributions 4. Audiences 5. Case study (challenges/solutions) 6. Expected results and deliverables 7. Conclusions Case study 1.4. Preventing use of 17-4 PH stem material 1. Introduction 2. Aim and objective 3. Importance and contributions 4. Audiences 5. Case study (challenges/solutions) 6. Expected results and deliverables 7. Conclusions Case study 1.5. Corrosion under insulation and its prevention by coating 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audiences 5. Case study (challenges/solutions) 6. Expected results and deliverables 7. Conclusions Case study 1.6. Pitting and CLSCC and their prevention by coating 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audiences 5. Case study (challenges/solutions) 6. Expected results and deliverables 7. Conclusions Case study 1.7. Application of austenitic stainless steel to industrial valves in offshore environment 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audiences 5. Case study (challenges/solutions) 6. Expected results and deliverables 7. Conclusions Case study 1.8. Upgrading SS316 tubes for piping and valve actuators to 6MO 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audiences 5. Case study 6. Expected results and deliverables 7. Conclusions Questions and answers Further reading Chapter 2: External offshore subsea corrosion Case study 2.1. HISC corrosion and prevention 1. Introduction 1.1. Susceptible material 1.2. Loads and stresses 1.2.1. Applied loads and stresses 1.2.2. Residual loads and stresses 1.3. Cathodic protection 2. Aim and objectives 3. Importance and contributions 4. Audiences 5. Case study (challenges/solutions) 5.1. HISC analysis method for duplex and super duplex steels as per DNV-RP-F112 guideline 5.2. HISC assessment 5.3. HISC analysis for hard nickel alloys 6. Expected results and deliverables 7. Conclusions Case study 2.2. Coating and cathodic protection to prevent external corrosion 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audiences 5. Case study (challenges/solutions) 5.1. Project description and manifolds 5.2. Type and function of valves 5.3. Valve and actuator material selection 5.4. Review of coatings 5.5. Cathodic protection 6. Expected results and deliverables 7. Conclusion Case study 2.3. Valve bolt material selection 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audiences 5. Case study (challenges/solutions) 6. Expected results and deliverables 7. Conclusions Case study 2.4. Application and usage justification of carbon and low-alloy steel valves 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audiences 5. Case study (challenges/solutions) 6. Expected results and deliverables 7. Conclusions Case study 2.5. Evaluation of usage of martensitic stainless steel 13Cr (chromium)-4Ni (nickel) for valve stems 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audiences 5. Case study (challenges/solutions) 6. Expected results and deliverables 7. Conclusions Questions and answers Further reading Chapter 3: Cross-contamination Case study 3.1. Using Teflon powder on stainless steel valve bodies to prevent cross-contamination 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audience 5. Case study 6. Expected results and deliverables 7. Conclusions Case study 3.2. Passing PTFE pipeline injected gadget through pipeline valves during factory acceptance test 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audience 5. Case study 6. Expected results and deliverables 7. Conclusion Questions and answers Further reading Chapter 4: Carbon dioxide (CO2) corrosion Case study 4.1. Carbon dioxide (CO2) corrosion prediction for carbon and low-alloy steel valves 1. Introduction 1.1. CO2 corrosion calculations 1.2. Basic CO2 corrosion rate 1.3. Corrective CO2 corrosion rate 1.4. Effect of glycol/methanol 1.5. Effect of scaling 1.6. Effect of inhibitor 1.7. Effect of water cut 1.8. Effect of condensate 1.9. Effect of pH 1.10. Final CO2 corrosion rate 2. Aim and objectives 3. Importance and contributions 4. Audience 5. Case study 6. Expected results and deliverables 7. Conclusions Questions and answers Further reading Chapter 5: Hydrogen sulfide corrosion Case study 5.1. Material consideration to prevent hydrogen sulfide corrosion 1. Introduction 1.1. HE 1.2. HIC 1.3. SSC 1.4. SCC 1.5. SWC 1.6. SOHIC 1.7. SZC 2. Aim and objectives 3. Importance and contributions 4. Audiences 5. Case study 5.1. Material selection for industrial valves for onshore refineries and petrochemical plants 5.2. Material selection for industrial valves for topside offshore oil and gas industry 5.3. Material selection for industrial valves for subsea offshore oil and gas industry 5.4. Material qualification and selection for sour service 5.4.1. Carbon and low-alloy steels 5.4.2. Corrosion-resistant alloys Austenitic stainless steel requirements in sour service Super austenitic stainless steel requirements in sour service Solid solution nickel-based alloy requirements in sour service Ferritic stainless steel alloy requirements in sour service Martensitic stainless steel alloy requirements in sour service Duplex stainless steel alloy requirements in sour service Precipitation-hardened stainless steel alloy requirements in sour service Precipitation-hardened nickel alloy requirements in sour service Cobalt-based alloy requirements in sour service Titanium alloy requirements in sour service Copper alloy requirements in sour service Cladding, overlays, and wear-resistant alloys Coating 6. Expected results and deliverables 7. Conclusions Questions and answers Further reading Chapter 6: Crevice corrosion Case study 6.1. Crevice corrosion prevention on valve grooves made of carbon steel by applying Inconel 625 weld overlay 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audience 5. Case study 6. Expected results and deliverables 7. Conclusions Case study 6.2. Crevice corrosion prevention after removing threaded lifting lugs from valves during installation 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audience 5. Case study 6. Expected results and deliverables 7. Conclusions Questions and answers Further reading Chapter 7: Pitting corrosion Case study 7.1. Using NAB valves instead of titanium in sea water service 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audience 5. Case study 6. Expected results and deliverables 7. Conclusions Case study 7.2. Failure of Inconel X750 valve springs in sea water service 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audience 5. Case study 6. Expected results and deliverables 7. Conclusion Case study 7.3. Challenge of material selection for bearing of butterfly valves in sea water service 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audience 5. Case study 6. Expected results and deliverables 7. Conclusion Case study 7.4. Hardfacing material selection for industrial valves in sea water service 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audience 5. Case study 6. Expected results and deliverables 7. Conclusion Questions and answers Further reading Chapter 8: Galvanic corrosion Case study 8.1. Galvanic corrosion between valve stem and graphite packing for valves in sea water service 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audience 5. Case study 6. Expected results and deliverables 7. Conclusions Case study 8.2. Galvanic corrosion between valve stem and stem key 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audience 5. Case study 6. Expected results and deliverables 7. Conclusion Questions and answers Further reading Chapter 9: Erosion corrosion Case study 9.1. Erosion mitigation for industrial valves installed upstream and downstream of first stage separator on a topsi 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audience 5. Case study 6. Expected results and deliverables 7. Conclusions Case study 9.2. Erosion prevention for subsea valves 1. Introduction 2. Aim and objectives 3. Importance and contributions 4. Audience 5. Case study 6. Expected results and deliverables 7. Conclusion Questions and answers Further reading Index Back Cover This book looks at the applications of coating in piping, valves and actuators in the offshore oil and gas industry. Providing a key guide for professionals and students alike, it highlights specific coating standards within the industry, including ISO, NORSOK, SSPC and NACE.In the corrosive environment of a seawater setting, coatings to protect pipes, valves and actuators are essential. This book provides both the theory behind these coatings and practical applications, including case studies from multinational companies. It covers different offshore zones and their corrosivity level alongside the different types of external corrosion, such as stress cracking and hydrogen-induced stress cracking. The key coatings discussed are zinc-rich coatings, thermal spray zinc or aluminum, phenolic epoxy and passive fire protection, with a review of their defects and potential failures. The book also details the role of coating inspectors and explains how to diagnose faults. Case studies from companies such as Aker Solutions, Baker Hughes, Equinor and British Petroleum illustrate the wide range of industrial applications of coating technologies.This book is of interest to engineers and students in materials, coating, mechanical, piping or petroleum engineering. Prevention of Actuator Emissions in the Oil and Gas Industry delivers a critical reference for oil and gas engineers and managers to get up-to-speed on all the factors in actuator fugitive emissions. Packed with a selection process, the benefits of switching to an electric system, and the technology around open and closed loop hydraulic systems helps today's engineer understand all their options. Rounding with a detailed explanation around High Integrity Pressure Protection Systems (HIPPS), this book gives provides the knowledge necessary to lower emissions on today's equipment. Gives readers all they need to understand all the sources and key factors contributing to fugitive emissions and leakage from oil and gas actuators Teaches how to select environmentally friendly actuators, particularly all electric systems Introduces the High Integrity Pressure Protection System (HIPPS) and the ways it reduces flaring