Coating Application for Piping, Valves and Actuators in Offshore Oil and Gas Industry

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. Cover Half Title Title Page Copyright Page Table of Contents Preface Author Chapter 1 Types of Corrosion in the Offshore Environment 1.1 Introduction to the Marine Environment 1.2 Offshore Zones 1.3 Basics of Corrosion 1.4 Offshore Corrosion Types 1.4.1 General Corrosion 1.4.2 Localized Corrosion 1.4.2.1 Crevice Corrosion 1.4.2.2 Pitting Corrosion 1.4.2.3 Galvanic Corrosion 1.4.2.4 Corrosion under Insulation (CUI) 1.4.3 Environmental Cracking Corrosion 1.4.3.1 Chloride Stress Cracking Corrosion 1.4.3.2 HISC Corrosion 1.5 Conclusion 1.6 Questions and Answers Bibliography Chapter 2 Surface Preparation 2.1 Introduction 2.2 Initial Surface Conditions 2.3 Surface Contaminants 2.4 Steelwork 2.5 Surface Cleaning Methods 2.5.1 Cleaning with Liquid or Gas 2.5.1.1 Water Cleaning 2.5.1.2 Steam Cleaning 2.5.1.3 Emulsion Cleaning 2.5.1.4 Alkaline Cleaning 2.5.1.5 Organic Solvent Cleaning 2.5.1.6 Chemical Cleaning 2.5.2 Blast Cleaning 2.5.2.1 Blast Cleaning Equipment 2.5.2.2 Blast Cleaning Preparation Grades 2.5.3 Mechanical Cleaning 2.6 Conclusion 2.7 Questions and Answers Bibliography Chapter 3 Coating Protection 3.1 Coating Definition 3.2 Coating Composition 3.3 Coating Purposes 3.4 Coating Standards and Specifications 3.5 NORSOK Coating Standard M-501 3.5.1 General Requirements 3.5.2 Coating Systems 3.5.2.1 Coating System 1: Organic and Inorganic Zinc-Rich Coating 3.5.2.2 Coating System 2: Thermal Spray Aluminum or Thermal Spray Zinc 3.5.2.3 Coating System 5: Passive Fire Protection Epoxy or Cement 3.5.2.4 Coating System 6: Coating on HDG or Phenolic Epoxy 3.5.2.5 Coating System 7: Two-Component Epoxy 3.6 Coating Health, Safety and Environment (SHE) 3.7 Conclusion 3.8 Questions and Answers Bibliography Chapter 4 Coating Defects and Inspection 4.1 Introduction 4.2 Coating Formulation 4.3 Coating Defects 4.3.1 Run and Sags 4.3.2 Orange Peel 4.3.3 Blistering 4.3.4 Blush (Blushing) 4.3.5 Cratering (Pitting) 4.3.6 Fish Eyes 4.3.7 Chalking 4.3.8 Fading 4.3.9 Dry Spray 4.3.10 Wrinkling 4.3.11 Crinkling 4.3.12 Swelling 4.3.13 Solvent Boil 4.3.14 Pinhole and Holiday 4.3.15 Delamination 4.3.16 Undercutting 4.3.17 Cracking 4.3.18 Bleeding 4.4 Coating Inspection 4.4.1 Essence of Coating Inspection and Inspector 4.4.2 Coating Checkpoints 4.4.3 Inspector Capability Levels 4.4.4 Inspection and Test Plan (ITP) 4.4.5 Inspection Tools and Methods 4.4.5.1 Visual Inspection 4.4.5.2 Weather Conditions Measurement 4.4.5.3 Soluble Salt Measurement 4.4.5.4 Abrasive Contaminant Inspection 4.4.5.5 Coating DFT Measurement 4.4.5.6 Coating Adhesion Measurement 4.4.5.7 Coating Curing Test 4.5 Conclusion 4.6 Questions and Answers Bibliography Chapter 5 Valve and Actuator Technology for the Offshore Industry 5.1 Introduction 5.2 Offshore Field Development Options 5.2.1 Topside 5.2.2 Subsea 5.3 Industrial Valves for the Offshore Industry 5.3.1 Valves for Topside 5.3.1.1 On/Off Valves 5.3.1.2 Fluid Control Valves 5.3.1.3 Non-Return Valves 5.3.1.4 Safety Valves 5.3.2 Valves for Subsea 5.4 Industrial Actuators for the Offshore Industry 5.4.1 Topside Actuators 5.4.1.1 Linear Actuators 5.4.1.2 Rotary Actuators 5.4.2 Subsea Actuators 5.5 Conclusion 5.6 Questions and Answers Bibliography Chapter 6 Piping, Valves and Actuator Offshore Coating Case Studies 6.1 Introduction 6.2 Coating Applications for Topside Valves and Actuators 6.2.1 Topside Piping and Valve Coating Case Studies 6.2.1.1 No Coating on Titanium and Nickel Aluminum Bronze Valve Bodies 6.2.1.2 Manual Valve Coating Standardization 6.2.1.3 Valve Color Coding in Firefighting Systems 6.2.1.4 Fire Nuts versus Insulation Boxes on Valves and Flanges 6.2.1.5 Thermal-Spray Coating Thickness Inspection Challenge for Duplex and Super Duplex Materials 6.2.1.6 No Coating on Flange Faces 6.2.1.7 No Coating on Bolt Holes and Nut-Bearing Areas on Flanged Connections 6.2.1.8 No Coating under the Clamp in Mechanical Joints 6.2.1.9 Clamp Coating Selection 6.2.1.10 Minimizing the Usage of HDG Bolting 6.2.1.11 Coating the Valve after the Pressure Test 6.2.1.12 Insulation Boxes 6.2.1.13 Coating the Valves’ Top Flange 6.2.1.14 Using a Stainless Steel 316 Gearbox 6.2.1.15 Lack of TSA Coating Adhesion 6.2.1.16 Coating to Prevent Cross-Contamination 6.2.1.17 Coating and Poor Marking on Valves 6.2.1.18 Coating Close to Welded Areas 6.2.2 Topside Actuator Coating Case Studies 6.2.2.1 Actuator Color-Coding 6.2.2.2 Coating the Area under the Actuator End Stopper 6.2.2.3 Handwheel Coating for Valves and Electrical Actuators 6.2.2.4 Actuator Disassembly from the Valve during Coating 6.2.2.5 Passive-Fire Protection around a Double-Acting Hydraulic Actuator 6.3 Coating Applications for Subsea Valves and Actuators 6.3.1 Subsea Valves 6.3.1.1 Subsea Valve Coating 6.3.1.2 Subsea Valve ROV Bucket and Position Indicator Coating 6.3.1.3 Subsea Valve Bolting 6.3.2 Subsea Actuators 6.3.2.1 Subsea Actuator Coating 6.3.2.2 ROV Override Coating 6.4 More Cases and Figures 6.5 Conclusion 6.6 Questions and Answers Bibliography Index This book looks at the applications of coating in piping, valves, 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 sea water setting, coatings to protect pipes, valves and actuators are essential. This book provides both the theory behind these coatings, as well as practical application, including case studies from multinational companies. It begins by covering different offshore zones and their corrosivity level, alongside the different type of external corrosion such as stress cracking and hydrogen induced stress cracking. Key coatings discussed are zinc rich coating, thermal spray zinc or aluminum, phenolic epoxy, and passive fire protection, with a review of their defects and potential failures. It also details the role of a coating inspector and explains how to diagnose faults. Case studies from companies including AkerSolutions, Baker Hughes, Equinor and British Petroleum illustrate the wide range of industrial applications of coating technologies. The book will be of interest to engineers and students working and studying in materials, coating, mechanical, piping or petroleum engineering.