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CASE STUDIES OF MATERIAL CORROSION PREVENTION FOR OIL AND GAS VALVES This page intentionally left blank CASE STUDIES OF MATERIAL CORROSION PREVENTION FOR OIL AND GAS VALVES KARAN SOTOODEH GulfProfessionalPublishingisanimprintofElsevier 50HampshireStreet,5thFloor,Cambridge,MA02139,UnitedStates TheBoulevard,LangfordLane,Kidlington,Oxford,OX51GB,UnitedKingdom Copyright©2022ElsevierInc.Allrightsreserved. Nopartofthispublicationmaybereproducedortransmittedinanyformorbyanymeans,electronicormechanical, includingphotocopying,recording,oranyinformationstorageandretrievalsystem,withoutpermissioninwriting fromthepublisher.Detailsonhowtoseekpermission,furtherinformationaboutthePublisher’spermissions policiesandourarrangementswithorganizationssuchastheCopyrightClearanceCenterandtheCopyrightLicensing Agency,canbefoundatourwebsite:www.elsevier.com/permissions. ThisbookandtheindividualcontributionscontainedinitareprotectedundercopyrightbythePublisher(otherthanas maybenotedherein). Notices Knowledgeandbestpracticeinthisfieldareconstantlychanging.Asnewresearchandexperiencebroadenour understanding,changesinresearchmethods,professionalpractices,ormedicaltreatmentmaybecomenecessary. Practitionersandresearchersmustalwaysrelyontheirownexperienceandknowledgeinevaluatingandusingany information,methods,compounds,orexperimentsdescribedherein.Inusingsuchinformationormethodsthey shouldbemindfuloftheirownsafetyandthesafetyofothers,includingpartiesforwhomtheyhaveaprofessional responsibility. Tothefullestextentofthelaw,neitherthePublishernortheauthors,contributors,oreditors,assumeanyliabilityfor anyinjuryand/ordamagetopersonsorpropertyasamatterofproductsliability,negligenceorotherwise,orfromany useoroperationofanymethods,products,instructions,orideascontainedinthematerialherein. ISBN:978-0-323-95474-7 ForinformationonallGulfProfessionalpublications visitourwebsiteathttps://www.elsevier.com/books-and-journals Publisher:CharlotteCockle SeniorAcquisitionEditor:KatieHammon SeniorEditorialProjectManager:JoshuaMearns SeniorProductionProjectManager:SuryaNarayananJayachandran SeniorCoverDesigner:ChristianJ.Bilbow TypesetbySTRAIVE,India Contents 1. Externaltopsideoffshore corrosion 1 Casestudy1.1.Valvegearboxmaterialselectionandcorrosionprevention intopsideoffshoreoilandgasindustry 1 1 Introduction 1 2 Aimandobjective 4 3 Importance 4 4 Audiences 5 5 Casestudy 5 6 Expectedresultsanddeliverables 8 7 Conclusions 8 Casestudy1.2.Minimizingusageoflow-alloysteelboltsandcarbonsteelnuts forvalvesintopsideoffshoreoilandgasindustrythroughselectionofsuitable boltingmaterial 9 1 Introduction 9 2 Aimandobjective 15 3 Importance 15 4 Audiences 16 5 Casestudy(challenges/solutions) 16 6 Expectedresultsanddeliverables 23 7 Conclusions 23 Casestudy1.3.Materialselectionforhubandclamp(mechanicaljoint) connections 26 1 Introduction 26 2 Aimandobjective 29 3 Importanceandcontributions 29 4 Audiences 30 5 Casestudy(challenges/solutions) 30 6 Expectedresultsanddeliverables 32 7 Conclusions 34 Casestudy1.4.Preventinguseof17-4PHstemmaterial 34 1 Introduction 34 2 Aimandobjective 35 3 Importanceandcontributions 36 4 Audiences 36 5 Casestudy(challenges/solutions) 37 6 Expectedresultsanddeliverables 41 7 Conclusions 41 v vi Contents Casestudy1.5.Corrosionunderinsulationanditspreventionbycoating 42 1 Introduction 42 2 Aimandobjectives 46 3 Importanceandcontributions 47 4 Audiences 47 5 Casestudy(challenges/solutions) 47 6 Expectedresultsanddeliverables 50 7 Conclusions 50 Casestudy1.6.PittingandCLSCCandtheirpreventionbycoating 51 1 Introduction 51 2 Aimandobjectives 54 3 Importanceandcontributions 54 4 Audiences 55 5 Casestudy(challenges/solutions) 55 6 Expectedresultsanddeliverables 62 7 Conclusions 62 Casestudy1.7.Applicationofausteniticstainlesssteeltoindustrialvalves inoffshoreenvironment 63 1 Introduction 63 2 Aimandobjectives 67 3 Importanceandcontributions 67 4 Audiences 67 5 Casestudy(challenges/solutions) 68 6 Expectedresultsanddeliverables 79 7 Conclusions 80 Casestudy1.8.UpgradingSS316tubesforpipingandvalveactuatorsto6MO 81 1 Introduction 81 2 Aimandobjectives 83 3 Importanceandcontributions 83 4 Audiences 83 5 Casestudy 84 6 Expectedresultsanddeliverables 88 7 Conclusions 89 Furtherreading 95 2. External offshore subsea corrosion 97 Casestudy2.1.HISCcorrosionandprevention 97 1 Introduction 97 2 Aimandobjectives 105 3 Importanceandcontributions 105 Contents vii 4 Audiences 106 5 Casestudy(challenges/solutions) 106 6 Expectedresultsanddeliverables 116 7 Conclusions 116 Casestudy2.2.Coatingandcathodicprotectiontopreventexternal corrosion 118 1 Introduction 118 2 Aimandobjectives 118 3 Importanceandcontributions 118 4 Audiences 118 5 Casestudy(challenges/solutions) 119 6 Expectedresultsanddeliverables 136 7 Conclusion 137 Casestudy2.3.Valveboltmaterialselection 137 1 Introduction 137 2 Aimandobjectives 139 3 Importanceandcontributions 139 4 Audiences 140 5 Casestudy(challenges/solutions) 140 6 Expectedresultsanddeliverables 142 7 Conclusions 142 Casestudy2.4.Applicationandusagejustificationofcarbonand low-alloysteelvalves 142 1 Introduction 142 2 Aimandobjectives 143 3 Importanceandcontributions 144 4 Audiences 145 5 Casestudy(challenges/solutions) 145 6 Expectedresultsanddeliverables 149 7 Conclusions 150 Casestudy2.5.Evaluationofusageofmartensiticstainlesssteel 13Cr(chromium)-4Ni(nickel)forvalvestems 150 1 Introduction 150 2 Aimandobjectives 152 3 Importanceandcontributions 152 4 Audiences 152 5 Casestudy(challenges/solutions) 152 6 Expectedresultsanddeliverables 153 7 Conclusions 157 Furtherreading 161 viii Contents 3. Cross-contamination 165 Casestudy3.1.UsingTeflonpowderonstainlesssteelvalvebodiestoprevent cross-contamination 165 1 Introduction 165 2 Aimandobjectives 167 3 Importanceandcontributions 167 4 Audience 167 5 Casestudy 168 6 Expectedresultsanddeliverables 168 7 Conclusions 169 Casestudy3.2.PassingPTFEpipelineinjectedgadgetthroughpipelinevalves duringfactoryacceptancetest 170 1 Introduction 170 2 Aimandobjectives 172 3 Importanceandcontributions 172 4 Audience 172 5 Casestudy 172 6 Expectedresultsanddeliverables 173 7 Conclusion 173 Furtherreading 174 4. Carbon dioxide (CO )corrosion 175 2 Casestudy4.1.Carbondioxide(CO )corrosionpredictionforcarbon 2 andlow-alloysteelvalves 175 1 Introduction 175 2 Aimandobjectives 183 3 Importanceandcontributions 184 4 Audience 184 5 Casestudy 185 6 Expectedresultsanddeliverables 187 7 Conclusions 187 Furtherreading 189 5. Hydrogen sulfide corrosion 191 Casestudy5.1.Materialconsiderationtopreventhydrogensulfidecorrosion 191 1 Introduction 191 2 Aimandobjectives 200 3 Importanceandcontributions 200 4 Audiences 201 5 Casestudy 201 6 Expectedresultsanddeliverables 221 Contents ix 7 Conclusions 221 Furtherreading 225 6. Crevicecorrosion 227 Casestudy6.1.Crevicecorrosionpreventiononvalvegroovesmadeofcarbon steelbyapplyingInconel625weldoverlay 227 1 Introduction 227 2 Aimandobjectives 234 3 Importanceandcontributions 234 4 Audience 235 5 Casestudy 235 6 Expectedresultsanddeliverables 236 7 Conclusions 237 Casestudy6.2.Crevicecorrosionpreventionafterremovingthreadedlifting lugsfromvalvesduringinstallation 237 1 Introduction 237 2 Aimandobjectives 239 3 Importanceandcontributions 240 4 Audience 240 5 Casestudy 241 6 Expectedresultsanddeliverables 241 7 Conclusions 241 Furtherreading 244 7. Pitting corrosion 245 Casestudy7.1.UsingNABvalvesinsteadoftitaniuminseawaterservice 245 1 Introduction 245 2 Aimandobjectives 246 3 Importanceandcontributions 247 4 Audience 248 5 Casestudy 248 6 Expectedresultsanddeliverables 253 7 Conclusions 253 Casestudy7.2.FailureofInconelX750valvespringsinseawaterservice 254 1 Introduction 254 2 Aimandobjectives 257 3 Importanceandcontributions 257 4 Audience 258 5 Casestudy 258 6 Expectedresultsanddeliverables 258 7 Conclusion 259