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

311 Pages·2022·22.498 MB·English

by  Karan Sotoodeh

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 stu-
dents 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 multina-
tional 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 coat-
ings, 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.

Coating Application
for Piping, Valves and
Actuators in Offshore Oil
and Gas Industry
Karan Sotoodeh
First edition published 2023
by CRC Press
6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487-2742
and by CRC Press
4 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN
© 2023 Karan Sotoodeh
CRC Press is an imprint of Taylor & Francis Group, LLC
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Trademark notice: Product or corporate names may be trademarks or registered trademarks and
are used only for identification and explanation without intent to infringe.
ISBN: 9 78- 1- 032- 18719-8 ( hbk)
ISBN: 9 78- 1- 032-1 8722-8 ( pbk)
ISBN: 9 78-1 -0 03- 25591-8 ( ebk)
DOI: 10.1201/ 9781003255918
Typeset in Times
by codeMantra
Contents
Preface..................................................................................................................xi
Author ................................................................................................................xiii
Chapter 1 Types of Corrosion in the Offshore Environment ...........................1
1.1 Introduction to the Marine Environment .............................1
1.2 Offshore Zones .....................................................................2
1.3 Basics of Corrosion ...............................................................5
1.4 Offshore Corrosion Types ....................................................8
1.4.1 General Corrosion ...................................................8
1.4.2 Localized Corrosion ..............................................12
1.4.2.1 Crevice Corrosion ..................................12
1.4.2.2 Pitting Corrosion ....................................18
1.4.2.3 Galvanic Corrosion ................................24
1.4.2.4 Corrosion under Insulation ( CUI). .........27
1.4.3 Environmental Cracking Corrosion ......................32
1.4.3.1 Chloride Stress Cracking Corrosion ......32
1.4.3.2 HISC Corrosion .....................................35
1.5 Conclusion ..........................................................................43
1.6 Questions and Answers ......................................................43
Bibliography ..................................................................................47
Chapter 2 Surface Preparation .......................................................................51
2.1 Introduction ........................................................................51
2.2 Initial Surface Conditions ...................................................51
2.3 Surface Contaminants ........................................................52
2.4 Steelwork ............................................................................59
2.5 Surface Cleaning Methods .................................................69
2.5.1 Cleaning with Liquid or Gas .................................70
2.5.1.1 Water Cleaning ......................................70
2.5.1.2 Steam Cleaning ......................................74
2.5.1.3 Emulsion Cleaning ................................75
2.5.1.4 Alkaline Cleaning..................................75
2.5.1.5 Organic Solvent Cleaning ......................75
2.5.1.6 Chemical Cleaning ................................75
2.5.2 Blast Cleaning .......................................................77
2.5.2.1 Blast Cleaning Equipment .....................81
2.5.2.2 Blast Cleaning Preparation Grades........84
2.5.3 Mechanical Cleaning ............................................90
v
vi Contents
2.6 Conclusion ..........................................................................96
2.7 Questions and Answers ......................................................96
Bibliography ................................................................................100
Chapter 3 Coating Protection .......................................................................103
3.1 Coating Definition ............................................................103
3.2 Coating Composition ........................................................106
3.3 Coating Purposes ...............................................................111
3.4 Coating Standards and Specifications ...............................112
3.5 NORSOK Coating Standard M -501 ..................................113
3.5.1 General Requirements ..........................................113
3.5.2 Coating Systems ...................................................115
3.5.2.1 Coating System 1: Organic and
Inorganic Z inc-Rich Coating ................115
3.5.2.2 Coating System 2: Thermal Spray
Aluminum or Thermal Spray Zinc ......120
3.5.2.3 Coating System 5: Passive Fire
Protection Epoxy or Cement ................123
3.5.2.4 Coating System 6: Coating on HDG
or Phenolic Epoxy ................................126
3.5.2.5 Coating System 7: Two-Component
Epoxy ...................................................129
3.6 Coating Health, Safety and Environment ( SHE) ..............130
3.7 Conclusion ........................................................................133
3.8 Questions and Answers ....................................................133
Bibliography ................................................................................138
Chapter 4 Coating Defects and Inspection ...................................................141
4.1 Introduction .......................................................................141
4.2 Coating Formulation ..........................................................141
4.3 Coating Defects ................................................................144
4.3.1 Run and Sags .......................................................144
4.3.2 Orange Peel .........................................................145
4.3.3 Blistering .............................................................145
4.3.4 Blush ( Blushing) ...................................................147
4.3.5 Cratering ( Pitting) ...............................................148
4.3.6 Fish Eyes ..............................................................148
4.3.7 Chalking ..............................................................148
4.3.8 Fading ..................................................................149
4.3.9 Dry Spray ............................................................150
4.3.10 Wrinkling ............................................................150
4.3.11 Crinkling .............................................................150
4.3.12 Swelling ...............................................................152
Contents vii
4.3.13 Solvent Boil .........................................................153
4.3.14 Pinhole and Holiday ............................................153
4.3.15 Delamination .......................................................153
4.3.16 Undercutting ........................................................155
4.3.17 Cracking ..............................................................155
4.3.18 Bleeding ..............................................................155
4.4 Coating Inspection ............................................................156
4.4.1 Essence of Coating Inspection and Inspector .....156
4.4.2 Coating Checkpoints ...........................................157
4.4.3 Inspector Capability Levels .................................160
4.4.4 Inspection and Test Plan ( ITP) ............................162
4.4.5 Inspection Tools and Methods.............................163
4.4.5.1 Visual Inspection .................................163
4.4.5.2 Weather Conditions Measurement .......164
4.4.5.3 Soluble Salt Measurement ...................166
4.4.5.4 Abrasive Contaminant Inspection .......168
4.4.5.5 Coating DFT Measurement .................169
4.4.5.6 Coating Adhesion Measurement ..........169
4.4.5.7 Coating Curing Test ..............................173
4.5 Conclusion .........................................................................173
4.6 Questions and Answers .....................................................173
Bibliography ................................................................................177
Chapter 5 Valve and Actuator Technology for the Offshore Industry ..........181
5.1 Introduction .......................................................................181
5.2 Offshore Field Development Options ................................181
5.2.1 Topside ................................................................182
5.2.2 Subsea ..................................................................186
5.3 Industrial Valves for the Offshore Industry .......................191
5.3.1 Valves for Topside ................................................191
5.3.1.1 On/ Off Valves .......................................191
5.3.1.2 Fluid Control Valves .............................211
5.3.1.3 Non-Return Valves ...............................217
5.3.1.4 Safety Valves .......................................222
5.3.2 Valves for Subsea ................................................223
5.4 Industrial Actuators for the Offshore Industry .................226
5.4.1 Topside Actuators ................................................226
5.4.1.1 Linear Actuators ..................................227
5.4.1.2 Rotary Actuators ..................................231
5.4.2 Subsea Actuators .................................................236
5.5 Conclusion ........................................................................236
5.6 Questions and Answers ....................................................236
Bibliography ................................................................................241
viii Contents
Chapter 6 Piping, Valves and Actuator Offshore Coating Case Studies .....243
6.1 Introduction ......................................................................243
6.2 Coating Applications for Topside Valves and
Actuators ......................................................................243
6.2.1 Topside Piping and Valve Coating Case
Studies .............................................................243
6.2.1.1 No Coating on Titanium and Nickel
Aluminum Bronze Valve Bodies .........243
6.2.1.2 Manual Valve Coating
Standardization ...................................244
6.2.1.3 Valve Color Coding in Firefighting
Systems ................................................247
6.2.1.4 Fire Nuts versus Insulation Boxes
on Valves and Flanges .........................247
6.2.1.5 Thermal-Spray Coating Thickness
Inspection Challenge for Duplex
and Super Duplex Materials ................248
6.2.1.6 No Coating on Flange Faces ................251
6.2.1.7 No Coating on Bolt Holes and
Nut-Bearing Areas on Flanged
Connections .........................................252
6.2.1.8 No Coating under the Clamp in
Mechanical Joints ................................254
6.2.1.9 Clamp Coating Selection .....................255
6.2.1.10 Minimizing the Usage of HDG
Bolting .................................................256
6.2.1.11 Coating the Valve after the
Pressure Test ........................................258
6.2.1.12 Insulation Boxes ..................................260
6.2.1.13 Coating the Valves’ Top Flange ...........260
6.2.1.14 Using a Stainless Steel 316 Gearbox ...261
6.2.1.15 Lack of TSA Coating Adhesion ...........261
6.2.1.16 Coating to Prevent Cross-
Contamination .....................................261
6.2.1.17 Coating and Poor Marking
on Valves ..............................................263
6.2.1.18 Coating Close to Welded Areas ...........266
6.2.2 Topside Actuator Coating Case Studies ..............267
6.2.2.1 Actuator Color-Coding ........................267
6.2.2.2 Coating the Area under the Actuator
End Stopper .........................................268
6.2.2.3 Handwheel Coating for Valves and
Electrical Actuators .............................269
Contents ix
6.2.2.4 Actuator Disassembly from the
Valve during Coating ...........................271
6.2.2.5 Passive-Fire Protection around a
Double-Acting Hydraulic Actuator ......271
6.3 Coating Applications for Subsea Valves and Actuators ...272
6.3.1 Subsea Valves ......................................................272
6.3.1.1 Subsea Valve Coating ..........................272
6.3.1.2 Subsea Valve ROV Bucket and
Position Indicator Coating ...................274
6.3.1.3 Subsea Valve Bolting ...........................274
6.3.2 Subsea Actuators .................................................276
6.3.2.1 Subsea Actuator Coating .....................276
6.3.2.2 ROV Override Coating ........................276
6.4 More Cases and Figures ...................................................276
6.5 Conclusion ........................................................................283
6.6 Questions and Answers ....................................................283
Bibliography ................................................................................288
Index .................................................................................................................289