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.
Author(s): Karan Sotoodeh
Publisher: Gulf Professional Publishing
Year: 2022
Language: English
Pages: 324
City: Cambridge
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
