Preface |
|
xi | |
Author |
|
xiii | |
|
Chapter 1 Types of Corrosion in the Offshore Environment |
|
|
1 | (50) |
|
1.1 Introduction to the Marine Environment |
|
|
1 | (1) |
|
|
2 | (3) |
|
|
5 | (3) |
|
1.4 Offshore Corrosion Types |
|
|
8 | (35) |
|
|
8 | (4) |
|
1.4.2 Localized Corrosion |
|
|
12 | (1) |
|
1.4.2.1 Crevice Corrosion |
|
|
12 | (6) |
|
1.4.2.2 Pitting Corrosion |
|
|
18 | (6) |
|
1.4.2.3 Galvanic Corrosion |
|
|
24 | (3) |
|
1.4.2.4 Corrosion under Insulation (CUI) |
|
|
27 | (5) |
|
1.4.3 Environmental Cracking Corrosion |
|
|
32 | (1) |
|
1.4.3.1 Chloride Stress Cracking Corrosion |
|
|
32 | (3) |
|
|
35 | (8) |
|
|
43 | (1) |
|
1.6 Questions and Answers |
|
|
43 | (8) |
|
|
47 | (4) |
|
Chapter 2 Surface Preparation |
|
|
51 | (52) |
|
|
51 | (1) |
|
2.2 Initial Surface Conditions |
|
|
51 | (1) |
|
|
52 | (7) |
|
|
59 | (10) |
|
2.5 Surface Cleaning Methods |
|
|
69 | (27) |
|
2.5.1 Cleaning with Liquid or Gas |
|
|
70 | (1) |
|
|
70 | (4) |
|
|
74 | (1) |
|
2.5.1.3 Emulsion Cleaning |
|
|
75 | (1) |
|
2.5.1.4 Alkaline Cleaning |
|
|
75 | (1) |
|
2.5.1.5 Organic Solvent Cleaning |
|
|
75 | (1) |
|
2.5.1.6 Chemical Cleaning |
|
|
75 | (2) |
|
|
77 | (4) |
|
2.5.2.1 Blast Cleaning Equipment |
|
|
81 | (3) |
|
2.5.2.2 Blast Cleaning Preparation Grades |
|
|
84 | (6) |
|
2.5.3 Mechanical Cleaning |
|
|
90 | (6) |
|
|
96 | (1) |
|
2.7 Questions and Answers |
|
|
96 | (7) |
|
|
100 | (3) |
|
Chapter 3 Coating Protection |
|
|
103 | (38) |
|
|
103 | (3) |
|
|
106 | (5) |
|
|
111 | (1) |
|
3.4 Coating Standards and Specifications |
|
|
112 | (1) |
|
3.5 NORSOK Coating Standard M-501 |
|
|
113 | (17) |
|
3.5.1 General Requirements |
|
|
113 | (2) |
|
|
115 | (1) |
|
3.5.2.1 Coating System 1: Organic and Inorganic Zinc-Rich Coating |
|
|
115 | (5) |
|
3.5.2.2 Coating System 2: Thermal Spray Aluminum or Thermal Spray Zinc |
|
|
120 | (3) |
|
3.5.2.3 Coating System 5: Passive Fire Protection Epoxy or Cement |
|
|
123 | (3) |
|
3.5.2.4 Coating System 6: Coating on HDG or Phenolic Epoxy |
|
|
126 | (3) |
|
3.5.2.5 Coating System 7: Two-Component Epoxy |
|
|
129 | (1) |
|
3.6 Coating Health, Safety and Environment (SHE) |
|
|
130 | (3) |
|
|
133 | (1) |
|
3.8 Questions and Answers |
|
|
133 | (8) |
|
|
138 | (3) |
|
Chapter 4 Coating Defects and Inspection |
|
|
141 | (40) |
|
|
141 | (1) |
|
|
141 | (3) |
|
|
144 | (12) |
|
|
144 | (1) |
|
|
145 | (1) |
|
|
145 | (2) |
|
|
147 | (1) |
|
4.3.5 Cratering (Pitting) |
|
|
148 | (1) |
|
|
148 | (1) |
|
|
148 | (1) |
|
|
149 | (1) |
|
|
150 | (1) |
|
|
150 | (1) |
|
|
150 | (2) |
|
|
152 | (1) |
|
|
153 | (1) |
|
4.3.14 Pinhole and Holiday |
|
|
153 | (1) |
|
|
153 | (2) |
|
|
155 | (1) |
|
|
155 | (1) |
|
|
155 | (1) |
|
|
156 | (17) |
|
4.4.1 Essence of Coating Inspection and Inspector |
|
|
156 | (1) |
|
4.4.2 Coating Checkpoints |
|
|
157 | (3) |
|
4.4.3 Inspector Capability Levels |
|
|
160 | (2) |
|
4.4.4 Inspection and Test Plan (ITP) |
|
|
162 | (1) |
|
4.4.5 Inspection Tools and Methods |
|
|
163 | (1) |
|
4.4.5.1 Visual Inspection |
|
|
163 | (1) |
|
4.4.5.2 Weather Conditions Measurement |
|
|
164 | (2) |
|
4.4.5.3 Soluble Salt Measurement |
|
|
166 | (2) |
|
4.4.5.4 Abrasive Contaminant Inspection |
|
|
168 | (1) |
|
4.4.5.5 Coating DFT Measurement |
|
|
169 | (1) |
|
4.4.5.6 Coating Adhesion Measurement |
|
|
169 | (4) |
|
4.4.5.7 Coating Curing Test |
|
|
173 | (1) |
|
|
173 | (1) |
|
4.6 Questions and Answers |
|
|
173 | (8) |
|
|
177 | (4) |
|
Chapter 5 Valve and Actuator Technology for the Offshore Industry |
|
|
181 | (62) |
|
|
181 | (1) |
|
5.2 Offshore Field Development Options |
|
|
181 | (10) |
|
|
182 | (4) |
|
|
186 | (5) |
|
5.3 Industrial Valves for the Offshore Industry |
|
|
191 | (35) |
|
|
191 | (1) |
|
|
191 | (20) |
|
5.3.1.2 Fluid Control Valves |
|
|
211 | (6) |
|
5.3.1.3 Non-Return Valves |
|
|
217 | (5) |
|
|
222 | (1) |
|
|
223 | (3) |
|
5.4 Industrial Actuators for the Offshore Industry |
|
|
226 | (10) |
|
|
226 | (1) |
|
|
227 | (4) |
|
|
231 | (5) |
|
|
236 | (1) |
|
|
236 | (1) |
|
5.6 Questions and Answers |
|
|
236 | (7) |
|
|
241 | (2) |
|
Chapter 6 Piping, Valves and Actuator Offshore Coating Case Studies |
|
|
243 | (46) |
|
|
243 | (1) |
|
6.2 Coating Applications for Topside Valves and Actuators |
|
|
243 | (29) |
|
6.2.1 Topside Piping and Valve Coating Case Studies |
|
|
243 | (1) |
|
6.2.1.1 No Coating on Titanium and Nickel Aluminum Bronze Valve Bodies |
|
|
243 | (1) |
|
6.2.1.2 Manual Valve Coating Standardization |
|
|
244 | (3) |
|
6.2.1.3 Valve Color Coding in Firefighting Systems |
|
|
247 | (1) |
|
6.2.1.4 Fire Nuts versus Insulation Boxes on Valves and Flanges |
|
|
247 | (1) |
|
6.2.1.5 Thermal-Spray Coating Thickness Inspection Challenge for Duplex and Super Duplex Materials |
|
|
248 | (3) |
|
6.2.1.6 No Coating on Flange Faces |
|
|
251 | (1) |
|
6.2.1.7 No Coating on Bolt Holes and Nut-Bearing Areas on Flanged Connections |
|
|
252 | (2) |
|
6.2.1.8 No Coating under the Clamp in Mechanical Joints |
|
|
254 | (1) |
|
6.2.1.9 Clamp Coating Selection |
|
|
255 | (1) |
|
6.2.1.10 Minimizing the Usage of HDG Bolting |
|
|
256 | (2) |
|
6.2.1.11 Coating the Valve after the Pressure Test |
|
|
258 | (2) |
|
6.2.1.12 Insulation Boxes |
|
|
260 | (1) |
|
6.2.1.13 Coating the Valves `Top Flange' |
|
|
260 | (1) |
|
6.2.1.14 Using a Stainless Steel 316 Gearbox |
|
|
261 | (1) |
|
6.2.1.15 Lack of TSA Coating Adhesion |
|
|
261 | (1) |
|
6.2.1.16 Coating to Prevent Cross-Contamination |
|
|
261 | (2) |
|
6.2.1.17 Coating and Poor Marking on Valves |
|
|
263 | (3) |
|
6.2.1.18 Coating Close to Welded Areas |
|
|
266 | (1) |
|
6.2.2 Topside Actuator Coating Case Studies |
|
|
267 | (1) |
|
6.2.2.1 Actuator Color-Coding |
|
|
267 | (1) |
|
6.2.2.2 Coating the Area under the Actuator End Stopper |
|
|
268 | (1) |
|
6.2.2.3 Handwheel Coating for Valves and Electrical Actuators |
|
|
269 | (2) |
|
6.2.2.4 Actuator Disassembly from the Valve during Coating |
|
|
271 | (1) |
|
6.2.2.5 Passive-Fire Protection around a Double-Acting Hydraulic Actuator |
|
|
271 | (1) |
|
6.3 Coating Applications for Subsea Valves and Actuators |
|
|
272 | (4) |
|
|
272 | (1) |
|
6.3.1.1 Subsea Valve Coating |
|
|
272 | (2) |
|
6.3.1.2 Subsea Valve ROV Bucket and Position Indicator Coating |
|
|
274 | (1) |
|
6.3.1.3 Subsea Valve Bolting |
|
|
274 | (2) |
|
|
276 | (1) |
|
6.3.2.1 Subsea Actuator Coating |
|
|
276 | (1) |
|
6.3.2.2 ROV Override Coating |
|
|
276 | (1) |
|
6.4 More Cases and Figures |
|
|
276 | (7) |
|
|
283 | (1) |
|
6.6 Questions and Answers |
|
|
283 | (6) |
|
|
288 | (1) |
Index |
|
289 | |