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External corrosion awareness handbook
A guide for visual recognition of external integrity threats to upstream oil and gas production plant
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Copyright © 2010 by the Energy Institute, London.The Energy Institute is a professional membership body incorporated by Royal Charter 2003. Registered charity number 1097899, England
All rights reserved. No part of this book may be reproduced by any means, or transmitted or translated into a machine language without the written permission of the publisher.
ISBN 978 0 85293 548 4
Published by the Energy Institute
The information contained in this publication is provided as guidance only and while every reasonable care has been taken to ensure the accuracy of its contents, the Energy Institute cannot accept any responsibility for any action taken, or not taken, on the basis of this information. The Energy Institute shall not be liable to any person for any loss or damage which may arise from the use of any of the information contained in any of its publications.
Further copies can be obtained from: Portland Customer Services, Commerce Way, Whitehall Industrial Estate, Colchester CO2 8HP, UK. t: +44 (0)1206 796 351 e: [email protected]
Electronic access to EI and IP publications is available via our website, www.energypublishing.org Documents can be purchased online as downloadable pdfs or on an annual subscription for single users and companies. For more information, contact the EI Publications Team.e: [email protected]
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Contents
Acknowledgements and foreword
Introduction ScopeIntended usersCorrosion basicsControlling corrosion
Atmospheric external corrosionGratings and railingsHandrails, decks and supportsPipework and vesselsBoltingElectrical equipmentMiscellaneous
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55567
8101112141516
Page
171820
232426
27282930
31
Page
Corrosion under insulationDamaged claddingCorrosion under insulation
Fatigue, vibration and frettingFatigue and vibrationFatigue and fretting
Corrosion of stainless steelsSS vessels and pipeworkSS pipework and tubingSS tubing
Bibliography
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AcknowledgementsThe development of this handbook was undertaken on behalf of the Corrosion Management Working Group (CMWG) and funded by the Energy Institute’s (EI) Technical Programme. The Institute wishes to record its appreciation of the work carried out by Dave Moore of Lloyd’s Register EMEA for compiling this handbook and members of the CMWG, including the Health and Safety Executive (HSE), who provided valuable direction, photographic examples and technical input.
ForewordThis publication was compiled to enhance the awareness of corrosion for a large cross-section of personnel within the upstream oil and gas industry. It is intended to supplement the EI Guidance for corrosion management in oil and gas production and processing1 and the Corrosion threats handbook2, which summarises internal corrosion threats for oil and gas process systems.
Whereas the published guidance is intended primarily for duty holders, managers of operations, engineering and maintenance functions, the handbooks are aimed primarily at those working on site who are operating and maintaining the process plant and visitors undertaking specific support tasks.
The information in this handbook should not be used to the exclusion of established and applicable codes, standards and criteria; nor should the threats and their manifestation
described herein be seen as exhaustive. Users should notify and consult with the relevant technical engineering authority/discipline specialists for investigation of potential threats or actual degradation that may be observed.
This document is for guidance only, and while every reasonable care has been taken to ensure the accuracy and relevance of its content, the Energy Institute, its sponsoring companies, the author and the CMWG members, shall not be liable to any person for any loss or damage which may arise from the use of any of the information contained in any of its publications.
This handbook may be reviewed from time to time and it would be of considerable assistance for any future revision if users would send comments or suggestions for improvements to:
The Technical DepartmentEnergy Institute61 New Cavendish StreetLondonW1G 7AR, UK
1. Guidance for corrosion management in oil and gas production and processing. EI, 2008. ISBN 978 0 85293 497 52. Corrosion threats handbook – Upstream oil and gas production plant. EI, 2008. ISBN 978 0 85293 496 8
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Introduction Atmospheric external corrosion is a threat to structural items (including structural steelwork, handrails, walkways, stairs, pipe supports, fittings, brackets, struts and cable trays), process equipment (including pipes, valves, bolted flanges, vessels), mechanical and electrical equipment on offshore oil and gas installations and onshore upstream terminals. Although the threat of corrosion applies mainly to carbon steels, certain threats also apply to corrosion-resistant materials and aluminium alloys.Effective control of corrosion and its contribution towards the maintenance of asset integrity has multiple benefits:
• Reduction in risk and environmental hazard from leaks and structural failures.• Assists with compliance with statutory and corporate health, safety and environmental requirements.• Increased plant availability.• Reduction in unplanned maintenance.• Assists with life extension of ageing assets.• Improvement in the working environment.
ScopeThis handbook is intended as an aid to personnel on upstream oil and gas production and processing facilities, particularly those located offshore and coastal onshore terminals. Common forms of external corrosion are provided together with information on:
• What to look for.• Where to look.• What can be done to manage the threat.
Intended usersOn-site personnel are very much the ‘eyes’ on the plant. There have been many examples of individuals, who were not specialists in corrosion or integrity management, noticing and reporting defects, which, had they not been detected, may have led to significant failures. Such contributions provide an additional defence and assist with realising effective control of degradation caused by atmospheric corrosion. Some facilities have introduced a more formal area inspection process, involving teams of personnel walking sections of the plant in turn, specifically to look for integrity defects. However, by raising general awareness, it is hoped that formal programmes of inspection will be enhanced further through everyday observation by all on-site personnel.
