6/26/2019 Material Selection and Corrosion Control for Offshore Platform and FPSO

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Material Selection and Corrosion Control for Offshore

Platform and FPSO (/kb/66/material-selection-and-
corrosion-control-offshore-platform-and-fpso/)

Detailed corrosion prediction evaluations including consideration for CO2 should be performed to establish a materials selection and corrosion
control report for all process and utility systems in the offshore environment.

Materials selection should be carried out in accordance with ISO 21457: “Materials Selection and Corrosion Control for Oil and Gas Production
Systems”, and any additional standards required and applicable per project.

Materials for all hydrocarbon containing systems should fulfill ISO 15156: “Materials for Use in H2S-containing Environments in Oil and Gas
Production”. Carbon and low-alloy steels should fulfill the standards requirements for SSC Region 3, irrespective of the service condition.

The following materials should not be used:

1. Asbestos
2. Chlorofluorocarbons and HydroChlorofluorocarbons (CFCs and HCFCs)
3. Tin or lead-based anti-fouling paint
4. Lead-based paint
5. Rockwool or glass wool insulation on process vessels and piping

The following table is the minimum materials requirements for piping systems. All equipment and components should as a minimum be from
materials with equivalent corrosion resistance to the piping system in which they are installed.

Materials Selection Table

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6/26/2019 Material Selection and Corrosion Control for Offshore Platform and FPSO
LTCS
SDSS DSS
SMO- CuNi + CS Elasto-
Area Service Titanium - - 316L LTCS GRE PP PVDF PE
254 90/10 625 (galv) Pipe
25Cr 22Cr
Clad

Process Hydrocarbon
systems,
X X X X
upstream
separation

Crude /
Condensate,
X X X
downstream
separation

Produced
X X X
water

Produced
water,
X X X X
downstream
degasser

Flare systems
X X X X
> -40°C

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6/26/2019 Material Selection and Corrosion Control for Offshore Platform and FPSO
LTCS
SDSS DSS
SMO- CuNi + CS Elasto-
Area Service Titanium - - 316L LTCS GRE PP PVDF PE
254 90/10 625 (galv) Pipe
25Cr 22Cr
Clad

Flare systems
X X X
< -40°C

Gas, Wet X X X

Gas, dry X

Closed drains X X X

Open drains X X

Fuel gas, wet X

Fuel gas, dry X X

Cooling Cooling water,

X
& closed circuit
seawater

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6/26/2019 Material Selection and Corrosion Control for Offshore Platform and FPSO
LTCS
SDSS DSS
SMO- CuNi + CS Elasto-
Area Service Titanium - - 316L LTCS GRE PP PVDF PE
254 90/10 625 (galv) Pipe
25Cr 22Cr
Clad

Seawater,
service/cooling
(serving safety X X X
critical
equipment)

Seawater,
service/cooling
(serving non X X X X
safety critical
equipment)

Seawater,
injection,
X X X X
upstream
deaerator

Seawater,
injection,
X
downstream
deaerator

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6/26/2019 Material Selection and Corrosion Control for Offshore Platform and FPSO
LTCS
SDSS DSS
SMO- CuNi + CS Elasto-
- -
Area Service Titanium 316L LTCS GRE PP PVDF PE
254 90/10 625 (galv) Pipe
25Cr 22Cr
Clad

Firewater,
normally wet
systems, X X X X
upstream
deluge valve
Firewater
Firewater,
normally dry
systems, X X X
upstream
deluge valve

Utilities Air systems,

X
breathing

Air systems,
X X
instrument

Air systems,
X X
utility

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6/26/2019 Material Selection and Corrosion Control for Offshore Platform and FPSO
LTCS
SDSS DSS
SMO- CuNi + CS Elasto-
- -
Area Service Titanium 316L LTCS GRE PP PVDF PE
254 90/10 625 (galv) Pipe
25Cr 22Cr
Clad

Potable water X X

Sewage X

Chemical
injection, X X X
piping

Chemical
injection, X
tubing

Ferric Chloride X X

Sodium
X X
Hypochlorite

Methanol,
X X X
MEG, TEG

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6/26/2019 Material Selection and Corrosion Control for Offshore Platform and FPSO
Piping

Topside process and utility piping materials should be selected in accordance as shown above. All equipment and components should as a
minimum be from materials with equivalent corrosion resistance to the piping system in which they are installed.

Piping design should allow for the installation of start-up filters/strainers in front of compressor and pumps.

Glass Reinforced Epoxy Piping

Glass reinforced epoxy (GRE) piping should be subject to dynamic surge analysis and static pipe stress and flexibility analysis, which should
be confirmed independently by the GRE material manufacturer. All valves and inline components larger than 2-inch nominal bore should be
independently supported.

Qualification of fabrication contractor and staff performing work on GRE piping systems, including work methods and procedures used, should
be subject to review and approval by the GRE material manufacturer.

GRE piping fabrication activities as well as the final GRE piping installation should be inspected by the GRE piping manufacturer. Upon
completion of the work, the GRE piping manufacturer should issue an unconditional acceptance certificate on a system by system basis.

Calibration Certificate for Pressure Relief Devices

Pressure relief devices that require periodic recalibration should be supplied with calibration certificates that are maximum 6 (six) months old at
time of final acceptance by Company of the system in which they are installed.

HP and Clean-Up/Test Separators

HP and clean-up/test separators should be made from solid corrosion resistant alloy (CRA) or alternatively carbon steel internally clad with a
minimum 3-mm thick layer of metallurgical bonded Inconel 625. The Inconel overlay should be extended over all gasket surfaces. Gasket
surfaces should be re-machined in accordance with ASME B16.5.

Pressure Vessels and Heat Exchangers

Materials for hydrocarbon and produced water containing pressure vessels and heat exchangers should be selected in accordance with above
materials selection guidance.

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6/26/2019 Material Selection and Corrosion Control for Offshore Platform and FPSO
The following materials should be considered as minimum requirements:

Solid corrosion resistant alloy (CRA)

Carbon steel internally clad with a minimum 3 mm-thick layer of metallurgical bonded Inconel 625. The Inconel overlay should extend over
all gasket surfaces. Gasket surfaces should be re-machined in accordance with ASME B16.5
For equipment with a design temperature lower than 93°C, carbon steel internally coated with 1000 micron hand applied Belzona 1391 or
alternative coating system approved by project team. The internal coating system should be applied, tested and inspected. Only application
procedures and personnel that have been qualified and approved by the coating manufacturer should be used. Upon completion of
application, cleaning, testing and conservation for shipping/storage, the coating manufacturer should issue an unconditional acceptance
certificate for each piece of equipment

Seawater Treatment Vessels

Deaerators and coarse and fine filter vessels should be carbon steel internally coated with 1000 micron hand applied Belzona 1391 or
alternative coating system approved by project team. The internal coating system should be applied, tested and inspected. Only application
procedures and personnel that have been qualified and approved by the coating manufacturer should be used. Upon completion of
application, cleaning, testing and conservation for shipping/storage, the coating manufacturer should issue an unconditional acceptance
certificate for each piece of equipment.

Shell and Tube Heat Exchangers

Strength of tube to tubesheet joints, whether welded or not welded, should be demonstrated through qualification testing in accordance with
EEMUA Publication No. 143 “Recommendations for Tube End Welding.”

Seawater and Firewater Lift Pumps

Seawater and firewater lift pumps materials should be solid 25% Super Duplex Stainless Steel with PREN >40.

Water Injection Pumps

Water injection pump materials should be solid 25% Super Duplex Stainless Steel with PREN >40.

Instrument Tubing Systems

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6/26/2019 Material Selection and Corrosion Control for Offshore Platform and FPSO
All instrument tubing systems, including pneumatic and impulse-tubing, tube fittings, valves, manifolds, instruments and bolting should be from
25% Super Duplex Stainless Steel with PREN >40.

Bolting

Austenitic stainless steel bolting should not be used for any exterior applications.

Qualification of Manufacturers of Special Materials

All raw material manufacturers of Class I special materials components as well as the product itself should be qualified in accordance with
Norsok M650, Rev. 3, 2004, or a similar qualification process approved by project team. Special materials in this context are defined as
follows:

1. Duplex stainless steel (all grades, product forms and dimensions)

2. High alloyed austenitic stainless steel (all product forms and dimensions)
3. Nickel base alloys (castings)
4. Titanium and its alloys (castings)

Duplex SS should also comply with the requirements of EEMUA 218, “Quality requirements for the manufacture and supply of duplex stainless
steels - Edition 1”

Corrosion Allowance

The requirements for corrosion allowance or minimum additional thickness to be added to exposed surfaces of structural components (for
instance, plates, stiffeners and girders) above the thickness required for strength, buckling and fatigue design are provided in the following
table.

The corrosion allowances in the following table should be used instead of the requirements of the Classification Society unless the
Classification Society corrosion allowance values are higher. The corrosion allowances in the table should form part of the overall corrosion
protection philosophy.

Required Corrosion Allowances for Service Life

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6/26/2019 Material Selection and Corrosion Control for Offshore Platform and FPSO
Hull Area Corrosion Allowance (mm)

Continuously ventilated spaces 0.8

Void spaces and permanently empty tanks 0.8

Void bottom plating 1.5

Ballast tank internal horizontal plates, webs, stiffeners and girders 3.25

Ballast tank internal vertical plates, webs, stiffeners and girders 2.5

Drain well for submerged pumps or ejectors 3.0

Outer shell except splash zone exterior 2.0

Structures exposed to marine atmosphere (for each exposed side) 1.25

Outer shell external surface in splash zone 6.0

All carbon steel caissons should have at least 6mm of corrosion margin.

Chain blocks and trolleys should be provided for each monorail. Trolleys should be non-sparking and corrosion resistant, and should be
geared and supplied with parking brakes to accommodate offshore motions.
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6/26/2019 Material Selection and Corrosion Control for Offshore Platform and FPSO
The corrosion protection of the platform should be achieved through a combination of protective coatings and cathodic protection with
sacrificial anodes.

Tags: platform (/kb/tagged/platform/) FPSO (/kb/tagged/fpso/) corrosion (/kb/tagged/corrosion/) material selection (/kb/tagged/material-selection/)

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