1、 Guidelines for materials selection and corrosion control for subsea oil and gas production equipment PUBLICATION 194 Edition 3 Released by IHS. NOT FOR RESALE THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION Guidelines for materials selection and corrosion control for subsea oil and gas pr
2、oduction equipment PUBLICATION 194 Edition 3 Copyright 2012 The Engineering Equipment and Materials Users Association. A company limited by guarantee. Registered in England. Company number 477838. ISBN 0 85931 188 5 Imprint reference 03-2012 Registered and Trading Address 63 Mark Lane London EC3R 7N
3、Q Telephone: +44 (0)20 7488 0801 Fax: +44 (0)20 7488 3499 E-mail: saleseemua.org Website: www.eemua.org EEMUA Publication 194 - Materials selection and corrosion control for subsea equipment EEMUA ii ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION About EEMUA The Engineering Equipment and Mate
4、rials Users Association is usually known by its initials, EEMUA. EEMUA is governed by a Council of members. This Council is responsible for the policies, financing, membership, and strategy of the Association. Any organisation that is a substantial user or purchaser of engineering products is eligib
5、le to apply to become a member of EEMUA. Membership is subject to the approval of Council. EEMUA Aims EEMUA aims to improve the safety, environmental and operating performance of industrial facilities in the most cost-effective way, pursuing and promoting leadership in industrial asset management by
6、 sharing engineering experiences and expertise, and by the active, enlightened promotion of the distinct interests of users of engineering products. These aims are achieved by various means, including: Providing the organisation within which networking, information sharing and collaboration among us
7、ers on non-competitive technical matters can take place Influencing the way written regulations are interpreted and applied in practice Promoting and presenting members views, and encouraging the application of good sound engineering practices Developing user guides, specifications, training and com
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9、 by way of dividend, bonus or otherwise to members. The work of the Association is mainly carried out by members representatives on EEMUA Technical Committees, Working Groups, and Forums, supported by EEMUA staff. Incorporation, Membership and Other Information For the purposes of conducting its bus
10、iness, EEMUA is incorporated in England and Wales as a company, limited by guarantee, not having share capital. All usual aspects of company management and business administration are dealt with by the EEMUA Executive Director, including policy implementation and leadership of the Executive team (th
11、e staff). A list of EEMUA publications for sale is given at the end of this Publication. The full list is also on the Associations website, including details of on-line shopping facilities. To enquire about corporate Membership, write to enquirieseemua.org or call +44 (0)20 7488 0801. EEMUA Publicat
12、ion 194 - Materials selection and corrosion control for subsea equipment EEMUA iii ABOUT THIS PUBLICATION Legal Aspects All rights, title and interest in this Publication belong to EEMUA. All rights are reserved. No part of this Publication may be reproduced, stored in a retrieval system, or transmi
13、tted in any form or by any means: electronic, mechanical, photocopying, recording or other, without the express prior written agreement of the EEMUA Executive Director. Infringement of copyright is illegal and also reduces the Associations income thereby jeopardising its ability to fund the producti
14、on of future publications. It has been assumed in the preparation of this Publication that: the user ensures selection of those parts of its contents appropriate to the intended application; and that such selection and application is correctly carried out by appropriately qualified and competent per
15、sons for whose guidance this Publication has been prepared. EEMUA and the individual members of the Work Group that prepared this EEMUA publication do not, and indeed cannot, make any representation or give any warranty or guarantee in connection with material contained herein. EEMUA and the individ
16、ual members of the Work Group that prepared this EEMUA publication expressly disclaim any liability or responsibility for damage or loss resulting from the use or reliance on this Publication. Any recommendations contained herein are based on the most authoritative information available at the time
17、of writing and on current good engineering practice, but it is essential for the user to take account of pertinent subsequent developments and/or legislation. Any person who encounters an inaccuracy or ambiguity when making use of this Publication is asked to notify EEMUA without delay so that the m
18、atter may be investigated and appropriate action taken. Consultation and Feedback EEMUA encourages constructive comments on this Publication from both Members of the Association and others. Comments should be sent on the standard feedback form, a copy of which is provided towards the end of this Pub
19、lication. An electronic version of the feedback form is available from EEMUA - e-mail your request for a copy to enquirieseemua.org, telephone your request to +44 (0)20 7488 0801, or download the form from the EEMUA website at www.eemua.org. Submit comments by e-mail (preferred) or post. Comments ar
20、e considered by the relevant EEMUA Technical Committees and may be incorporated in future editions of this Publication. New editions are publicised on the EEMUA website. Acknowledgements The Association is grateful to the American Petroleum Institute, Azur Offshore Ltd, Saab Seaeye, Statoil and to S
21、ubsea 7 for kindly permitting the reproduction of various diagrams and photographs from publications of those organisations. EEMUA Publication 194 - Materials selection and corrosion control for subsea equipment EEMUA iv EEMUA Publication 194 - Materials selection and corrosion control for subsea eq
22、uipment EEMUA v Contents Foreword . 1 1. Introduction 3 2. Scope 5 2.1 Technical Guidance 5 2.2 Extent of Application 5 3. General Principles of Materials Selection and Corrosion Control . 7 3.1 Reference Standards 7 3.2 The Need for Integrity 8 3.3 Equipment Criticality and Life-cycle Costing . 9 3
23、.4 Carbon and Low Alloy Steels 9 3.5 Applications of Corrosion Resistant Alloys 9 3.6 The Process-side Environment . 10 3.6.1 Introduction 10 3.6.2 H2S-Containing Environments 11 3.6.3 CO2-Containing Environments 13 3.6.4 Chloride Ion Environments 13 3.6.5 Erosion . 14 3.6.6 Chemical Treatment and D
24、eployment 17 3.6.7 Mercury 17 3.6.8 Preferential Weld Corrosion . 18 3.6.9 Other Considerations 18 3.7 The Seawater-side Environment . 19 3.8 Hydrotesting and Commissioning Environments 20 4. Cathodic Protection . 21 4.1 Introduction 21 4.2 Conventional Sacrificial Anode Designs 21 4.2.1 Existing Pr
25、actice . 21 4.2.2 Deep Water Sacrificial Anode CP Design 23 4.3 Low Voltage Cathodic Protection 24 4.3.1 Introduction 24 4.3.2 Diode Control 25 4.3.3 Low Voltage Anodes 25 4.3.4 Implications of Low Voltage CP 26 4.4 Anode Material Specifications 26 5. Wellheads and Trees . 29 5.1 Introduction 29 5.2
26、 Relevant Standards 29 5.3 Major Components in Wellhead Equipment 29 5.4 Material Considerations . 30 5.5 Material Options 31 5.5.1 Tree Body and Connector . 31 5.5.2 Wellhead Housing, Casing Hanger and Seal Assemblies . 32 5.5.3 Casing Hangers . 32 5.5.4 Tubing Hangers . 32 5.5.5 Valves and Chokes
27、32 5.5.6 Gaskets . 32 5.5.7 Hydraulic Tubing 32 5.5.8 Flow Spools 33 5.6 External Corrosion Protection . 33 6. Manifold Piping and Equipment . 35 6.1 Introduction 35 6.2 Design Codes 36 EEMUA Publication 194 - Materials selection and corrosion control for subsea equipment EEMUA vi 6.3 Typical Fabric
28、ation . 37 6.4 Duties 37 6.5 Materials Options for Piping and Vessels 38 6.6 Hub and Flange Connectors . 39 6.7 Multiphase Pumps 40 7. Flowlines and Risers 43 7.1 Introduction 43 7.2 Service . 43 7.3 Subsea Flowline Design 43 7.3.1 Flowlines from Trees to Manifolds (and between Cluster Trees) . 43 7
29、.3.2 Flowlines from Manifold to Processing Unit . 43 7.4 Materials Options . 44 7.4.1 Introduction . 44 7.4.2 Flowlines Carrying Production Fluids 44 7.4.3 Flowlines Carrying Other Products . 49 7.5 Installation of Subsea Flowlines . 50 7.5.1 Installation Methods 50 7.5.2 Welding of Flowlines 57 7.5
30、.3 Plastic-Lined Pipelines 59 7.6 Risers 61 7.6.1 General . 61 7.6.2 Steel Catenary Risers (SCRs) . 61 7.6.3 Titanium Risers and Stress Joints . 63 8. Valves . 65 8.1 General 65 8.2 Standards . 65 8.3 Materials Options . 65 8.4 Subsea Wellhead Valves to API Specs 6A and 17D 66 8.5 Pipeline, Subsea M
31、anifold and Flowline Valves 68 8.6 Erosion and Wear Resistant Materials 69 8.6.1 Introduction . 69 8.6.2 Carbide Coatings . 69 8.6.3 Electroless Nickel (ENP) and Hard Chromium Platings . 71 8.7 Weld Overlaying of Duplex Stainless Steels 72 8.8 Valve Internals Metallic . 72 8.9 Valve Internals Non-Me
32、tallic 73 8.10 Material Specifications and Testing . 75 8.10.1 General Requirements 75 8.10.2 Valve Shell . 75 8.10.3 Hardness 75 8.10.4 Impact Properties 76 8.10.5 Welding for Valve Fabrication and Installation 76 9. Fasteners and Gaskets 77 9.1 Introduction 77 9.2 Threaded Connectors . 77 9.2.1 Sc
33、ope . 77 9.2.2 Low Alloy Steel Bolting 77 9.2.3 CRA Bolting . 79 9.3 Circlips, Hub Connector Clamps and Other Connectors 82 9.3.1 Circlips . 82 9.3.2 Hub Connector Clamps 83 9.3.3 Collet Connector Systems 83 9.4 RTJ Gaskets and Other Metallic Sealing Rings 83 9.4.1 RTJ Gaskets 83 EEMUA Publication 1
34、94 - Materials selection and corrosion control for subsea equipment EEMUA vii 9.4.2 Other Metallic Sealing Rings . 84 9.5 Non-Metallic Seals . 84 9.6 Bolt Tensioning 84 10. Flexible Pipe 85 10.1 Introduction 85 10.2 Flexible Pipe Construction 85 10.3 Materials Issues for Flexible Pipes . 85 10.3.1 A
35、nnulus environment 85 10.3.2 Tensile Armour Wires 87 10.3.3 Pressure Armour Wires 87 10.3.4 Fatigue Life Considerations of Reinforcement Wires . 87 10.3.5 Internal Metal Carcass . 88 10.3.6 Thermoplastic Inner Sheath . 89 10.3.7 Anti-Wear Tapes. 90 10.3.8 Thermoplastic Outer Sheath . 90 10.3.9 Compo
36、site Reinforcement Wires . 91 10.3.10 Thermal Insulation 91 10.3.11 Fibre Optics . 91 10.4 End Fittings . 91 10.5 Bend Stiffeners 92 10.6 Flexible Pipe Integrity Management 92 11. Hydraulic Control and Chemical Injection Systems . 93 11.1 Introduction 93 11.2 Materials Selection . 93 11.2.1 Hydrauli
37、c Control System Fluids 93 11.2.2 Chemical Injection Systems . 95 11.3 Tubing Connections 95 11.3.1 Introduction. 95 11.3.2 Permanent Connections . 95 11.3.3 Demountable Connections . 96 11.4 Hydraulic and Chemical Injection Valves 97 11.5 Hydraulic and Chemical Injection Couplers . 97 11.6 Tubing D
38、esign and Supports 98 12. Umbilicals 99 12.1 Introduction 99 12.2 Umbilical Design 99 12.2.1 Types of Umbilical 99 12.2.2 Umbilical Specifications . 100 12.3 Materials Selection Considerations 101 12.3.1 Non-Metallic Hose Conduits 101 12.3.2 Metallic Tube Conduits 102 12.3.3 Umbilical Construction .
39、 103 12.3.4 End Terminations . 103 12.3.5 Bend Stiffeners 104 12.4 Materials Problems . 104 12.4.1 Service Experience . 104 12.4.2 Non-Metallic Hoses . 105 12.4.3 Metallic Tubes 106 12.4.4 Electric Cable Insulation 107 13. Instruments 109 13.1 Introduction 109 13.2 Materials Selection . 109 13.3 Mat
40、erials Problems Encountered . 109 14. Protective Coatings and Insulation 111 EEMUA Publication 194 - Materials selection and corrosion control for subsea equipment EEMUA viii 14.1 General Comments . 111 14.2 Protective Coatings . 111 14.2.1 Surface Preparation 111 14.2.2 Selection of Coatings 112 14
41、.2.3 Pipeline Field Joint Coatings . 115 14.3 Thermal Insulation . 116 14.3.1 Introduction. 116 14.3.2 Selection of Thermal Insulation Systems 117 14.3.3 Manufacturing and Installation Considerations 118 14.3.4 Thermal Insulation of Subsea Production/Process Equipment 119 14.3.5 System Qualification
42、 and Performance Verification 120 Appendix I Reference Documents . 121 Appendix II Typical Sour Service (H2S Partial Pressure) Limits for Duplex and Weldable Martensitic Stainless Steels . 127 II.1 ISO 15156/NACE MR0175 Recommendations . 127 II.2 Other Typical Limits . 127 Appendix III Duplex Stainl
43、ess Steels for Subsea Piping, Flowlines, and Associated Components (Excluding Fasteners) . 129 III.1 Introduction. 129 III.2 Hydrogen Embrittlement and Cracking . 130 III.2.1 Background . 130 III.2.2 Mechanism 130 III.2.3 Cathodic Protection Potential 131 III.2.4 Summary and Recommendations 132 Appe
44、ndix IV Weldable Martensitic Stainless Steels for Subsea Piping, Flowlines and Associated Components 135 IV.1 Introduction . 135 IV.2 Background 135 IV.3 Availability . 136 IV.4 Corrosion Resistance . 136 IV.5 Fabrication . 136 IV.6 Interaction with Hydrogen 137 IV.6.1 Fabrication Hydrogen Cracking
45、137 IV.6.2 Hydrogen Cracking from Cathodic Protection . 138 Appendix V CRA Clad and Lined Piping for Subsea Applications 141 V.1 General 141 V.2 Pipe . 141 V.3 Manufacturing Procedure Specification (MPS) . 143 V.4 Manufacturing Procedure Qualification Test (MPQT) . 143 V.5 Components Other Than Pipe
46、 . 144 Appendix VI Recommended Practice for the Automated Welding of Small Diameter CRA Tubing for Control and Chemical Injection 147 Appendix VII Automatic Ultrasonic Testing of Pipeline Girth Welds 149 Appendix VIII Abbreviations . 153 EEMUA Publication 194 - Materials selection and corrosion cont
47、rol for subsea equipment EEMUA ix Figures Figure 1 Severe internal corrosion of a 316 SS-clad subsea pipeline caused by excessive exposure time to seawater hydrotest fluid . 20 Figure 2 PTFE coated subsea fastener . 22 Figure 3 Umbilical connection head showing severe corrosion of the carbon steel c
48、omponents 22 Figure 4 Subsea umbilical termination unit recovered after 10 years subsea, showing extensive wastage of the aluminium anodes but no corrosion of the steel structure . 27 Figure 5 Typical subsea tree assemblies . 29 Figure 6 Typical subsea tree components 30 Figure 7 Some typical subsea
49、 manifolds 35 Figure 8 Cluster manifold connected to eight satellite wells . 36 Figure 9 Typical deep water production manifolds during fabrication . 38 Figure 10 Non-recommended design of welded joint for low alloy steel manifold components 40 Figure 11 Option 1 for fabrication of low alloy steel components and valve bodies with C-Mn buttering layer, welded to C-Mn steel pup piece with C-Mn butt weld . 41 Figure 12 Option 2 for fabrication of low alloy steel components and valve bodies with C-Mn buttering layer, welded to C-Mn steel pu
