A Review and Analysis of Industrial Valve Material Failures Due to Corrosion and Proposals for Prevention Measures Based on Industrial Experiences in the Offshore Sector of the Oil and Gas Industry

Abstract

Valve failure is a big risk and a costly phenomenon in the offshore sector of the oil and gas industry. It results in severe negative consequences such as loss of asset; loss of production due to plant shutdown; health, safety and environmental (HSE) issues such as hydrocarbon (oil and gas) spillage; environmental pollution; and sometimes loss of human life. Different types of valve failures have occurred in the Norwegian offshore industry for various reasons such as poor material selection, corrosion, mechanical failure of valve components due to high stresses and loads, lack of coating and lack of inspection. The aim of this paper is to review and critique some of the wrong material selection approaches for industrial valves in the offshore sector of the oil and gas industry that lead to the corrosion and failure of valves, and to provide an appropriate material selection solution to mitigate these failures. Seven cases of material failures due to corrosion, including a valve gear box in coated cast iron, bolting made of low alloy steel with hot dip galvanized coating, a stem key made of a low alloy steel, stem material in 17-4 PH, spring material in Inconel X750, duplex, super duplex and hard nickel alloys in subsea as well as graphite packing in seawater, are reviewed, and preventive measures are proposed to avoid corrosion risk. In general, the use of carbon and low alloy steel for valves in the offshore environment should be limited and the use of corrosion-resistant alloys (CRAs) is proposed.