North Sea

Bulletins
Galvanic Corrosion of
Nickel Aluminium Bronze
Valves in Seawater

Paul Badelek and Dave Moore

Dated February 1999

Main CD
Contents
BP Amoco No Corrosion Project - Technical Bulletin Rev. 0, February 1999

GALVANIC CORROSION OF NICKEL ALUMINIUM

BRONZE VALVES IN SEAWATER
SUMMARY
Nickel aluminium bronze can suffer high rates of corrosion in seawater when in galvanic contact with super duplex
stainless steel. The problem has cost one BP Amoco Asset more than £0.3 million to date in replacement materials
alone, with additional expenditure envisaged.

BACKGROUND
To reduce Capex costs, Nickel Aluminium Bronze (NAB) was
specified for valve bodies and trim in the seawater and firewater
systems of a BP Amoco platform. The majority of the piping in
these systems was fabricated from 25% chromium super duplex
stainless steel. Within a year of service, the NAB valves suffered
severe galvanic corrosion, preventing valves from sealing prop-
erly, leading to an inability to isolate systems.

IMPACT
A risk ranking process to manage the valve degradation, rec-
ommended immediate replacement of 16 key valves ranging
between 6" and 10" and 2 PSV valves (3") at a cost of ~£300K.
An additional 40+ maintenance valves on the platform are con-
sidered to be at risk from corrosion and are scheduled to be Galvanic corrosion of a NAB valve coupled to super duplex ss
"fixed on failure".

EXPERIENCE
It was initially believed that galvanic corrosion between NAB and super duplex stainless steel would not be a problem in seawater
service. However, the BP Amoco experience outlined above, failures on a platform on the NW Australian shelf and laboratory investi-
gation have highlighted that:
• NAB, coupled to an equal area of super duplex stainless steel in natural seawater, corrodes rapidly at localised areas, both at
crevices and on open surfaces. When the area ratio is increased, attack becomes much more widespread, but not much deeper.
• In chlorinated seawater, NAB did not suffer any significant accelerated corrosion when coupled to an equal area of super duplex,
but when the area of super duplex stainless steel was ten times that of NAB, pitting occurred at the creviced areas of NAB.
Tests were done in seawater at temperatures that did not exceed 25°C.
The operational experience is that corrosion first results in valves failing to seal properly. The valve bodies are sufficiently thick that
through wall penetration would take longer.

OPTIONS AND SOLUTIONS

Nickel aluminium bronze should not be coupled to super duplex stainless steel in natural seawater. NAB valves can be used in chlo-
rinated seawater up to operating temperatures of 25°C. Above this temperature, super duplex stainless steel valves must be used.
The approach taken by the BP Amoco Asset affected was to make a more detailed assessment of the risk. This led to the immediate
replacement of valves whose failure could impact safety or production. Less critical valves were scheduled to be fixed on failure.
Some operators have opted for internally coating stainless steel spool pieces coupled to NAB valves to mitigate the galvanic driving
force. This may provide satisfactory resolution, providing the coating maintains its integrity in the long term.
Chlorination will slow down corrosion on NAB, but not prevent it once corrosion crevices have been formed.

For more information contact:

Paul Badelek (Corrosion Consultant), BP Amoco Exploration, Farburn Industrial Estate, Dyce, Aberdeen AB21 7PB
Tel: 01224 834071 E-mail: badelekp@bp.com

This Bulletin has been sponsored by BP Amoco's "No Corrosion" Project to assist sharing of operations experience on corrosion and materials
issues to New Projects, Partners and Business Units.
01131043, February 1999