Health and Safety Executive

Offshore external corrosion guide

Corrosion policy
Regulation 5 of the Provision and Use of Work Equipment Regulations 1998 requires that Every employer shall ensure that work equipment is maintained in good repair. To achieve this requirement, the associated guidance to the Regulations provides further information on three maintenance management options. OSDs preferred option is that dutyholders use planned preventive maintenance, thereby precluding deterioration. However, where a dutyholder allows components to degrade and/or corrode as part of a condition-based option, performance standards must exist which define the point at which the component needs to be repaired or replaced. Such performance standards should be quantifiable and capable of being measured effectively and consistently. The performance standards need to be supported by sound engineering justification and should be consistent with the basis of design, taking account of any changes to service conditions. This should include the necessary safetyrelated strength and/or serviceability requirements of the component necessary to define the quantitative performance standard. Where such components are part of Safety Critical Elements, the components should be verified by an Independent Competent Person. Such verification should include both the justification for and ongoing compliance with the performance standard.

Purpose
This guide is intended to enable OSD inspectors to make consistent judgement on the extent of external corrosion related to the installations hydrocarbon systems. The guide identifies a sample of six common forms of external corrosion and provides information on:
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where to look; and what to look for.

The six areas of concern are:

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corrosion under insulation (CUI); firewater mains and deluge system; flanges and plant bolting; valves; pipe supports and pipe coatings; and threaded plugs.

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Corrosion under insulation

Where to look General target areas What to look for Water traps, eg low points, brackets, penetrations, support rings I Areas of personnel traffic I Insulation terminations I Rusty surface/corrosion holes? I Joint sealant condition? I External condensation/icing? I Sealed/sealant in good condition? I Signs of water ingress/wet insulation? I Salt encrustations around penetrations? I Are the joints generally in good condition? I Insulation visible through joints? I Deformed/poor fit? I Deformed? I Signs of being walked on? I Impact damage? I CUI inspection programme? I Personnel protection replaced by cages? I CUI problems/failures?
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Cladding condition

Penetrations (eg branches, supports, structural members)

Joints

Damaged insulation

Corrosion management

Firewater mains and deluge systems

What to look for Mixed metals, non-metallic? I Spray and monitor nozzles I Temporary repairs I Valves I Flanges Spray and monitor I Blocked? nozzles I Salt encrustations? I Corrosion products? Temporary repairs I Number? I Leaking? I Repair type? Flanges I Leaks? I Dissimilar metals? Valves I Leaks? I Dissimilar metals? Non-metallic piping I Leaks? I Joint condition? I Local colour changes? Corrosion management I Is it a wet or dry system? I What is the inspection programme? I How often is the deluge system tested? I What is the corrosion management programme? I What is the failure history? Where to look General target areas
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Offshore external corrosion guide

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Bolts and nuts

Where to look General target areas What to look for Mixed metals I Valves I Flanges I Pumps I Xmas trees I Corroded bolts/threads I Fractured bolts I Nuts grossly enlarged by corrosion product Corrosion protection I Unprotected I Grease I Denso tape I Galvanised I Nickel-plated I Corrosion-resistant alloy Corrosion management I What is the inspection programme? I What is the failure history?
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Valves
What to look for ESDVs I Xmas trees I Choke valves I Pressure relief valves I Drain valves I Block valves What to look/ask for I Corroded handles/wheels? I Corroded valve stems? I Leaking stems? I Leaking flanges? I Leaking valve bleed plugs? I Are valves properly supported? I Paint condition? I Corrosion-resistant materials? Corrosion management I What is the valve test programme? I What is the inspection programme? I What is the failure history? Where to look General target areas
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Offshore external corrosion guide

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Pipe supports and pipe coatings

Where to look General target areas What to look for Piping I Pipe supports I Spring supports I Fretting surfaces I Paint condition? I Thick corrosion deposits? I What are the paint and fabric maintenance programmes? I What action is taken to ensure areas around pipe supports are painted? I What external corrosion problems have there been?
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What to look/ask for

Corrosion management

Threaded plugs
What to look for Valve bodies I Xmas trees I Piping usually low and high locations on pipe work What to look/ask for I Are pipe plugs rare or numerous? I Are there dissimilar metal issues? I Condition of threads? I Leaking pipe plugs? I Rust stains? Corrosion management I Replacement by non-threaded equipment I No dissimilar metals I Replacement and thread inspection programme I What failures have there been? Where to look General target areas
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Offshore external corrosion guide

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For information about health and safety ring HSE's Infoline Tel: 0845 345 0055 Fax: 0845 408 9566 Textphone: 0845 408 9577 e-mail: hse.infoline@natbrit.com or write to HSE Information Services, Caerphilly Business Park, Caerphilly CF83 3GG, or visit the HSE website: www.hse.gov.uk.
This booklet is not available from HSE Books. It can be downloaded from the HSE website at: www.hse.gov.uk/offshore/index.htm Crown copyright This publication may be freely reproduced, except for advertising, endorsement or commercial purposes. First published 09/06. Please acknowledge the source as HSE.

Published by the Health and Safety Executive

09/06

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