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Inorganic zinc (IOZ) silicate coating was previously applied to partially fabricated low alloy, 21/4 Cr-1MoV, high temperature, hydrogen, reactor vessels for long-term storage corrosion protection prior to final welding and post weld heat treatment (PWHT) at 690-720°C (1274-1328°F). The need for complete coating removal to mitigate the known embrittlement and weld cracking that can occur after welding and PWHT led to the development of a novel, environmentally friendly method to remove IOZ to trace levels below 1 ppm.
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Over the past several years, the Bureau of Reclamation’s Materials Engineering Research Laboratory has been developing and refining a test method to evaluate a coating’s resistance to erosion damage in sediment-laden immersion exposure. This test has initially been utilized as a screening/ranking method in selection of new coatings for the aforementioned severe service environments.
Mineral scales frequently occur in tanks, pipelines, cooling and heating system, production wells ofoil and gas, external and internal membrane, and other equipment during industrial processes,causing the reduction of process efficacy and millions of dollars on dealing with the scale issues. Asoil and gas are produced increasingly in more unconventional reservoirs, such as deeper and tighterzones, with new technologies, more challenges are encountered to mitigate scale problems.
Several components in geothermal power plants need to be protected from the environment due to the corrosive nature of geothermal fluids used to generate the energy. Depending on the fluid properties for any location, the type of protection varies. In geothermal power plants, wear, erosion, corrosion, and scaling are all known problems1. These issues can lead to a variety of outcomes, ranging from decreased plant efficiency to upstream component failure. Failure of a component is thus a significant challenge in the geothermal industry, where materials need to operate in high temperature and high pressure environments. A major cost factor is also linked to the drilling of geothermal wells, where cost rises due to increased depth/distance of drilling, increased trip times, higher high temperature and high-pressure conditions which can lead to increased wear and corrosion of the materials. To address the issue, coatings can be considered to be a potential solution to extend the service life of downhole equipment.
Oilfield sulfide scale formation is peculiar to sour production scenarios, and for many oil and gas fields the issue of iron sulfide scale management downhole presents a major challenge. Historically iron sulfide scaling downwell have featured ‘reactive’ chemical dissolver interventions to recover well production once sulfide scale has deposited, and operators have published extensively on their experiences i.e. coiled tubing deployed dissolver technologies used in well clean-out treatments (Green, et.al. 2014, Wang et.al. 2017, Wang et.al. 2018, Buali et. al 2014).
Development of linings for high temperature, high-pressure applications present a number of special challenges. Challenges include chemical resistance, abrasion resistance, adhesion under cycling temperature and pressure conditions, flexibility, application properties, as well as resistance to pressure and temperature.
Protective coating systems provide the primary corrosion protection for assets in sea water. Protective coating systems are defined as a specific combination of surface preparation and coating material applied under specified conditions to a specific structure. Over the past many years, the paint industry has focused considerable resources toward the formulation, performance testing and fine tuning of coatings materials.
Offshore metallic structures have an average life-time of 20-25 years. They consist of four different zones, the buried, the submerged, the tidal/splash and the atmospheric one. According to NACE 2013 the global corrosion cost is estimated to be US$2.5 trillion, consisting a major economic problem. Hence, protection from corrosion is essential. Each zone is protected either with cathodic methods, or with a combination of cathodic methods and coatings. More specifically, the protection of the atmospheric zone, which is the aim of this research, due to the lack of continuous electrolyte (seawater) does not allow the application of cathodic protection.
Certain coating applications including those used in aerospace, industrial maintenance, construction and transportation industries require a combination of primer/topcoat or basecoat/clearcoat layers. These multilayered systems require complex application and curing procedures. Multiple formulation, application and processing steps not only contribute to environmental waste generation and pollution they also use an excessive amount of energy until a solid film has been produced
High pressure and high temperature processes are present in a wide variety of industries and are often pushing the limits of common materials. As a result, these applications have required advanced materials as well as an improved understanding of the in-situ conditions. Furthermore, those processes have become more and more present in a wide range of industries such as upstream oil and gas (O&G) and power generation (in supercritical CO2 or molten salt nuclear reactors). The corrosion performance of existing and emerging materials to the extreme environments present in next generation power must be well characterized to ensure material integrity and reduce the risk of catastrophic failures due to environmentally assisted cracking, homogeneous corrosion, thermal oxidation, or other mechanisms.
Wells in oil, gas and geothermal production experience a broad spectrum of operating conditions in terms of temperature, depth, pressure and production environments, which govern material selection. For severe environments, where high strength and toughness combined with excellent corrosion and cracking resistance are required, a new superaustenitic stainless steel has been recently developed. Aiming for a minimum yield strength of at least 120 ksi (827 MPa), strain hardening enables the desired mechanical properties, allowing users to avoid well known but HISC susceptible and less cost effective precipitation hardened (PH) nickel alloys.