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NACE MR0175 / ISO 15156 document part 2 provides material requirements for selecting cast irons and low-alloy steels for sour environments.1 Figure 1 is reproduced from this standard and describes different regions of environmental severity for Sulfide Stress Cracking (SSC): service in region 0 being the least susceptible to cracking, even for very sensitive materials, and region 3 being the worst.
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Epoxy-based coating used in the ships and marine structures can be quickly degraded after only a short period of exterior exposure. The weathering defects such as discoloration, chalking and gloss reduction are originated from a photo-oxidation of aromatic group in the epoxy resin under the UV light. Weather resistance coatings such as polyurethane and polysiloxane require more work due to the short over-coating interval and low compatibility with primer coating layers.
Precipitation hardened (PH) Ni-alloys are widely used in the oil and gas industry since they provide an excellent combination of corrosion resistance and mechanical strength. Their use in the manufacture of API1 6A pressure-containing and pressure-controlling components is subject to the stringent requirements of specification API Standard 6ACRA. However, matching the requirements of API Standard 6ACRA does not preclude susceptibility of some PH Ni-alloys to hydrogen embrittlement (HE) and this in some cases has led to premature and unexpected failures of components made from suchmaterials.(
Corrosion resistant alloys (CRAs) are used for many pipeline and wellhead components associated with oil and gas production environments but may be considered too costly for longer crude oil and natural gas production lines. Mitigation of internal corrosion for these types of pipelines is normally carried out by batch treatment or continuous injection of corrosion inhibitors, especially the surfactant type of organic inhibitors, which are more economical than using a CRA.
Besides economic considerations, ecological and regulatory factors play an increasingly decisive role nowadays in the formulation of innovative coating systems. It is therefore no surprise that the call for zinc-free anti-corrosive pigments or those that do not require labeling has steadily increased in recent years. Zinc-free technology is not new. Numerous pigments based on calcium, strontium, aluminum, and magnesium phosphate have been available on the market for a long time.
Industrial protective coatings can be surprisingly complicated for the inexperienced user or specifier. For example, when fabricating complex structures, the simple question of when during fabrication to paint can have an array of interesting cost and performance implications. Other issues include tradeoffs associated with degree of surface preparation and inspection for coating coverage. The paper will explore some of the reasons why they can be complicated in the context of four issues that can impact an industrial protective coatings project.
Coating specifications frequently reference industry standards from organizations such as SSPC, ASTM, ISO and NACE. While specifications may reference a specific version or “year,” many simply state, “the latest version of the standard applies.” Many standards writing organizations require a review of the content of their documents every 5-years (or more frequently), and updates/revisions to standards can and oftentimes do occur. And new standards are developed and published to fill voids when a need for a standard is identified.
Corrosion and wear resistance has always been among the highly important parameters forequipment and piping in oil and gas facilities. The corrosion is considered as the deteriorationof materials as a result of electrochemical reaction with surrounding environment or containedservice. Wear is defined as the removal and deformation of material due to mechanicalinteraction between two or more objects. Increased demand for surface protection and reducedoperative costs touts for protective coatings with improved mechanical, electrochemical, andtribological properties.
Duplex stainless steels (DSSs) are based on the Fe-Cr-Ni system and are constituted of 30 to 70 % ferrite and austenite. They combine high tensile strength, good toughness, weldability, and excellent corrosion resistance including stress-corrosion cracking and resistance to localized corrosion.1-3 DSSs can be classified according to the Pitting Resistance Equivalent Number (PREN = Cr + 3.3 Mo + 16 N) in lean duplex (PREN= 22-27), standard (PREN = 28-38), super duplex (PREN = 38-45) and hyperduplex (PREN > 45).
Inline cathodic protection current mapping is a unique method of assessing a pipeline’s cathodic protection. This is accomplished by measuring the actual current received by the pipeline continuously along the entire pipeline length. Unlike pipe to soil potentials, which can have a great deal of error in them due to forces often beyond our control, the CP mapping tool uses the physical properties of the pipe itself to measure the CP current. The pipe is a very stable part of the circuit, unlike the soil surrounding it.
In the oil and gas industry, oil country tubular goods or line pipes are exposed to wet H2S environments (sour environments) in some cases. The presence of H2S in the sour environment enhances hydrogen entry into the steel due to the catalytic action of H2S. The absorbed hydrogen enhanced by H2S affects hydrogen embrittlement. Hydrogen-induced cracking (HIC) is a hydrogen embrittlement phenomenon observed in sour conditions.
Hydrocarbons still remain as a fundamental contributor towards meeting the worldwide demand for energy, despite the growth of other alternative sources such as renewable and nuclear options. Due to low cost and availability, carbon steel, remains as the most commonly used material for pipelines in down and upstream activities within the oil and gas industry. However, carbon steel is not an exceptional metal alloy from the perspective of internal corrosion resistance. The economical cost for its degradation and related failures represent 10% to 30% of the maintenance budget in petroleum industry. It is therefore crucial that the corrosion of such a susceptible steel is managed and controlled accordingly.