AMPP Store - Individual Conference Papers

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Field And Laboratory Studies On The Effect Of UV Degradation And UV Protector Paints On Stockpiles Of FBE Coated Pipeline

Product Number: 51322-17853-SG

Author: Amal Al-Borno, Aissa VanDerVeen

Publication Date: 2022

$20.00

Fusion bonded epoxy (FBE) is the primary coating used in North America for new pipeline construction and is strongly featured in the Middle East¹. Pre-coated FBE pipe is routinely stockpiled and stored in large quantities at several locations close to pipeline right-of-ways. Once stockpiled, most of the pipesremain un-used until an inspection and remediation program is initiated². Integrity projects purchase FBE coated pipe in advance and stockpile it until it is required. In addition, project delays and left-over pipe from completed projects can cause stockpiling for future use for undetermined periods of time. Under ultraviolet (UV) exposure in the presence of air, photooxidative degradation of FBE coatings occurs due to photometrical reactions arising from UV absorption.

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Field Applicable PVDF Corrosion Protection Coating for Marine Assets

Product Number: 51324-20848-SG

Author: Kevin Chung; Thomas E. Pizanowski; Fred Lo; Albert Chung

Publication Date: 2024

$40.00

Marine environments are highly corrosive to ships and other assets that are made out of steel. Novel field applicable PVDF coating solutions have been developed to provide immediate relief when used as top coating or over-coat over existing protective coatings. This field applicable, patent-pending PVDF corrosion protection coating technology have the following key attributes: 1) At 30-50µm thickness, the corrosion protection coating is 100x more efficient than 500µm (20mils) of epoxy coatings in blocking moisture and moisture-carrying dissolved salts and acidic gases. 2) At 70% PVDF in the coating, it has been proven to withstand direct UV exposure for more than 60 years. The patent-pending 100% PVDF corrosion protection coating is now available to further the longevity of corrosion protection when applied over the epoxy coating as over-coat protection. 3) The inherent hydrophobic property of the PVDF polymer is maintained in the patent-pending field applicable coating technology to provide antifouling protection for below seawater line naval and marine assets. As top coatings in protecting the underlying coating, these field applicable PVDF coatings not only to resist, but also block UV light from damaging the underlying UV vulnerable epoxy and polyurethane coatings.

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Field Applicable PVDF Protection Coating for Corrosion and Carbonation Protection of Reinforced Concrete Structure

Product Number: 51324-20849-SG

Author: Kevin Chung; Robert Gill; Thomas E. Pizanowski; Fred Lo; Maurice Leblon

Publication Date: 2024

$40.00

The sudden and unforeseen 2021 collapse of the 12-story beachfront condominium in the Miami suburb of Surfside, Florida, United States is a wakeup call for building safety particularly to those older buildings facing the same seaside environment. In this paper, the authors provide test data and proven evidences in related fields for a surface, field applicable PVDF coating solution that arguably can arrest and stop further concrete degradation and rebar corrosion of reinforced concrete structures and buildings. A field applicable (by brushing, roller coating, or spraying) patent-pending PVDF coating when applied on the outside of the reinforced concrete structure, can provide protection for preventing concrete from carbonation and other chemical reactions and protect the steel rebar from corrosion. For a thickness of 30 µm 100% PVDF coating, established various scientific data and experiments reported here can provide more than 100 times that of the epoxy coated rebar in terms of corrosion protection by blocking off moisture and corrosive gases from penetrating through the thin field applicable PVDF concrete coating. In the experiments of exposing reinforced concrete subjected to saline water exposure, the rebars encased in concrete coated with the field applicable PVDF coating in comparison to those without PVDF coating showed the additive characteristics of concrete and that of the PVDF coating along with the synergistic aspect of PVDF coating on top of concrete also protected the concrete from the chemical reactions with the corrosive water laden with dissolved salt ions.

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Field Application of Corrosion Resistant Weld Overlay in Ultra-Supercritical Coal-Fired Boiler Waterwalls

Product Number: 51320-14660-SG

Author: Jun Jiang, Bingtao Li

Publication Date: 2020

$20.00

Weld overlay has been successfully used to mitigate high temperature corrosion issues in coal-fired boilers since the1990s, such as in waterwall and superheater/reheater area. Weld overlay is typically applied in shop or field by using Gas Metal Arc Welding (GMAW) process for boiler waterwall application, and the overlay welding is performed in vertical down welding mode (3G welding position) in subcritical and supercritical boiler waterwall applications. With the rapid development of coal-fired boiler market in China, ultra-supercritical boilers are becoming the dominated boiler type which often has spiral waterwall design. Most of ultra-supercritical coal-fired boiler waterwall consists of CrMo steel tubes, which could suffer severe high temperature corrosion attack after the installation of low NOx burners. It is expected that weld overlay could provide a long-term high temperature corrosion protection for ultra-supercritical boiler waterwall based on previous weld overlay study and application experience. However, for the spiral waterwall with inclined tube design, its field overlay welding is highly challenging and significantly different from typical vertical boiler waterwall overlay welding. The challenge and difference include welding position, welding sequence, welding parameters, and overlay properties, etc. This paper presents a successful field application of 309L stainless steel and 622 Ni-based alloy weld overlay on the spiral waterwall of an ultra-supercritical coal-fired boiler, including the welding development, simulation, and experience of overlay welding on the inclined tubes, along with the characterization of the weld overlay applied.

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Field Case Study: Impact of Corrosion Inhibitor on Scale Control

Product Number: 51324-20631-SG

Author: Alex Yi-Tsung Lu; Zhiwei Yue

Publication Date: 2024

$40.00

Mineral scale deposition and pipeline corrosion are two of the most common challenges that require chemical treatment in oil wells. Combination products including scale inhibitor (SI), corrosion inhibitor (CI) packages, surfactants, and other chemical additives are well accepted as an integrated solution to flow assurance and asset integrity problems. In this work, a case study in the Permian Basin field demonstrates a certain type of combination product exhibiting lower performance than expected. The raw material interference on the scale inhibitors was investigated and presented with detailed laboratory data. A series of laboratory tests were conducted to investigate the impacts on performance from the chemicals in the combination product. In the dynamic tube blocking test, the phosphonate-based SI shows much weaker performance in the presence of certain active CI components, while other raw materials (surfactants and quaternary amine) had a minor effect. Further bottle tests revealed a calcite inhibition drop from complete inhibition to 30% and 40% inhibition in the two phosphonate-based SI chemistries in the presence of the active component, respectively. In the additional barite inhibition tests, no significant impact on the SI performance was observed. Contrary to the previous literature reports about common CI chemicals, this active component expressed significantly adverse impacts on the SI performance for calcite prevention. This study demonstrates a root cause analysis for the adverse effect of certain active CI components on the scale prevention and suggests the impact of the CI package on SI should be carefully investigated in the product selection. A thorough evaluation of combination product performance is recommended before the field application.

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Field Data Collection for Cathodic Protection and Hydrogen Embrittlement of Super Duplex Stainless Steel for Deep Sea Application - Use of Low Voltage Anode

Product Number: 51324-20693-SG

Author: Nicolas Larché; Jean Vittonato; Anne-Marie Grolleau; Erwan Diler; Dominique Festy

Publication Date: 2024

$40.00

High-strength steels (HSS) might undergo hydrogen embrittlement (HE) in seawater under cathodic protection (CP) with traditional Aluminum-Indium (Al-In) or zinc (Zn) galvanic anodes. The actual failure risk will also depend on metallurgy, mechanical properties and local loads. Even though super duplex stainless steels (SDSS) generally do not require CP, they can unintentionally become polarized due to electrical continuity with protected carbon steel structures. CP current demand and hydrogen evolution depend on various factors, like dissolved oxygen, temperature, flow, microbial activity, calcareous deposits, and depth. Hence, the risk of HE varies with exposure site and must be assessed. Aluminum-gallium (Al-Ga) is a low-voltage anodic material aimed at reducing protective potential to mitigate HE in high-strength steels in seawater. However, long-term field data is limited. This study aimed to gather long-term CP data for SDSS at different depths and seawater types, and to assess HE risk using Al-Ga vs. conventional anode materials. Instrumented anchored lines, including CP sensors, stressed samples, and environmental sensors were deployed for over a year in shallow, intermediary, and deep seawaters. Results showed varying cathodic current demands, with deep seawater having the highest. Biofilm formation on SDSS caused depolarization at all sites, with differences noted between sites. Al-Ga significantly reduced hydrogen-induced cracks in SDSS.

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Field Evaluation of Cathodic Protection Index for Bare and Coated Steel in Seawater

Product Number: 51393-93528-SG

Author: V. Van Blaricum and A. Kumar

Publication Date: 1993

$20.00

Polarization measurements were conducted over a 21-year period on bare and coated steel "H" pilings 6 inch by 6 inch by 30 feet (15.2 cm by 15.2 cm by 9.1 m) installed in seawater. A DC power source was used to shift from the corrosion potential of each pile to -0.85V. The amount of potential shift was recorded as 6V. The current (6I) required to shift the potential was measured, and a nonlinear pseudoresistance (6V/6I), called the Cathodic Protection Index (CPI), was calculated. The CPI was compared with the coating condition of the steel pilings as determined visually using ASTM standards. Results of these tests will be presented and discussed.

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Field Experience Identifying and Investigating Internal Coating Failure in Water Injection Piping

Product Number: 51319-13550-SG

Author: Itoro Akrasi

Publication Date: 2019

$20.00

For a highly corrosive water injection media (wasia water) which has very high total dissolve solid (TDS) and high oxidizing agents internal fusion bonded epoxy (FBE) coatings in addition to corrosion inhibitor was provided for internal corrosion protection of water injection plant Piping.A year after start-up of water injection plant the plant started experiencing internal FBE coating failure. The failed coating were found at the strainer and recycle valve after causing high differential pressure during operation. Seven types of failed coating film were collected from the suction strainer. Comprehensive failure investigation was conducted to determine the root cause of the failure and identify the source of various failed coating films received. Fourier transform infrared spectroscopy (FT-IR) energy dispersive X-ray Spectroscopy (EDS) X-ray diffractometer (XRD) and differential scanning calorimetry (DSC) were all used to identify the type of coating and their manufactures. Robotic video crawler (RVC) was used to inspect the internal coating condition for the piping system. Effect of corrosion inhibitor injection and plant operating parameters on the coatings were all reviewed and evaluated. It was concluded that improper coating application was the root cause of the failure. Keywords: Failure Investigation FBE Coating Robotic video crawler (RVC) Fourier transform infrared spectroscopy (FT-IR) Energy dispersive X-ray Spectroscopy (EDS) X-ray diffractometer (XRD) and Differential scanning calorimetry (DSC).

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Field Experience of Duplex Stainless-Steel Pipes in Stagnant Condition

Product Number: 51324-20361-SG

Author: Amjad Al Kharusi; Janardhan Rao Saithala; Mohammed Al Ghafri; Talal Nabhani

Publication Date: 2024

$40.00

Flowlines in the Oil & Gas industry play a pivotal role in ensuring the safe and dependable production of hydrocarbons. Maintaining their integrity stands as a critical responsibility for all operators. Duplex stainless steel (DSS) materials find extensive use within our organization, particularly in upstream Oil & gas, across various critical applications such as pipelines and flowlines. These DSS pipelines are versatile, serving not only in traditional oil transmission but also in diverse applications like water supply, un-stabilized condensate transportation, and the conveyance of wet gas. In recent years, PDO has faced challenges associated with the premature failure of DSS flowlines and pipelines. These failures have been linked to issues arising during hydrotesting, maintenance, and subsurface fracking operations, primarily due to liquid stagnation. This paper presents a comprehensive case study focusing on premature DSS failures, offering insights into our strategies for preserving the integrity of flowlines during extended well shutdowns.

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Field Experience of Various Coating Systems in Oil & Gas Industry

Product Number: 51324-20360-SG

Author: Amjad Kharusi; Janardhan Rao Saithala; Mohammed Al Ghafri; Mohammed Ossama; Talal Nabhani

Publication Date: 2024

$40.00

Internal and external coatings have been used extensively for the corrosion protection of a wide range of process components such as flowlines, pipelines, piping, vessels, tanks etc. that are used in oil and gas industry. Coatings are a critical barrier as part of a corrosion management strategy and shall be capable of providing long term corrosion protection in corrosive environment. Coatings are exposed to wide range of temperatures, high pressure environments, and acid gases (H2S and CO2), and are subjected to mechanical damage, etc. during operating service life. The authors’ company has extensive experience of using various coating systems for over 40 years. Fusion bonded epoxy (FBE) coatings and glass reinforced epoxy (GRE) linings are primarily used as internal coatings, and three-layer polypropylene (3LPP), three-layer polyethylene (3LPE), thermal spray aluminum (TSA), and epoxy coatings are used as external coatings in hydrocarbon and water injection service. During design, it is anticipated that coatings will meet expected design life, however, premature coating failures are reoccurring for various reasons, which result in significant oil & gas deferment and unplanned shutdowns. This paper will present two case studies on field experience of different coating systems and contributing factors that led to premature failures. The three main contributing factors to premature failure are quality QA/QC during coating application, incorrect coating selection, and coating damage during installation.

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Field Experience On Why Pipeline In-Line Inspections (ILI) Fail

Product Number: 51321-16884-SG

Author: Itoro L. Akrasi; Mohammad S. Hamaqi; Tawfiq I. Hathloul; Abdullah F. Almakinzi; Abdulaziz A. Naim

Publication Date: 2021

$20.00

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Field Metallography and Replication on Liquefied Natural Gas Assets: Non-Destructive Metallurgical Testing to complement other regular Non-Destructive Tests

Product Number: 51320-15140-SG

Author: Anil Kumar Chikkam, Mehrooz Zamanzadeh, Sunil Kumar Pulagam, Ganesh P, Dhandabani, Bangaru Murali, Jeevanandam Shanmugam

Publication Date: 2020

$20.00

During plant shutdown maintenance, some components cannot be removed out of service immediately for metallurgical examination due to high cost involved and loss of production hours. The best alternative is to replicate the lab based metallography work under the field conditions. Field Metallography and Replication (FMR) also known as in-situ metallography is a powerful non-destructive test (NDT) tool used to examine the microstructure of the component when it is still in service. Moreover, FMR is also used to study the microstructural alterations for the fitness for service assessment.

This paper provides case studies of materials in Natural Gas Processing facility where FMR was used as an NDT tool without sectioning the component. This paper discusses the damage mechanisms such as sigma phase embrittlement, stress relaxation cracking and creep.

Individual Conference Papers

Association for Materials Protection and Performance