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Failure Investigation of Internal Girth Weld Coating Surface Preparation: A Case Study

Product Number: MPWT19-14360

Author: Rashed Alhajri, Yousef Alrayes, Fahad Alhindas, Ghassan Bahamden

Publication Date: 2019

$0.00

During the construction of a 56km long 16 in. carbon steel sour gas pipeline, repetitive surface
preparation failures were detected during visual inspection of pipeline girth weld internal surface prior to
coating application. Such failures represented 67% of the total pipeline girth welds and were manifested
by excessive sharp-edges at the root pass. To identify the failure causes, an investigation was
performed through reviewing the pipeline, fabrication and coating application specifications and
procedures, quality control records and performing an extensive visual inspection through an advanced
video robotic crawler on all pipeline girth welds made. Upon investigation analysis, the failures were
caused by sharp-edges in the root pass which were attributed to improper practices during
manufacturing, field fabrication and pre-coating quality control. The failure analysis indicated that the
mechanized Gas Metal Arc Welding process, with the parameters used, was not suitable for internal
girth weld coating application. In addition, a more stringent requirement should be applied to the
acceptable pipe-end diameter tolerance and pre-coating quality control to ensure absence of similar
premature surface preparation failures. The pre-coating quality control can be improved through
utilization of robotic laser contour mapping crawler for precise detection and sizing of unsatisfactory
surface weldment defects, including sharp edges.

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Failure of a Vaned Diffuser in a Sour Gas Compressor

Product Number: 51317--9073-SG

ISBN: 9073 2017 CP

Author: Vishwas Gadgil

Publication Date: 2017

$20.00

Failure of a diffuser (with vanes, made from material P265GH) is investigated. The gas compressor was in service for over 10 years. The gas contained both CO2 and H2S. Relative humidity of the gas was 100 %. It was found that the diffuser was fractured in 3 locations.

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Failures of Brass Components in Water and Steam Systems

Product Number: 51317--9123-SG

ISBN: 9123 2017 CP

Author: James Dillon

Publication Date: 2017

$20.00

Case histories will illustrate failures that occurred in components that were made of different brass alloys in water and steam systems. Recommendations will be made to mitigate the damage that occurred in each case.

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Fast Curing Anticorrosion Primers for Steel Protection

Product Number: 41206-229-SG

Author: Jean-Luc Dallons

Publication Date: 2006

$20.00

Phenalkamine curing agents for epoxy resins provide an outstanding anticorrosion protection, fast and low temperature curing, high surface tolerance, large overcoat window and low VOC formulations.

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Fast Evaluation of Corrosion Inhibitors Used in Oil/Water Mixed Fluids

Product Number: 51319-12887-SG

Author: Ziming Wang

Publication Date: 2019

$20.00

Corrosion inhibitors are widely used for prolonging the lifetime of oil production facilities such as pipelines and separators. In practice it is important to quickly screen the effectiveness of a certain kind of corrosion inhibitor before its use in target environments. Since in an oil/water mixed fluid the presence of crude oil may completely change the protectiveness of an inhibitor it is important to evaluate the inhibition efficient directly in the oil/water fluid. However the evaluation is actually quite challenging which generally needs to be conducted in a simulated complex fluid by the aid of a large-scale multiphase flow loop. In this paper a method was proposed to acquire electrochemical response from an electrode surface alternately wetted by oil and water. It can be employed to measure the potentiostatic polarization curve of an oil/water alternately wetted electrode. An optimized 2-oleyl-1-oleylamidoethyl imidazoline ammonium methyl sulfate (ODD) type corrosion inhibitor was evaluated by using this method in a CO2 containing brine solution. It was found that the inhibitor behaved much more effective and reached extremely high efficiency of 99% in the oil/water condition. The significant retardation of the measured current peak values could be due to the adsorption of crude oil molecules on the electrode surface in the presence of a trace amount of ODD inhibitor. Field experiment was conducted in a water treatment station of Shengli oilfield. It indicated that this ODD inhibitor was effective in preventing the pipeline from corrosion in an oil-contaminated CO2-containing water transportation system. Therefore the proposed test method is simple and cheap compared with the conventional flow loop experiments and can rapidly screen corrosion inhibitors in oil/water mixed fluids in the lab.

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Fast screening of Sulfide Stress Corrosion resistance of Supermartensitic Stainless Steel thought alternative test methods

Product Number: 51320-14577-SG

Author: Martien Duvall, Cécile Millet, Daniela Garcia, Guilaume Neel, Harold Evin

Publication Date: 2020

$20.00

In order to meet growing energy demand, oil and gas industries are facing many challenges, including the exploitation of increasingly deep fields with high pressure and high temperature in sour environments containing CO2 and H2S. Operators must carefully select materials that are resistant to these aggressive environments. The main risk associated with the use of martensitic stainless steels is the risk of sulfide stress cracking under well shut-in conditions.
The aim of this study is to evaluate the performance of supermartensitic stainless steels (13Cr-5Ni- 2Mo) based on NACE TM-0177-2016 method A and alternative methods such as slow strain rate test according to TM-0198-2016 and ripple strain rate test. Cyclic potentiodynamic polarization measurements were also performed to evaluate pitting and repassivation performance. The interest of this study is to present reliable and fast criteria to predict sulfide stress cracking performance of supermartensitic stainless steels through alternative methods. The effect of buffer and chloride content on pitting resistance and sulfide stress corrosion cracking resistance will also be discussed as well as the effect of Mo and Cr on pitting resistance.

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Fatigue And Static Crack Growth Rate Study Of X-65 Line Pipe Steel In Gas Transmission Pipeline Applications

Product Number: 51321-16721-SG

Author: Ashwini Chandra; Ramgopal Thodla; Joseph Tylczak; Margaret Ziomek-Moroz

Publication Date: 2021

$20.00

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Fatigue Crack Growth Rate Behavior of Welded Line Pipe Steel in Sour Environments

Product Number: 51317--9200-SG

ISBN: 9200 2017 CP

Author: Thodla Ramgopal

Publication Date: 2017

$20.00

Frequency scan fatigue crack growth rate tests were performed at a fixed stress intensity factor range to determine the effect of frequency in two different sour environments. Both sour environments had the same partial pressure of H2S (0.21psia) but different pH values.

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Fe3O4, FeCO3 or FeS - Which Corrosion Product Will Prevail at High Temperature in CO2/H2S Environments?

Product Number: 51320-14413-SG

Author: Shujun Gao, Bruce Brown, David Young, Srdjan Nesic, Marc Singer

Publication Date: 2020

$20.00

Sweet (CO2) and sour (H2S) corrosion have continuously been a challenge in oil and gas production and transportation. Yet, some key issues are still not well understood, especially at high temperature production conditions. A CO2/H2S ratio of 500, which has been used (often inaccurately) to determine which corrosion mechanism is dominant, is probably even less valid at high temperature. The nature of the corrosion products forming at high temperature in CO2/H2S environments and their effects on the corrosion rate are not known. Finally, the impact on pipeline integrity of environmental changes between sweet and sour production conditions (simulating reservoir souring) has not been well documented. CO2, H2S, and CO2/H2S corrosion experiments were conducted at 120oC to investigate corrosion mechanisms and corrosion product layer formation at high temperature. The results show that the corrosion products were still clearly dominated by H2S under the pCO2/pH2S ratio of 550. Formation of Fe3O4, FeCO3, and FeS corrosion product layers had a direct impact on the measured corrosion rates and was dependent on the gas composition and on the sequence of exposure (CO2 then H2S and vice versa). Compared with H2S corrosion alone, the presence of CO2 could retard Fe3O4 formation in CO2/H2S mixture environment. No obvious change in steady state corrosion rate was observed when the corrosion environment was switched from CO2 to H2S and vice versa.

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Ferrite Measurement in Duplex Stainless Steels

Product Number: 51319-13437-SG

Author: Kasra Sotoudeh

Publication Date: 2019

$20.00

Duplex stainless steels typically contain 50% austenite and 50% ferrite. Phase balance is important in duplex stainless steels as it helps to impart optimum mechanical properties and corrosion resistance. Welding may alter the phase balance and so it is necessary to assure that phase balance is still within acceptable ranges. Ferrite measurement practice will be reviewed in terms of existing established techniques and recent advances in materials characterisation tools. Measurement precision and accuracy will be discussed.

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Ferrite Phase Fraction Quantification in Stress Corrosion Cracked Duplex Welds

Product Number: 51319-13263-SG

Author: Majid Abbasi

Publication Date: 2019

$20.00

Recent experiences with duplex 2205 stainless steel welds have shown that stress corrosion cracking can occur which may lead tocatastrophic failures. Known microstructural parameters such as ferrite phase fraction seems to play a significant role in crack propagation. Therefore quantifying ferrite phase fraction is an important step in ensuring weld quality. Several methods such as ASTM E562 point count electro-etching color-etching and optical image analysis as well as electron backscattred diffraction (EBSD) are utilized to quantify the ferrite fraction in duplex welds that have failed in service. Results of quantification by these methods are compared in terms of accuracy versatility and ability to apply in-field. Quantification results in cross-sectional samples indicate that local ferrite phase fraction is more meaningful than average fraction as cracks tend to propagate along high ferrite regions. Investigations on a number of cracked welds reveal that initiated cracks from the root pass reach the high ferrite region in coarse-grained heat affected zone (CGHAZ) and propagate along this region into filling passes. Further detailed microstructural results will be presented and discussed.Keywords: Duplex 2205 Stainless Steel; Welding; Ferrite Fraction; Stress Corrosion Cracking (SCC).

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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.

NACE Conference Papers

Association for Materials Protection and Performance