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Material Efficiency through Modern Repair Coating Solutions for Offshore Corrosion Protection

Product Number: 51324-21158-SG

Author: J. Viertel; A. Petrikat

Publication Date: 2024

$40.00

The increasing demand for affordable and environmentally friendly electric energy, accelerates the global plans for offshore wind energy plants. Due to the growing number of wind farm installations, for example, along US coatlines, the need for efficient repair and maintenance of the corrosion protection coatings will significantly increase over time. Many structures are already, locally damaged during their errection. Modern repair solutions have been developed over the last years, in order to keep up with the growing need for maintenance and repair of the atmospheric exposure zones of offshore windfarms. Material and process- efficiency are key in an area where labour and materials are extremely costly. In order to carry out highly efficient and durable repair jobs of the corrosion protection coating systems and therefore to ensure the extended lifetime of offshore wind powerplants, a modern repair coating and procedure has been developed. This paper compares the new single layer, direct to metal coating with the previously used standard products, in terms of corrosion protection performance (according to ISO 203401, ISO 46242, ISO 6272-13 etc.), application methods and complexity, the overall physical-chemical properties and in terms of overall process efficiency. The positive transformation in terms of occupational safety and environmental impact were amongst the central criteria of the project.

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Material Qualification of Sour Service Grades for Extreme Sour Conditions

Product Number: 51323-19113-SG

Author: John Fortaillier, Florian Thébault, Carine Landier, Nicolas Bouchart

Publication Date: 2023

$20.00

Oil and gas operations are pushing the limits of Sour Service always further with the need to combine high Sulfide Stress Cracking resistance (SSC) in H2S partial pressure while keeping high levels for Specified Minimum Yield Strength (SMYS). Operators are indeed entering into new drilling challenges when targeting complex well formations where production casings could be exposed to Sour Service environment and tubing completions to increased differential pressure. Having high levels for Specified Minimum Yield Strength (SMYS) paves the way for addressing Multi-Stage Fracturing (MSF) developments that reach pressure differentials as high as 15,000psi during fracturing operations in challenging environments with minimum intervention possibilities.

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Material Selection and Process Control in Tail Gas Treating Unit (TGTU)

Product Number: 51323-19397-SG

Author: Ameer Hamza, Rakan M Samman

Publication Date: 2023

$20.00

TGTU is one of the most versatile units in sulphur complex that will help in achieving sulphur
recovery up to 99.9% and reduce the SO2 emission to the atmosphere.

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Material Selection for anthropogenic CO2 injection: mechanical and corrosion performances of steels under dense CO2 with impurities

Product Number: 51323-18886-SG

Author: Cécile Millet, Guillaume Néel, Luciana Lima, Diana Rodriguez Barrera

Publication Date: 2023

$20.00

Carbon capture and storage (CCS) are technologies aimed at capturing CO2, followed by transportation to a storage site and injection into one of several types of stable geological formations, to trap and prevent its subsequent emission. Though CO2 transport and injection for Enhanced Oil Recovery (EOR) are known for over 40 years, new challenges arise when the CO2 source is anthropogenic, meaning with a human-cause origin and not natural (as in EOR). EU Directive 2009/31/EC states that CO2 streams from power stations or industrial plants "shall consist overwhelmingly of CO2" but may contain associated incidental substances (e.g., SOx, NOx, O2, H2S).

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Material Selection for Carbon Capture and Storage (CCS) Wells

Product Number: 51323-18760-SG

Author: Willem Maarten van Haaften, Hisashi Amaya, Bostjan Bezensek, Yuji Arai, Brian Chambers, Hiroki Kamitani

Publication Date: 2023

$20.00

The goal of the Paris Agreement is to limit global warming to below 2°C, preferably 1.5°C, compared to pre-industrial levels.1 While the world is slowly transitioning to more sustainable energy sources to reach this target, one of the ways to reduce the CO2 in the atmosphere is to capture it and store it in depleted gas fields. According to the IOGP1, the total number of CCS projects in Europe is 65 in 2022.2 The aim of these projects is to store around 60 MtCO₂/yr by 2030.

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Material Selection for CCUS Injection Well: A Case Study in North Sea

Product Number: 51324-21062-SG

Author: Luciana Lima; Cecile Millet; Diana Rodrigues Barrera; Guillaume Néel; Robert Conder

Publication Date: 2024

$40.00

Carbon capture utilization and storage (CCUS) are technologies aimed at capturing CO2 and preventing its subsequent emission. Though CO2 transport and injection for enhanced oil recovery (EOR) has been a common practice for the Oil and Gas industry for over 40 years, new challenges arise when the CO2 source is anthropogenic. Industrial CO2 stream composition will carry impurities such as NO2 (nitrogen oxides), SO2 (sulfur oxides), O2 (oxygen), H2S (hydrogen sulfide) that could affect material corrosion behavior. A complete testing program was undertaken to assess the main corrosion risks associated to the application: Sulfide Stress Cracking (SSC), Stress Corrosion Cracking (SCC), crevice and mass loss resistance. The results confirm the effects of impurities such as SO2, NO2 and oxygen on corrosion behavior. Carbon low alloyed steel (N80Q) material presented a higher corrosion rate, and it is not suitable for injection tubing but may be acceptable for casing materials when not permanently exposed to the CO2 stream. UNS S41426 (S13Cr) material needs special considerations for CCS application due the presence of some localized corrosion when exposed to a high saline water phase. UNS S31803 (22Cr) could be suitable for a less severe environment including additional testing, whilst UNS S32760 (25CrS) presented good corrosion behavior and is suitable for the application.

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Material Selection For Storage Tanks – Life Cycle Cost Analyses

Product Number: 51322-17505-SG

Author: Sandra Le Manchet, John Grocki

Publication Date: 2022

$20.00

This paper will provide recent corrosion data for stored chemicals. Duplex stainless steel corrosion curves obtained in nitric, sulfuric, phosphoric acids as well as several kinds of waters will be provided. In addition, atmospheric corrosion data obtained after 15+ years of sample exposures in several geographic areas will be shown. These results will be compared to those obtained with other materials commonly used for the construction of storage tanks.

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Material Selection Methodology Using Halite Tendency Indicators for Gas Wells: A Case Study

Product Number: 51320-14586-SG

Author: Eugenia Marinou, Valdir De Souza, David Roberts, Qi Zhao

Publication Date: 2020

$20.00

In gas wells, where a low or unknown amount of the naturally occurring saline formation water is expected to be produced, tubing material selection relies on selecting a fixed dataset of input parameters and extrapolating to the entire well life. This is intended to represent the worst-case scenario; while this can be the case regarding pressure and temperature, the produced water composition as a function of time is less likely to be as reliable. This is because during production, gas can cause water evaporation, leading to a significant increase in the chloride ion concentration compared to the analyzed values – and hence, potentially an unsuitable material selected. To this end, it is important to: (a) ensure that the formation water composition analyzed is correct, (b) that this composition is reconciled to initial reservoir conditions and (c) calculate any evaporation/condensation effects in different sections of the well as a function of production forecasts. This makes it easier to establish operational envelopes that both prevent productivity impairment and provide appropriate thresholds of acceptability for the tubing material selected. This paper describes the methodology applied for tubing material selection for a high temperature-high pressure (HTHP) gas well in the North Sea.

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Material Testing and FFS Modelling for HTHA of Less-Common Alloys: C-0.3Mo

Product Number: 51324-21142-SG

Author: Jorge Penso; Nathaniel Sutton; Brandon Rollins

Publication Date: 2024

$40.00

Tremendous attention has been devoted to understanding the behavior of common engineering alloys in high temperature hydrogen service. Nelson curves from API RP 9411 are available for the alloys most widely used in HTHA service. However, the aging international fleet of equipment in hydrogen service, across the refining, petrochemical and fertilizer industries means that in-service equipment constructed from less-common alloys must sometimes be evaluated for HTHA. The authors are involved with an 10-year joint industry project studying HTHA. One major outcome of this project is a volumetric HTHA damage FFS model which incorporates stresses from methane pressure within the material into an MPC Omega Multiaxial damage formula. A crack growth model using the fracture mechanics parameter C* (commonly used in creep crack growth)12 is also under development. These two are related in that the C* crack growth law parameters can be calculated utilizing the MPC Omega material creep properties. With sufficient creep data for an uncommon alloy like C-0-.3Mo, lot centered MPC Omega creep properties can be regressed. Such data have been compiled by the authors and resulting Omega creep properties are reported. These creep properties, along with other material properties, are used in the HTHA damage progression and the C* crack growth models. Model predictions using this approach are compared to historically available ex-service HTHA data from API RP 9411 for alloys with Mo contents between that of carbon steel and C-0.5Mo. Selective testing (creep and crack growth testing in both air and hydrogen environments) is in-progress to verify the FFS approach.

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Materials and Corrosion Challenges for the Development of Plastics Recycling Processes

Product Number: 51324-20733-SG

Author: François Ropital; Jean Kittel; Wilfried Weiss; Alexandra Chaumonnot; Frederic Favre

Publication Date: 2024

$40.00

To support the booming demand of plastics by the industry, and to reduce the environmental footprint, circularity is a collective imperative. Since plastics are divided into a large number of families, there is no universal recycling process. Depending on the type of polymer, recycling processes involve one or several steps such as conversion, depolymerization, dissolution, mechanical treatment, etc Highly corrosive environments can be found, including high temperature and aggressive fluids. Some of the elementary steps of plastics recycling resemble proven processes of the petrochemical or refining industries. The long-lasting experience of these industrial sectors can help for material selection. However, plastics recycling also opens unexplored conditions, e.g. due to the presence of contaminants such as chlorides and bromides. In this paper, we intend to describe several plastics recycling routes and develop on their potential corrosiveness. Guidelines for materials selection will be discussed, and need for further experimental work will be identified.

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Maximizing Materials Utility through a Next Life Optimization Process

Product Number: 51324-20604-SG

Author: William Kovacs; Christopher David Taylor

Publication Date: 2024

$40.00

The carbon footprint of assets will increasingly be of importance to obtain beneficial, economic, social and environmental outcomes of design and engineering projects. Inclusion of a Next Life strategy at asset or product end-of-life can significantly reduce the greenhouse gas (GHG) emissions of First Life assets and Next Life reuses compared to the same uses made from virgin material or recycled content. Traditional engineering design and asset management often only plan for initial use and the management or maintenance strategies necessary to extend First Life, where the First Life is the primary engineering role of the asset. Critically missing from this picture are the costs and environmental impacts incurred throughout the asset or product lifecycle, especially associated with the end-of-life of an asset. A Next Life optimization process for these decisions is described herein that can aid in maximizing the overall Materials Sustainability and Materials Utility (i.e., longevity of fruitful usage) embedded in assets. It consists of appraisal, brainstorming, partnering and evaluation of beneficial impact for particular Next Life options allowing the benefits they can provide to First Life and Next Life opportunities. These benefits can include a reduction in carbon footprint over a lifecycle, cost savings related to GHG emissions, cost savings related to reused material/labor for Next Life assets, or other beneficial impact (even if increased financial cost). The process includes a qualitative conceptual assessment that can feed into a more detailed quantitative assessment for optimization of Next Life materials usage.

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Measurement of surface hydrogen concentration of steels in concreate with electrochemical hydrogen permeation method

Product Number: 51323-19016-SG

Author: Ryuta Ishii, Takuya Kamisho, Masayuki Tsuda

Publication Date: 2023

$20.00

High-strength steel is one of the basic materials for supporting a well-functioning society. Prestressed concrete (PC) is a typical example of a material in which high-strength steel is used. In PC, tensile stressed steel is embedded inside the concrete, and internal bars apply compressive stress to the concrete for preventing cracks in concrete that is vulnerable to tensile stress. Moreover, corrosion inside the steel is suppressed by the alkaline environment in the concrete, so the concrete and internal bars basically work to compensate for each other's weaknesses.

Online Conference Paper

Association for Materials Protection and Performance