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Ammonia Stress Corrosion Cracking of Admiralty Brass Heat Exchanger Tubes in Refinery Cooling Water System

Product Number: 51324-20970-SG

Author: Sudharsanan Soundararajan

Publication Date: 2024

$40.00

Instrument air (IA) system is one of the critical systems in the utilities section of a refinery complex. IA system of this refinery consists of compressor package and dryer package to supply air to refinery header at 0.9Mpa (128 psi) with dew point less than -20degC (-4degF). The 3 stage compressors have intercoolers with extended plate surface fin type tubes. The metallurgy of the tubes is Admiralty brass SB-111 C44300. In this cooler, compressed air is in the shell side and fresh cooling water on the tube side. All 8 intercoolers in the compressor package leaked in a period of 1 month. A failed sample tube was analyzed using Optical Emission Spectroscopy, Stereo Microscope, SEM/EDS and XRD. This paper discusses the findings and the methodology used to identify the reason for failure as Ammonia Stress Corrosion Cracking. Process parameter analysis revealed that the leak from a recycle gas cooler in Hydrocracker unit as the possible source for ammonia in cooling water system. The full-length tube expansion for plate type fins is the source for residual stress. This paper briefs upon the IOW and the monitoring mechanisms for such mixed metallurgy closed loop cooling water system.

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An Approach to Assess Environmental Severity Categories Using Corrosion Sensors

Product Number: 51324-20739-SG

Author: James Dante; Erica Macha; Andrew Keller; Michael Hartnett; Shengyen Li

Publication Date: 2024

$40.00

This work examines data from a multi-year, large deployment of corrosion sensors in a variety of locations representing a range of corrosivity severities. The corrosion sensors used in this work measure atmospheric parameters including relative humidity and temperature in addition to conductance of the electrolyte formed by salt deposition. First, a rudimentary model is developed based on a small sampling of corrosion sites to demonstrate a means by which environmental parameters (RH, temperature, and conductance) can be viewed to assess environmental severity. The model is simplified and applied to a broader number of sites to determine its viability for predicting severity. Results are compared to current Air Force severity rankings and literature data separately.

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An Approach To Optimize The Wall Thickness Of In-Service Pipelines

Product Number: 51321-16885-SG

Author: Ajay Arakere; Marlane Rodriguez; Dirk Oostendorp; Prasanna Swamy; Robert McStravick; Alex Bridges

Publication Date: 2021

$20.00

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An Artificial Intelligence Based Application to Predict Internal Corrosion Risk in Produced Gas Flowlines

Product Number: MECC23-20098-SG

Author: Mohammed S. Alqahtani; Muhammad Sohaib Khan

Publication Date: 2023

$20.00

Corrosion in pipes is a major challenge for the oil and gas industry which leads to expensive failures, production loss and safety issues. The corrosion problems in gas producing operations are complex and depends on lot of factors including but not limited to process stream chemistry, material of construction and operating conditions.

CO2 corrosion of carbon steel (C-steel) materials is one of the main corrosion mechanisms encountered in the oil and gas industry.

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An Enhanced Prediction Model For Simultaneous Naphthenic Acid And Sulfidic Corrosion Quantification

Product Number: 51322-17901-SG

Author: Winston Robbins, Sridhar Srinivasan, Abbey Wing, Gerrit Buchheim

Publication Date: 2022

$20.00

Sulfur and acidic impurities in crude oils pose serious hot oil corrosion problems in crude distillation units (CDU) and associated vacuum distillation units (VDU), especially with the increase in processing of lowquality, opportunity crudes.^1-4 In the range of 200-400˚C, reactive sulfur compounds cause sulfidation corrosion of ferritic carbon and chrome steels in CDU, VDU, and front ends of downstream units operating at hot oil temperatures.^5-7 Over the same temperature range, naturally occurring carboxylic acids in crudes can be so aggressive that higher alloy, austenitic stainless steels containing >2.5% Mo are required for processing high acid oils.^8-11 Although sulfidation and acid corrosion occur over the same temperature range, they differ in two significant ways. Sulfidation forms an iron sulfide solid that is semiresistant to further corrosion and relatively insensitive to flow velocity. Acids form oil soluble organic salts that can be washed away especially in areas of high turbulence.^12-14

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An Environmental Performance Comparison of Premium Vs. Standard Grades Used in Non-Magnetic Drill Collars

Product Number: 51324-20685-SG

Author: Flavia Kudla; Manuel Marya

Publication Date: 2024

$40.00

Non-magnetic drill collar (NMDC) alloys are (Cr-Mn/Cr-Mn-Ni)-Mo-N proprietary austenitic stainless steels that meet minimum API Specification 7-1 requirements. Among NMDC alloys, a wide range of chemical compositions and environmental performance exist with similar mechanical requirements. NMDC alloy proprietary compositions may be grouped into premium and standard grades and, depending on the product and operation requirements, the drilling conditions may lean more towards one group versus the other. This paper evaluates and compares the corrosion performance of representative alloys from these two groups in terms of weight-loss corrosion, localized corrosion, and environmentally assisted cracking in two simulated drilling muds. The test program accounts for different levels of chlorides, dissolved oxygen, brine pH, and temperature, in order to reproduce corrosion in the environment(s) and temperature(s) representative of field jobs. This investigation aims to understand and identify corrosion and cracking limits of the alloys from the premium and standard groups; and consequently, provide guidance to improve operational reliability and increase NMDCs life in the field.

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An Evaluation of Well Completion Materials for Impure Carbon Dioxide Supercritical Streams in Hydrocarbon Production and Geological Carbon Sequestration

Product Number: MECC23-20034-SG

Author: Manuel Marya

Publication Date: 2023

$20.00

Carbon capture and storage (CCS) represents to traditional industrial emitters a critical transitional technology to globally manage greenhouse gas emission, meet the latest carbon net-zero ambitions, and continue the commercial use of fossil fuels. In CCS, anthropogenic CO2 is captured near emission, treated, compressed, transported (usually by steel pipelines), injected underground through casings, tubings, and completion equipment, and finally permanently stored into saline formations, aquifers, depleted (abandoned) reservoirs, or un-mineable coal seams. [1] Depending upon emitters, the injected CO2 is either near or in a dense state (i.e., indistinctly including a supercritical phase and potentially liquids) having various impurities.

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An Expanded Characterization of Environmental Severity for Naval Air Stations

Product Number: 51324-20665-SG

Author: Steven Kopitzke; Ian Long; Alexander Lilly; Kaylee Canales; Allison Muenzer

Publication Date: 2024

$40.00

Characterizing the risk of corrosion due to environmental severity is critical when developing condition-based maintenance practices, planning facility maintenance or developing predictive corrosion models. In light of that, a research study was conducted to characterize and rank the environmental severity of Naval Air Stations across the world. In addition, the research team utilized the most recent recommendation for environmental severity assessment from the AMPP SC-07 committee as a secondary effort in this study. This report will describe both the environmental severity rankings of the sites along with evaluating the effectiveness of the SC-07 recommendations.

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An Experimental Investigation of Ductile Material Deformation as a Result of Single Particle Impacts

Product Number: 51323-19438-SG

Author: Yeshwanth Raj Rajkumar, Siamack A. Shirazi, Hadi Arabnejad, Krishnaraj Sambath, Soroor Karimi, Hariprasad J. Subramani

Publication Date: 2023

$20.00

In many industrial applications such as oil and gas production, mining, and renewable energy systems such as concentrated solar power (CSP), solid particles impact the walls of the pipeline, piping components, and equipment resulting in wear and degradation of the component material. Erosion is the dynamic process of removing material from a solid surface due to the repeated impact of solid particles. When a single solid particle impacts the surface, the material deforms, and eventually, the material is removed upon successive impacts of particles.

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An Experimental Method for Environmental Assisted Fatigue of 304L Stainless Steel in Simulated LWR Water

Product Number: ED22-18335-SG

Author: Mustafa Subasic, Jean Smith, Pål Efsing, Martin Bjurman, Mattias Thuvander, Carl Dahlberg, Bo Alfredsson

Publication Date: 2022

$20.00

Environmental assisted fatigue, also known as corrosion fatigue, is a well-known degradation phenomenon in structural materials that may develop as a consequence of long-time exposure of components to cyclic loads at the presence of an aggressive environment. This phenomenon constitutes an increased environmental risk for fatigue initiation in many industrial applications. One such application is the piping system in a nuclear power plant where the structural material is subjected to an aggressive water environment. Here, the cyclic loads arise from thermal fluctuations and mechanically induced vibrations.

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An Exploratory Investigation of the Cracking Susceptibility of Three Corrosion Resistant Alloys under Thermal Cycles and Conditions Exceeding the Traditional NACE MR0175/ISO 15156 Recommendations

Product Number: 51324-20455-SG

Author: Manuel Marya

Publication Date: 2024

$40.00

The environmentally-assisted cracking (EAC) of three wrought corrosion-resistant alloys (CRAs) with a minimum yield strength of 110ksi (760MPa) was investigated between 70°F (21°C) and 450°F (232°C) through weekly thermal cycles totalizing 42 days. The thermal cycling was introduced to approximate service equipment conditions and gain additional confidence on the EAC-free limits of all three CRAs. Alloys 17-4PH, K-500, and 925 were selected and exposed to a 180,000-ppm NaCl brine (pH=2.75) in equilibrium with 1000 psi (68.95 bar) H2S, 1000 psi (68.95 bar) CO2, and 2500 psi (172.37 bar) CH4. All three CRAs were (a) acquired as per the NACE MR0175/ISO 1516 requirements (1), (b) tested as per NACE TM0177 Method C at 30-to-90% of the CRA minimum specified minimum yield strength (SMYS), and (c) also compared for their weight-loss corrosion and localized corrosion. The results show: (a) Alloy 17-4PH remains resistant to EAC below 45% of its SMYS, (b) Alloy K-500 resists cracking at an estimated 80% of its SMYS, but uniformly corrodes by sulfide conversion under film at a rate of 64 mpy (1.63 mm/yr.), and (c) Alloy 925 continues to be immune to EAC at 90% of its SMYS. Alloy 17-4PH also corroded at a rate of 22.8 mpy (0.58 mm/yr.) in comparison to only 0.6 mpy (15.2 mm/yr.) for Alloy 925, with no CRA showing experiencing crevice corrosion.

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An In-Depth Investigation into the Causes of the Performance Variations of Liquid-Applied Pipeline Coatings on Different Types of Abrasives Prepared Surfaces

Product Number: 51323-19561-SG

Author: Shan (Sherry) Rao

Publication Date: 2023

$20.00

Dry abrasive blast cleaning is a commonly used surface preparation method to achieve the necessary surface cleanliness and roughness for the application of high-performance protective coatings. The effectiveness of abrasive blast cleaning depends on various factors, and some studies have indicated that the blasting abrasive used to clean the surface is crucial for the performance of the coating. The previous work evaluated the performances of two liquid-applied epoxy pipeline coatings (coating A and coating B) applied to 15 different surfaces.

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Association for Materials Protection and Performance