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Specially Developed Welding Consumables for Pipeline Welding Applications

Product Number: MPWT19-14364

Author: MPWT19-14364

Publication Date: 2019

$0.00

Apart from the well-tried cellulosic electrodes, in the range from E6010-E9010, there are
also low hydrogen grades of weld consumables, which are used in vertical downhill
position - commonly called as BVD (Basic Vertical Down) electrodes. In addition, the
seamless flux cored wires, are gaining prominence in the welding industry as a better
solution compared to the conventional cellulosic electrodes.
The development of BVD electrodes started because of the desire to use high-strength
TM pipe steels with relatively high toughness (e.g. X80). Cellulosic electrodes could not
meet the requirements for cold crack resistance and high toughness properties of the
weld metal. To a high degree, economical efficiency is determined by the achievable
deposition rate and the possible welding speeds. In comparison to basic vertical-up
electrodes, significant time advantage of 40-50% can be achieved with the use of BVD
electrodes for the fill and cap layers.
Seamless Flux Cored wires for pipeline applications follow a different manufacturing
approach compared to the conventional folded techniques and are much reliable with
consistent performance in terms of weldability and quality. The seamless FCAW wires,
offers a unique and trustworthy solution in terms of arc stability and low defect rates.
These wires are also suitable to be used under sour service applications having been
tested for Hydrogen Induced Cracking (HIC) and Sulfide Stress Cracking applications.

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Specialty Corrosion Inhibitor Successfully Inhibits Offshore Corrosive Mercury-Containing Gas Stream Offering

Product Number: MECC23-19889-SG

Author: Mohamed Abou Zour; Dumrong Chuachawna

Publication Date: 2023

$20.00

In oil and gas production, corrosion is a major cause of failures. These failures result in significant environmental contaminants, safety problems, increase in the high operating costs and decrease in the production rates. Extensive literature is available about various corrosion drivers and their mechanisms, helping operators to avoid or mitigate these catastrophic failures.

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Splash Zone Coating Performance after Long Term Offshore Exposure

Product Number: 51323-19143-SG

Author: Anette Pedersen, Kari Lønvik, Erik Krogstad Sverre, Lars Lichtenstein, Anders W. B. Skilbred, Andreas Løken

Publication Date: 2023

$20.00

Following the worlds growing need for sustainable energy solutions, offshore wind farms are important contributions to the generation of renewable energy. One key element for a profitable and sustainable operation of offshore wind farms is that the installations are protected with the most cost-effective corrosion protective solution for the entire lifetime. In practice, this means that today’s projects are planned with an estimated lifetime of a minimum of 25 years without major maintenance of the corrosion protective solution.

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Split Chamber Zero Resistance Ammetry Technique (SC-ZRA) For Detecting And Quantifying Microbially Influenced Corrosion In Oil And Gas Systems

Product Number: 51322-18191-SG

Author: Anwar Sadek, Sai Prasanna Chinthala, Joshua Davis, Chelsea Monty-Bromer, John Senko

Publication Date: 2022

$20.00

Microbiologically influenced corrosion (MIC) is one of the most aggressive forms of corrosion leading to infrastructure and equipment damage in various industries, including but not limited to the oil and gas industry,¹ water systems,² medical devices,³ marine environments,⁴ nuclear waste storage facilities,⁵ and aviation fuel systems⁶ and storage.⁷ MIC received great attention because of the increasing cost associated with corrosion damage, particularly in oil and gas industry. The overall cost of corrosion has been estimated to be approximately 3.4% in the global Gross National Product⁸ which equates to approximately $2.9 trillion in 2018.⁹ A conservative estimate shows that 20% of all corrosion in aqueous system is MIC,¹⁰ which accounts to billions of dollars in the US.

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Spring Failure at North Sea Valve (NSV)

Product Number: 51323-19367-SG

Author: Matheus Biava, Gustavo Brandolin, Nathalia Mota

Publication Date: 2023

$20.00

The function of the NSV (hose-end non-return valve, first used in the North Sea) is to create a safety
connection between the FPSO and the shuttle tanker during mooring and oil transfer. This connection
is made using the Loading System at the Bow of the tanker vessel through the BLS (Bow Loading
System). After carrying out all necessary checklist and communicating with the tanker, the marine crew
from FPSO start to pay the offloading mooring cable that connects on Dynamic Positioning Shuttle
Tanker (DPST).

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SRU Reaction Furnace Waste Heat Boiler Tube Failure Causing Unscheduled Shutdown

Product Number: MPWT19-14391

Author: Qasem J. Al-Hassan, Iyad A. Al-Buraiki

Publication Date: 2019

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A sulfur recovery unit (SRU) train in a gas processing facility went under an emergency shutdown due to the failure of a reaction furnace waste heat boiler (WHB) tube. The failed tube had been in service for approximately 18 years. The failed tube was subjected to a number of metallurgical laboratory examinations in order to determine the damage mechanism and root cause(s) of the failure. Examinations included visual inspection, scale analysis, chemical analysis, metallographic examination and mechanical testing. The examination revealed internal corrosion thinning in the tube which led to rupture since the tube could no longer withstand the pressure. Metallographic examination revealed spheroidized microstructure indicating that the tube experienced high metal temperature. This is suggesting that something was impeding heat transfer between the tube and water. Scale analysis results from a sample collected from the tube internal surface indicated the presence of iron sulfide corrosion products. Based on the aforementioned findings, it was concluded that the corrosion thinning was caused by sulfidation. Sulfidation is one of the potential damage mechanisms in WHB tubes and is caused by reactive sulfur species as a result of the thermal decomposition of sulfur compounds at high temperatures (above 500oF). Failure contributing factors as well as corrective actions to prevent recurrence of such failure are discussed in this paper.

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SSC of TMCP Materials: Criticalities among the Methodologies for Load Definition

Product Number: 51324-21105-SG

Author: Joao Paulo Costa; Fabio Arroyo; Philippe Darcis

Publication Date: 2024

$40.00

The Sulfide Stress Cracking evaluation based on Four Point Bend Test specimens (FPBT-SSC) is widely used to assess Line Pipes performance on sour environments. An important stage of the test configuration is to determine the strain corresponding to the desired load (e.g., 90% AYS) and different methodologies can be used. The present work studies these different methodologies and their influence on the applied FPBT-SSC load. Tensile specimens were machined from DNV450 sour grade pipes at a location as close as possible to 4PBT samples. The tensile test results were used to define the strains considering: i. the linear behavior until the Yield Strength and ii. the actual Stress-Strain curve considering both flattened and un-flattened specimens. The stress-strain curve exhibits a deviation from the linear behavior, typical of the tensile evaluation of cold-formed materials (Ramberg-Osgood). This deviation is higher in flattened specimens, due to additional Bauschinger effect. The deviation caused a higher obtained strain by considering the stress-strain curve method in comparison with the linear method (approx. 20%).

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Stainless Steels for Automotive Applications – Hydrogen Embrittlement Testing for High Pressure Hydrogen Gas Using Different Methods

Product Number: 51323-19241-SG

Author: Ulf H. Kivisakk, Björn Bosbach, Emil Cederberg, Ulrika Borggren, Nian Zhou

Publication Date: 2023

$20.00

Today hydrogen for use as fuel for vehicles is getting more and more attention as an alternative to vehicles using fossil-based fuels. Hydrogen is used in both electric fuel cell cars and in heavy vehicles using direct combustion of hydrogen. Such vehicles require stainless tubing for transport of the hydrogen and for bosses to composite tanks in addition to tubing and fittings in hydrogen fueling stations.

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State of The Art Erosion Control Technology

Product Number: MPWT19-15301

Author: Prasad Laxman Kane* and Terry Wood, Ghulam Haider, Alireza Asgharpour, and Siamack A. Shirazi**

Publication Date: 2019

$0.00

Erosion of piping systems is a significant issue for many operators of hydrocarbon infrastructure causing a significant loss in revenue and an increase in installations, repair and maintenance costs. Currently, the use of erosion resistant coatings, reduction of flow rates and replacement/repair are the only mitigation controls against erosion. INTECSEA has been developing a novel Erosion Control Technology (ECT) that can reduce the impact of erosion on piping via the strategic placement of custom engineered inserts into the product stream. The two phases of ECT prototype testing under real-field multiphase conditions representing gas condensate fields have been performed at the E/CRC (The University of Tulsa). The superficial gas velocity (VSG) was varied from 31 m/s to 23 m/s with the superficial liquid velocity (VSL) fixed at 0.04 m/s and the sand particles were varied from 300 μm to 75 μm. The metal loss due to erosion was monitored using a set of UT probes in two consecutive elbows spaced 11D apart oriented in a vertical-horizontal loop. The erosion tests using prototype ECT inserts have shown a significant reduction in erosion at both the gas flow conditions. Computational Fluid Dynamics (CFD) has been a backbone in developing this technology and CFD results have shown good correlation with the physical tests. Discussions with leading operators for a field trial targeted for 2020 is ongoing.

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Statistical Analysis Of U.S. Onshore Hazardous Liquid Pipeline Accidents From 2010 To Present Caused By Internal Corrosion And Possible Solutions

Product Number: 51321-16910-SG

Author: Alvaro A. Rodriguez; Darren Lemmerman

Publication Date: 2021

$20.00

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Statistical Analysis Of U.S. Reportable Onshore Hazardous Liquid And Natural Gas Pipeline Accidents/Incidents From January 2010 To January 2021 Caused By External Corrosion

Product Number: 51322-17661-SG

Author: Alvaro A. Rodriguez

Publication Date: 2022

$20.00

In this paper, several cases will be showcased to highlight the contributing causes and underlying mechanisms of corrosion damage of components that resulted in significant releases of hazardous substances onto operator’s property, rights-of-way, and the environment. The objectives of this paper are to understand the causes of the failures and their consequences, to identify the risk factors involved, to discuss mitigative measures after failure, and to observe trends that may indicate the need for additional preventative and mitigative actions. The over-riding goal is to provide details in areas for potential improvement in pipeline operations to reduce risk and improve integrity management.

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Steam Header Silencer Failure

Product Number: MPWT19-14241

Author: Hassan Ali Al-Hammad,

Publication Date: 2019

$0.00

Steam system in Utility Plant produces Super High Pressure (SHP), High Pressure (HP), Medium Pressure (MP), and Low Pressure (LP) steam. The header of every steam type has a control valve and a silencer downstream to open in case of high pressure. The MP steam header suddenly spiked up following a malfunction of the high range letdown valve from the HP header to the MP header. The MP header vent control valve opened up to control the header pressure. However, the opening of the vent valve led to severe damage to the internals of the silencer. Fortunately, there was no personnel injury or environmental impact, only equipment damage. The direct and root cause of the failure was identified after silencer was offered for internal inspection. Gross corrosion of silencer internals, and silencer design were the direct root causes of this failure. However, an effective mitigation and resolution was implemented by preventing condensate accumulation and providing a way to clean drain lines and prevent pluggage.

Online Conference Paper

Association for Materials Protection and Performance