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Oil field operating company’s (1) flowline network in North and West Kuwait (NWK) has over 3000 wells connected through 6” carbon steel pipelines flowing from wellhead to the nearest Gathering Center (GC). Untreated wet crude is transported through the flowlines to GC’s directly or passing through the Remote Headers and Manifold (RHM) to GCs. In RHM, mixing of the wet crude takes place before it is sent to GC’s via transfer lines for further separation. The flowlines are laid aboveground except at road crossings where they are buried.
A remarkable amount of financial loss is incurred every year because of premature failures of paints and coatings. The budget to repair such failures extremely outweighs the initial cost of coatings, since excessive engineering may be looked-for to access the deteriorating areas of a coating system. Additional accountability may also be anticipated if a facility stops operation for the essential repairs to be made.
AC interference analyses are an important part of designing an adequate cathodic protection system on a pipeline when collocations with high voltage powerline(s) occur. Modeling software has been developed to create accurate simulations of what is occurring in the real world to create the best mitigation designs for operators. Many of these studies are proposed due to pipeline replacements that update pipelines from coatings with coal tar to fusion bonded epoxy (FBE).
Caustic corrosion is sometimes referred to as “caustic attack or “caustic gouging.” Corrosion of this type may result from internally fouled heat transfer surfaces and the presence of sodium hydroxide in the boiler water; and concentrated solutions of alkali where the normal washing of the tube metal ID is restricted after Departure from Nucleate Boiling (DNB), i.e., when the steam bubble release exceeds the rinsing rate.
Evaluating the location-based risk of corrosion is critical to a number of fields of industry. Within naval aviation, knowing the risk of corrosion from environmental factors can be used to ensure that maintenance intervals are properly planned. From a basic research aspect, understanding how different sites behave allows researchers to better correlate how performance at a standard test site can be extrapolated in future research efforts. However, a survey of literature and conversations with many corrosion experts has shown variability in how environmental factors are assessed.
Bulk items such as cast and forged valves are installed under various temperature conditions. It is exposed to a wide range of temperatures, therefore the coating product applied to bulk items should have appropriate heat resistance performance. However, it is very difficult to select a suitable coating system since the temperature condition is not determined in the valve manufacturing stage. For this reason, unsuitable coating systems are often applied, causing coating defects in the field operation. Therefore, it is necessary to apply a coating system that can cover a wide temperature range to prevent this problem.
Atomic hydrogen can enter metallic microstructures from deposition processes like Cr plating or phosphatizing, chemical and electrochemical pickling treatments, during welding operations if the humidity of consumables is too high, by cathodic processes resulting from corrosion phenomena or contact with high pressure gaseous hydrogen. According to different chemical-physical mechanisms, atomic hydrogen can enter the metallic structure resulting in damages of various forms, such as HIC (hydrogen induced cracking), SOHIC (stress oriented HIC), delayed fracture and hydrogen embrittlement (HE).
The pitting corrosion and crevice corrosion of oilfield production alloys (e.g., 13Cr/UNS S41000, 17-4PH/UNS S17400, 25Cr/UNS S32750, A286/UNS S66286, 718/UNS N07718) and proprietary austenitic stainless steels for directional drilling (PREN between ~20 to ~45) has been investigated. Specifically, series of electrochemical tests have been conducted to rank the alloys, establish simple correlations between electrochemical parameters, PRENmod, and 3-to-60-day immersion tests in 3.5% NaCl at ambient temperature. For all but one alloy, pitting was absent in stark contrast to crevices. Upon tracking populations and dimensional characteristics of crevices over time, trendlines comparing the susceptibility of the alloys towards crevice corrosion were established. Practical conclusions were reached, including the following: (1) 13Cr consistently developed crevices within days, (2) 17-4PH as well as all traditional directional drilling stainless steels developed crevices within one to five weeks, and, (3) neither 718, 25Cr, nor newer directional drilling alloys with both high nickel and high PRENmod showed any sign of crevices upon being tested up to 60 days. Through a variety of comparisons, this investigation also reveals useful technical directions for the development of new, economical, and fit-for-service Oil & Gas alloys for both production and drilling.