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Case Study Based On Failure And Application Of Surface Coating (Powder Coating)

Product Number: 51322-18109-SG

Author: Syed Umair Niaz Bukhari, Ahmad Raza Khan Rana,

Publication Date: 2022

$20.00

Plant assets for hydrocarbon and power generation systems are prone to numerous damage mechanisms that arise from operating and/or upset conditions, environmental factors, material defects as well as other neighborhood factors ^1-2. Corrosion is one of the key degradations that pose a substantial economic burden, and may result in severe safety and environmental hazards ³. While considering the percentage for global economy in terms of corrosion, the total cost of corrosion globally amounts to ∼2.5 trillion US dollars per year. Among the corrosion mitigation measures, organic protective coatings are the most widely used, and their costs add up to two-thirds of all anti-corrosion overheads ⁴.

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Case Study of Hybrid Onshore-Offshore CP Life Extension Retrofit for East Texas Facility

Product Number: 51324-20974-SG

Author: Yuxi Duan; Colette Brogna-Nichols

Publication Date: 2024

$40.00

Dock components of an East Texas oil and gas facility required a cathodic protection retrofit, however the scour in the area precluded traditional bottom-laid anode approaches. A pre-existing impressed current cathodic protection (ICCP) system protecting onshore assets was integrated with the offshore components to protect and extend the useful life of the associated facility docks and near-shore assets. Scour-protected bonds were used to integrate the onshore ICCP system to offshore assets, reducing the cathodic protection (CP) retrofit’s design footprint. Sacrificial anodes were installed where cable voltage drop and/or seabed scouring operations precluded bonding to the onshore ICCP system. This case study demonstrates that an ICCP-first hybrid retrofit is capable of protecting both offshore and onshore assets. The sacrificial anode cathodic protection (SACP) retrofit provided CP to remote dolphins and piles where installing bonding cables would have been impractical, given that routine scouring is expected in the area. The inspection data shows that above-ground storage tanks (ASTs), coated onshore pipelines, dock structures, both the land- and water-side bulkheads, and near-shore piles and dolphins can simultaneously meet NACE CP criteria with a properly-designed CP continuity retrofit.

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Case Study of the Premature Coating Failure on the Boiler Tubes

Product Number: 51324-21187-SG

Author: Ahmad Raza Khan Rana; George Jarjoura; Shahzad Karim; Syed Umair Niaz Bukhari

Publication Date: 2024

$40.00

Boiler tubes in the penthouse portions are meant to extract the heat from the flue gases. The tube material and coatings on the boiler tubes are generally selected to mitigate the high-temperature oxidation and other metallurgical damage mechanisms. Tubes are not designed to experience aqueous corrosion from the external environment. For these reasons, boilers are designed and laid out in a fashion to limit the ingress of moisture and corrosive ions from external sources such as wind, cooling tower drift, etc. This paper addresses the case study on the failure of primer coating on the boiler tubes from the upset condition that allowed the flooding inside the penthouse leading to aggressive corrosion on the tube skin. This paper also discusses the multiple corrosion modes observed and their associated mechanisms followed by recommending corrective measures. Finally, the paper addresses the contribution of insulation material in heterogeneous corrosion morphologies.

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Case Study On Caisson & Piston Cylinder Protection Failure

Product Number: 51323-19340-SG

Author: Prantosh Naha, Nadeem J. Sait, Salim Y. M, Vaseem J. Sait

Publication Date: 2023

$20.00

This case has been selected because we see this industry doesn’t get much attention and there are several cases came to our attention in the recent past. The corrosion protection of caisson was designed using painting only and no CP system was considered. The location is adjacent to the sea and water table is about 5-6 meters.

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Case Study on the Failure of Duplex Stainless Steel Heat Exchanger from Thermal Shock

Product Number: 51324-20923-SG

Author: Immad Ovais Rohela; Yasar Irshad; Ahmad Raza Khan Rana; Syed Umair Niaz Bukhari

Publication Date: 2024

$40.00

Shell & tube heat exchangers are prone to degradation from corrosion and fouling. Recent advents in the industry recommend the use of corrosion-resistant alloys to reduce failure risks. This paper addresses the case study on the two different failure incidents of a formic acid heat exchanger (material: SS 316L, UNS S31603) that failed due to the corrosivity of the service which was followed by the material upgrade to super duplex SS Grade (UNS S32750). The exchanger later failed due to unanticipated cracks at the tube-tube sheet weld joints. The study investigates the root cause(s) behind the failures in light of inspection findings, operating history, and a review of the material’s mechanical and metallurgical properties. This study also recommends mitigative measures to avoid such failure events.

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Case Study On The Failure Of Polyurea Elastomer (PU) Coating in a Sea Water Storage Tank

Product Number: 51323-19160-SG

Author: Ahmad Raza Khan Rana, George Jarjoura, Syed Umair Niaz Bukhari

Publication Date: 2023

$20.00

Protective coatings are widely used for shielding metal surfaces against service-induced degradations. Immersion-grade coatings protect the metal surfaces by hindering the interaction of steel (i.e., substrate) with service thereby providing corrosion and even abrasion resistance. Coatings nowadays are the most efficient method to shield metals and thus has been widely engaged among various protective techniques.

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Case Study: Design and Installation Aspects of Cathodic Protection of Above Ground Storage Tanks in a large Tank Farm Project in Africa

Product Number: 51323-19040-SG

Author: Shailesh Javia

Publication Date: 2023

$20.00

A large-scale refinery is being set up in Africa. The refinery includes the construction of tank farms consisting of 150+ above ground storage tanks with diameter varying from 4.1m to 92m for the storge of crude oil, intermediate and products. Tanks are constructed on various types of tank foundations such as Ring beam foundation, sand pad foundation with fire bricks and without fire bricks.

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Case Study: Foreign Operator DC Interference On An Existing Pipeline Systems

Product Number: 51322-17587-SG

Author: Jessica Jaskolka

Publication Date: 2022

$20.00

EN Engineering (ENE) completed an AC interference study over 68 miles of an operator’s transmission line. In addition, an ACVG survey of approximately one (1) mile of the pipeline was conducted at the take-off point of the 8” line. As a result of this AC interference study, evidence of elevated AC corrosion risk has not been found on the operator’s pipeline. However, a review of the provided data shows evidence of DC interference due to a nearby foreign rectifier groundbed at the take-off point of the operator’s line.

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Case Study: HDD CP Retrofit For Existing Critical Service Ethylene Above Ground Storage Tank.

Product Number: 51322-18035-SG

Author: Shailesh Javia, Venkat Sreenivas

Publication Date: 2022

$20.00

Corrosion has long been recognized as an extremely costly naturally occurring phenomenon that can be controlled through the proper application of corrosion prevention and control methods protecting public safety, extending the service life of assets and preventing damage to property and the environment. The landmark Cost of Corrosion Study published by the U.S. Federal Highway Administration estimated that corrosion costs were approximately 3.1% of the nation’s GDP. Within the study, several key sectors of the US economy were studied. This paper is focused on one of those areas – the corrosion risks associated with storage tanks that contain hazardous materials. The study determined that the annual direct cost of corrosion for above ground hazardous material storage tanks (ASTs) in the US was ~$4.5 billion.

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Case Study: Integrated External Corrosion Management for A 12-Inch Crude Oil Pipeline

Product Number: 51323-18970-SG

Author: Keith Parker, Trey Johnston, Christophe Baeté, Michael Snow

Publication Date: 2023

$20.00

The Enbridge External Corrosion Prevention team (ECP) is developing an Integrated External Corrosion Management (IECM) process by which management of external corrosion control systems can be optimized while
maintaining asset integrity and safety. IECM is intended to provide a methodology by which operators can move from a traditional reactive approach to a state-of-the-art proactive strategy commensurate with industry expertise and technology. Here we discuss a case study intended to demonstrate and assess the outcomes of IECM. The subject is a 12-inch diameter crude oil pipeline located in North America. Results of the process reveal opportunities for improvement and efficiencies in operation and maintenance (O&M).

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Casing Corrosion in Geothermal Environments Containing Sulfuric Acid

Product Number: 51324-20932-SG

Author: Joseph Thevakumar; Joshua Owen; Richard Barker; Evgeny Barmatov

Publication Date: 2024

$40.00

This work focusses on understanding corrosion severity and material performance within model geothermal sulfuric acid (H2SO4)-containing environments. With the use of a tantalum-lined high pressure/high temperature autoclave, the corrosion behavior of N80 carbon steel was compared against duplex stainless steel when exposed to H2SO4 solutions (pH 2-4) at temperatures up to 150°C. Electrochemical linear polarization resistance measurements were implemented to gather real time corrosion kinetic data. Complimentary ex-situ analyses (scanning electron microscopy and white light interferometry) were conducted to understand the corrosion mechanism and quantify localized corrosion rates. A quantitative relationship was identified in terms of pH, temperature and metal corrosion for the selected materials to highlight material capability within such low pH geothermal environments.

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Cathodic Prevention/Protection Of Marine Corrosion Of Steel In Previously Cracked Concrete

Product Number: 51321-16952-SG

Author: M. Dugarte; A.A. Sagüés

Publication Date: 2021

$20.00

Online Conference Paper

Association for Materials Protection and Performance