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Corrosion Characterization And Performance Evaluation Of Co-Cr Alloys By Laser Powder Bed Fusion And Suitability Of Their Use For Pressure Containing Down-Hole Wear Components

Product Number: 51322-17580-SG

Author: Krutibas Panda, Reece Goldsberry, Brendan Voglewede

Publication Date: 2022

$20.00

Cobalt (Co) - Chromium (Cr) based alloys are known for exhibiting a superior combination of corrosion resistance, erosion resistance, galling resistance, and high temperature strength. They have found a wide variety of applications in automotive, aerospace, chemical and biomedical applications. They are frequently known as the Stellite† grade of families (ex: Stellite† 1, Stellite† 6, Stellite† 12, Stellite† 21, etc.) and are broadly classified into the Co-Cr-Mo-C and the Co-Cr-W-C systems. The relatively high Carbon (C)and Tungsten (W) containing (Co-Cr) alloys are mostly used for their high wear properties.

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Corrosion Condition Assessment Program For Marine Asset Management

Product Number: 51322-17750-SG

Author: Jeffrey S. West, Casey Jones, Stephen W. Foster

Publication Date: 2022

$20.00

This paper describes the development of a formal corrosion inspection and condition assessment program to support corrosion and asset management planning for maritime structures at Port Houston. A hierarchical, elemental-based inspection approach was developed using visual inspection criteria and prescribed measurements to characterize the condition of coatings and cathodic protection systems for above- and underwater elements in maritime structures.

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Corrosion Control and Integrity Management of Flare Gas Recovery Units

Product Number: MECC23-20160-SG

Author: Mohamed M. Farah; Abdulaziz Al-Qahtani; Ibrahim Zahrani

Publication Date: 2023

$20.00

Gas flaring is often a frequent occurrence in the oil and gas industry, where significant unrecovered gas is flared to the atmosphere with wide ranging negative environmental implications such as increased greenhouse emission, and other pollutants that have negative health implications on local populations. However, recent environmental awareness, drive to lower emission and economic benefits associated with flare gas recovery has seen a shift in flaring practice. The recovery of flared gas reduces noise and thermal radiation, operating and maintenance costs, air pollution and gas emission and reduces fuel gas and steam consumption.

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Corrosion Control In Water Injection Pipelines

Product Number: 51322-17692-SG

Author: Jonathan Marsh

Publication Date: 2022

$20.00

Dubai Petroleum (the Operator) operates five offshore oil fields in the Emirate of Dubai (Fateh, South West Fateh, Falah, Jallilah and Rashid), in addition to various onshore gas production, storage, distribution and import facilities, and LNG import facilities. The assets within these offshore fields consist of approximately 80 platforms of various sizes, comprising central bridge linked processing facilities in Fateh and South West Fateh, and outlying normally unmanned wellhead production platforms. These platforms are linked by a network of over 150 subsea pipelines, of which over 30 are presently operational sea water injection pipelines.

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Corrosion Control of Acid Flare Lines at Gas Treatment Facility

Product Number: MPWT19-15242

Author: Ibrahim Albrahim, Ricardo Costa, Jehad Al-Aithan, Maher Al-Abdullatif, Abdulaziz Al- Tijani

Publication Date: 2019

$0.00

In any operating facility, the integrity of flare or relief lines should always be closely maintained, as it is one of the most important safeguards during plant upsets or emergency conditions. The most common damage mechanism in acid flare lines is acid gas dew point corrosion”. Corrosion in such systems is often dependent on fluid stagnation, especially in the presence of acidic water, during idle conditions.
The intent of this paper is to shed light on the efforts done in a gas treatment facility to identify different root causes that impacted or accelerated Acid Gas Dew Point Corrosion. These included design deficiencies, equipment integrity, and process challenges. Moreover, the paper provides findings and recommendations to avoid the occurrence of similar events in acid flare lines.

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Corrosion Control of Pilings in Seawater: Buzzards Bay, Ma

Product Number: 51384-84345-SG

Author: A. Kumar, A. Beitelman, E. Meronyk

Publication Date: 1984

$20.00

This report assesses (1) the rate of corrosion of bare steel with and without cathodic protection, and (2) the effectiveness of various commercially avail able coating systems in preventing corrosion of steel piles in seawater. Eighteen coatings and four sacrificial anodes were tested on 24 sets (three piles per set) of ASTM A 36 or ASTM 690 steel H-piles exposed for 5 years at Buzzards Bay, Massachusetts. Performance ratings were established for the following coatings: organic, organic over metal-filled, organic over metal filled with cathodic protection, metallic organic over metallic, and organic with cathodic protection. It is concluded that sacrificial anodes of zinc and aluminum effectively reduced the corrosion rate of bare carbon steel (ASTM 36) piles in the immersed zone from 0.076-0.102 mm/yr (3-4 mils/yr) to zero, and the coating performing best was coal tar epoxy over zinc-rich primer.

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Corrosion Data Management Using 3D Visualisation and a Digital Twin

Product Number: 51320-14535-SG

Author: Robert Adey, Cristina Peratta, John Baynham

Publication Date: 2020

$20.00

There is a gap between the Integrity management systems used by companies to manage their assets and the needs of the CP engineer. Integrity management systems do not fully meet the needs of the engineer responsible for corrosion as they do not provide access and visualizations of all the data the engineer needs to make fast and informed decisions. There is also often no easy way to see the trends in the data, or easily access the relevant video and photographic data also recorded during the survey.

Data from surveys is normally contained in reports and EXCEL spreadsheets often with different measurement locations and inconsistent naming of the locations between reports. In this paper a system is introduced which enables engineers to manage and visualise in 3D CP survey data and provide access to all the relevant information through a 3D visual interface to any member of the teams. The software gives the engineer the ability to visualize in 3D the historical and predicted CP protection on the structure and the status of the anodes in the CP system. It also provides information on long term trends in the survey data.

By integrating the corrosion data with a simulation model a “digital twin” of the structure can be created to make predictions of the present and future protection of all parts of the structure. For example the engineer can easily use the software to systematically monitor the differences between the model predictions and survey data to identify anomalies and give early identification of problems which will require action.

The paper will describe the system developed and present applications of both the 3D corrosion data visualisation and the simulation based digital twin

$Picture for Corrosion Deposits Data Base - X-Ray Diffraction Analysis of Deposits from Oil and Gas Upstream Well/Production Systems$

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Corrosion Deposits Data Base - X-Ray Diffraction Analysis of Deposits from Oil and Gas Upstream Well/Production Systems

Product Number: 51324-20831-SG

Author: Anil Kumar Chikkam; Mehrooz Zamanzadeh; Sunil Kumar Pulagam; Ganesh P; Perry Mortel

Publication Date: 2024

$40.00

This paper presents the analysis results of a wide range of corrosion deposits, scale deposits, and sludge collected from various components within the oil and gas upstream well/production systems. The accumulation of corrosion deposits within equipment can lead to catastrophic failures and unplanned shutdowns of well/production operations. Therefore, understanding the nature of these deposits and identifying their composition is crucial. This study aims to identify the phases and compounds present in corrosion deposits and determine their source. Furthermore, the identification and characterization of these deposits assist clients in determining the underlying causes of corrosion, enabling the development of effective corrosion mitigation strategies. The X-ray Powder Diffraction (XRD) data presented in this paper serves as a valuable resource for clients during major problems and shutdowns, as no comprehensive database of this nature currently exists. The paper also outlines the sample preparation and analysis procedures employed to examine these corrosion deposits thoroughly.

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Corrosion Failures of Stainless Steel Plate Exchangers in Oil Sands Pond Effluent Water

Product Number: 51324-20821-SG

Author: Reinaldo J Chung; Marilin Garcia; Jiaren (Jimmy) Jiang

Publication Date: 2024

$40.00

The premature failure of various plate exchangers used in pond effluent water service were investigated to identify the failure mechanism and take the necessary corrective actions to prevent reoccurrence. All the exchangers were made of austenitic stainless steel 316L plates. The heat exchanger units served to recover the waste heat, and to heat up the pond effluent water which is used for the primary extraction process. The study included a review of the equipment design and original materials selection criteria, chemical analysis of the water streams and characterization of the scales, metallurgical and electrochemical testing of the 316L plates in the lab under representative conditions. Results of the investigation and recommendations are discussed throughout the paper.

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Corrosion Fatigue and Chloride-Induced Stress Corrosion Cracking in Sulfur Recovery Units

Product Number: 51324-20691-SG

Author: Saud I Al Otaibi; Mohamud Farah

Publication Date: 2024

$40.00

Sulfur Recovery units (SRUs) are widely used in the oil and gas industry to recover sulfur from refined products and acid gas waste from the natural gas process. This involves routing acid gas rich in hydrogen sulfide through a reaction furnace to produce molten sulfur in a thermal Claus reaction. Central to the operation of the SRUs is the Sulfur storage pit, which is an underground high depth structure used to temporarily store sulfur product before shipment. Sulfur pits contain a range of critical equipment and piping, such as sulfur product pumps and steam coils.The pumps are crucial for shipping the sulfur product, while the steam coils are used for maintaining the molten sulfur temperature between 270-280 °F to prevent solidification and higher sulfur viscosity. Consequently, any impact to the integrity of this equipment impacts the unit’s operational efficiency or worse, leads to total unit shutdown. This equipment is susceptible to a range of damage mechanisms resulting from both operational conditions, such as sulfuric acid corrosion and environmental cracking, resulting from steam leakage and ground water seepage respectively. This paper investigates sulfuric acid corrosion and corrosion fatigue — in sulfur pumps — resulting from the synergistic effects of both dynamic loading and chloride-induced pitting corrosion. The steam coils in the pit were also found to suffer from both sulfuric acid corrosion and chloride stress corrosion cracking. These damage mechanisms were determined following extensive metallurgical analysis of samples recovered from the pit. Furthemore, laboratory compositional analysis from various samples collected from the pumps and the pits showed significant quantity of sodium chloride, resulting from ground water ingress alongside corrosion, and cementitious products, such as iron sulfide, quartz – SiO2 and iron sulfate. These findings, alongside sample results of the post-inspection findings for the sulfur recovery unit pit and equipment, will be highlighted and discussed. Effective mitigations, including the use of permanent dewatering, will also be discussed.

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Corrosion Fatigue Of X80 Weld In Mild Sour Environment

Product Number: 51322-17778-SG

Author: Laurent Ladeuille, Richard Jones, Yifei Zeng, Xin Yue, Chih-Hsiang Kuo, Florian Thébault, Grégory Toguyeni

Publication Date: 2022

$20.00

Pipelines and rigid risers made in conventional X65 grade require large wall thickness to withstand the high loads imposed during installation and under operating conditions in deep and ultra-deepwater field developments. The use of high-strength steels like X80 is an attractive alternative since it improves catenary weight by reducing wall thickness.

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Corrosion Fatigue Performance of Materials in Delayed Cokers and Coker Blowdown Piping System

Product Number: 51324-20618-SG

Author: Haixia Guo; Millar Iverson; Simon Yuen; Sudeep Bohra; Liu Cao

Publication Date: 2024

$40.00

Very often the current body of knowledge and literature of fatigue performance in coke drums and blowdown piping system are linked to fatigue testing performed in air or in water. This paper summarizes the test results that were conducted using process fluids collected from a delayed coker. Both fatigue crack growth rate (FCGR) tests and stress/strain – cycle fatigue endurance tests in sour water at 200°F (93°C) or in a hot oil mix at 460°F (238°C), with gas mixture containing H2S were conducted. Carbon steel, Alloy 625 and their corresponding weld metal specimens were tested. The test results indicate remarkable impact of environment on fatigue behavior. Frequency scanning FCGR tests in sour water environment showed that FCGR increased with decreasing load frequency, particularly with high ?K (32 ksi·vin or 35 MPa·vm ). When ?K was between 12 ksi·vin (13MPa·vm) and 36 ksi·vin (40 MPa·vm), FCGR of all specimens in sour water are higher than the mean + 2 SD (Standard Deviation) curve of carbon steel in air. Fatigue endurance tests in both sour water and hot oil environments showed various ranges of knock-down factors compared to test results in air. This testing program provides a better definition of the corrosion fatigue cracking mechanism of materials in delayed coker process. It also helps in the inspection planning of delayed coker equipment and in decisions on material selection.

Online Conference Paper

Association for Materials Protection and Performance