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Corrosion under Insulation: Case Studies and Challenges in the Use of Corrosion Inhibitors

Product Number: 51324-20778-SG

Author: Takehiro Toyoda; Yoshiyasu Kushima; Koji Watanabe; Toshiyuki Sunaba

Publication Date: 2024

$40.00

Corrosion Under Insulation (CUI) is a significant concern in the oil and gas industry. This paper presents several case studies of CUI, including instances of External Chloride Stress Corrosion Cracking (ECSCC). In our facilities, applying insulation material sprayed with a specific corrosion inhibitor to the internal surface is considered a temporary solution for equipment where CUI is a concern due to damaged coatings. In our previous study, this non-combustible corrosion inhibitor containing phosphate and nitrite showed effective corrosion inhibition in carbon steel even when rusted. However, we considered that an Active Path Corrosion can be occurred under loaded stress portions. To replicate chloride-concentrated environments under insulation, a 70-day immersion test was conducted using U-bend type test specimens of carbon steel in a NaCl solution with the inhibitor. The tested specimens with the inhibitor maintained a metallic appearance without stress corrosion cracking. However, crevice corrosion was observed. These results suggest that the corrosion inhibitor may have limited effectiveness in chloride-concentrated environments. We concluded that it is beneficial to perform cleaning before applying the insulation with corrosion inhibitor and to implement other permanent measures before chloride concentration significantly increases.

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Corrosion Under Pipe Supports - Beyond Simply Inspection

Product Number: 51322-18155-SG

Author: Connor Tiegs

Publication Date: 2022

$20.00

Petrochemical facilities and refineries consist of many miles of above ground piping that transports product between processing and storage units. These pipes are either supported at ground level or in multi-story pipe racks on varying types and sizes of supporting structures. A common problem these structures create is corrosion and erosion at the junction between the pipe and the support, which reduces the remaining wall thickness of the pipe and compromises the integrity of the entire system.

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Corrosion-Induced Hydrogen Entry to Steel and a Risk of Hydrogen Embrittlement

Product Number: 51323-19560-SG

Author: Darya Rudomilova, Gerald H. Luckeneder, Tomáš Prošek, Josef Faderl, Andreas Muhr

Publication Date: 2023

$20.00

Hydrogen embrittlement is a process that results in a decrease of the ductility of metals as a result of absorbed hydrogen. Advanced high-strength steels used in the automotive industry are materials that are considered prone to hydrogen embrittlement. Hydrogen can enter the material during steelmaking or processing steps, such as pickling, cleaning, phosphating, and electroplating.

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Corrosivity Assessment Of New Gas Transmission Lines

Product Number: 51321-16973-SG

Author: Yahya T. Al-Janabi

Publication Date: 2021

$20.00

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Corrosivity Laboratory Investigations Of Streams Associated With Gas Compression Plants And Liquid Separation Stations

Product Number: 51322-17911-SG

Author: Yahya T. AlJanabi

Publication Date: 2022

$20.00

The design packages are being optimized for the construction of gas transmission lines associated with nine (9) Gas Compression Plants (GCPs) and six (6) Liquid Separation Stations (LSSs). The objective of this study was to assess the service corrosivity of all gas transmission lines associated with these GCPs and LSSs. The results of the study will assist in selecting a cost-effective and efficient corrosion management program in terms of both materials and corrosion control options. To address this objective, the study involved conducting laboratory tests simulating the conditions in these lines. Three types of corrosion attacks were investigated, namely, general corrosion, pitting corrosion, and gas phase corrosion.

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Corrosivity Mapping as a Fundamental Tool in Assessing the Integrity of the Distribution/Transmission System for the Electricity Trust of South Australia

Product Number: 51393-93638-SG

Author: King, G.A.

Publication Date: 1993

$20.00

The aggressiveness of the atmospheric environment can be assessed by measurement of climatic and pollution factors, or by determination of the corrosion rates of metals and coatings. The latter is a low cost technique which has traditionally been employed at single isolated sites with different types of environments. This approach does not, however, adequately portray the levels of corrosivity across a city or region which can vary by an order of magnitude. A technique has been devised at the Commonwealth Scientific and Industrial Research Organization (CSIRO) in which specimens are exposed across a grid of contiguous sites and the results computer contoured to generate corrosivity maps. A new method of h hyperbolic interpolation of the data has been developed to model corrosivity approaching the coastline. The paper presents results from surveys around an industrial point source of S02, conducted over two different periods. The technique of corrosivity mapping was demonstrated to be a sensitive indicator of localized zones of enhanced corrosion, and the two maps reflected changed conditions in the plant's operation in the two periods. The paper also discusses corrosion mapping in countries other than Australia and examines the costs of such exercises and the potential savings they can provide.

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Cost of Corrosion Model for Corrosion Under Insulation (CUI) Program Scoping and Optimization

Product Number: MECC23-20377-SG

Author: Muhammad Zaid Kamardin, Muhammad Afiq Mansor, Hambali Chik, Azniza Azmy

Publication Date: 2023

$20.00

Corrosion under insulation (CUI) is a form of corrosion resulting from water trapped under insulation. CUI is a main asset integrity threat to many processing facilities. CUI damage is not readily identifiable and hidden underneath the insulation.

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Cost-effective Optimization of Midstream Pipeline Corrosion Management with Advanced Technologies

Product Number: 51324-21193-SG

Author: Pankaj Tandon

Publication Date: 2024

$40.00

Midstream pipeline integrity teams face ongoing challenges due to corrosion and deteriorating conditions, which can impact transmission infrastructure reliability. Adhering to regulations and maintaining operational continuity requires operators to adopt advanced technologies to maximize outcomes. This paper highlights the application of Praemia™ Inc. software as a robust tool for planning and monitoring integrity management activities, more specifically threats such as internal and external corrosion and SCC. The software utilizes powerful analytics to incorporate threat-specific assessment and risk analysis, focusing on optimizing budgeting and prioritizing mitigation measures, evaluating repair vs. replace options and ultimately enhancing decision-making. Additionally, the paper showcases the practical implementation of AI technologies in midstream pipeline corrosion management. Real-world examples and case studies illustrate the benefits of technology-driven solutions, empowering operators to proactively manage corrosion. Join us to explore how advanced technologies revolutionize midstream pipeline corrosion management, ensuring long-term integrity while optimizing operational efficiency and cost-effectiveness.

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Could This Nobel Prize Winning Technology Generate a "New Class of Material" for the Coating Industry?

Product Number: 51324-20687-SG

Author: Jeremy Daum; Ilhan Ulkem; Andrew Recker

Publication Date: 2024

$40.00

Grubbs catalysts and ring opening metathesis polymerization (ROMP) have been explored to develop a new class of material for the coating industry. In this study, ROMP has been successfully utilized to obtain 100 % solids, fast reacting polymeric networks. Products rapidly exhibited higher Tg and Shore D hardness values compared to other coating resins like epoxies. They also exhibited superior hydrophobicity behavior compared to the industry standards with much lower hysteresis and almost no water absorption upon immersion into water. When carefully formulated, these materials have also been found to be resistant to high temperatures at a level that could compete with low end of the TSA (thermally sprayed aluminum) products.

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CP upgrade options for aboveground storage tanks

Product Number: MPWT19-14297

Author: Mohammed Alotaibi

Publication Date: 2019

$0.00

Storage tanks are the primary means for storing large volumes of liquids and gaseous products. Metal
loss from internal and external corrosion can reduce the service life of a tank. It is important to maintain
the integrity of steel storage tanks for safety, economic, and environmental reasons.
Saudi Aramco implemented three different scenarios of cathodic protection (CP) during bottom plate
replacement for three typical tanks. The tanks’ bottom plates were replaced based on thickness
measurements and visual inspection that revealed severe corrosion from soil. The main reason for
such corrosion was due to the asphalt layer underneath the tank. It was considered during the
replacement of the bottom plate to provide a reliable external (CP) and leak detection system. The
purpose of this paper is to demonstrate the experience gained from executing CP upgrades, and to
provide the best option to ensure integrity, cost saving and fewer shutdown periods.

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Crack Growth Behaviour Of Cobalt Based Alloy In High Temperature Water

Product Number: ED22-17294-SG

Author: T.Yamada, T.Terachi, T.Sasaoka, K.Arioka

Publication Date: 2022

$20.00

Co-based alloy (30Cr-4W-Bal.Co), such as Stellite TM grade 6 (UNS No. ERCOCr-A) valve seat, is used extensively in applications where superior resistance to wear corrosion are required. But there are only rare data about crack growth behavior of the alloy in the high temperature water. It is difficult to extract specimen from as welded Stellite-6, because of the valve sheet did not have enough volume. So, to evaluate the crack growth behavior and its temperature dependence, crack growth rate measurements were performed using forged Co-based alloy bar (Stellite TM grade 6B) (UNS No. R30016) in a simulated PWR primary water at temperature ranging from 250 to 320°C using half-inch size compact tension specimens (1/2TCT).

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Crack Growth Rate Testing Of Alloy 82 In BWR Environments

Product Number: ED22-17295-SG

Author: Johan Stjärnsäter, Katsuhiko Kumagai

Publication Date: 2022

$20.00

The nickel base weld metal Alloy 82 is used in various applications in boiling water reactors (BWRs). Applications that are vital from a safety point of view are e.g., welds between core shroud support legs and the reactor pressure vessel (RPV), and feedwater nozzle to safe end welds. Laboratory testing and service history have shown that Alloy 82 is susceptible to stress corrosion cracking (SCC) in BWR environments. However, in comparison with Alloy 182, fewer failure cases have been reported, which could be related to the higher Cr content in Alloy 82 (~ 15 vs. ~ 20 %). It is also possible that the higher frequency of SCC in Alloy 182 is related to the wider use of this weld metal, and the larger surface area exposed to reactor water. Given the lower frequency of failures in Alloy 82, the database regarding SCC in BWR environments is much larger for Alloy 182.

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Association for Materials Protection and Performance