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Various corrosion prediction tools for CO₂/H₂S corrosion have been developed in the past thirty years. For corrosion analysis in oil and gas production, the water chemistry largely determines the corrosion rate which is mainly driven by in-situ pH.
The in-situ water or brine is pressurized with acid gases (CO₂/H₂S) which results in a decrease in pH and typically an increase in the corrosion rate.
There have been several studies and publications over the past decade that clearly illustrate how initial assumptions about monopile interiors being perfectly sealed compartments were not correct in practice. Oxygen ingress through various points in the monopile contributes to persistent internal corrosion, and planned inspections are also opportunities to introduce fresh oxygen into the monopile. The replenishment of oxygen has been found to continue the corrosion reaction between the monopile wall and entrapped water.
This paper outlines and summarizes the robust testing and assessment program developed and implemented by the Electric Power Research Institute (EPRI), following upon an initial feasibility evaluation completed in 2015. A multi-year, multi-discipline program has been developed, incorporating significant industry input, to address the identified technical gaps in materials, fuels, chemistry, and radiation safety that need evaluation to support a plant demonstration in a Western-design PWR.
Methodology to simulate actual oil and gas field condition in laboratory tests. A sulfide stress cracking test is carried out on 13% Cr stainless steel with various buffer solutions. Then, pH behavior was estimated. A suitable composition of the solution is proposed by using thermodynamic calculations.
Boiler system is one of the most critical systems for a utility plant. A utility plant had experienced high percentages of boiler downtime owing to boiler tube sheet cracking failures. Investigations carried out revealed high stress at the tube-to-tube sheet joint in the boiler fire-side entrance. Tube-to-tube sheet joints at the boiler fire-side entrance had been fabricated by strength welding and without any expansion. The strength welded joint had created undue stress leading to cracking of the weld joint by thermal expansion. A higher quality expanded joint consisting of expanding, flaring and seal welding the fire-side entrance was implemented during the re-tube process. The utility plant has now zero downtime due to boiler tube failure. This article summarizes the description and history of failures with the boiler at the utility plant; investigations and corrective actions carried out; and the present improved condition of the boilers.