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This paper presents the findings of an investigation that was carried out to determine the root cause of the premature failure of Ni-coated carbon steel fittings on the water injection composite piping system installed at an oil production facility in Western Canada. The facility had been in operation since 2011 without major corrosion issues. Many of the Ni-coated fittings, which are expected to have a service life of 20 years, started to fail (developed leaks) unexpectedly after about 4 years. The core structure of composite pipe is a high-density polyethylene (HDPE) inner pipe, a middle layer of high-strength dry fiberglass, and a protective thermoplastic outer jacket. The interconnecting fittings are made of carbon steel coated with a thin, ~40 micron (1.5 mil) layer of Nickel.
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The most commonly available non-metallic options for piping systems handling corrosive fluids - thermoplastic, thermoplasticlined metallic, thermoset, thermoplastic lined composite, fiberglass reinforced plastic (FRP) and Engineered Structural Composite (ESC) piping.