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Three layer polypropylene (3LPP) pipeline coatings failed prematurely in the oilfields of Abu Dhabi in the United Arab Emirates (UAE). A failure investigation and analysis into this phenomenon was instigated. The coating disbondment has been found to be due to high residual stress concentration and adhesion loss.
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CO2 is well recognized to be a major factor accelerating the corrosion process. When CO2 dissolves in water, it forms carbonic acid which is a weak acid and it dissociates only slightly to form bicarbonate ion followed by further dissociation to form carbonate ions (Figure 1). At pH levels lower than 5.5, the bicarbonate ions (HCO3-) are the main carbonic species in solution.
As oilfield technologies have advanced, they have made high temperature (HT) reservoirs more accessible. HTs make the application of chemical more difficult because chemical instability at HT restricts what intermediates will work in these environments and the safety and complexity of HT testing further adds to the challenge.
Nickel-base N06235 alloy is a solid-solution strengthened Ni-Cr-Mo-Cu alloy that was developed to resist metal dusting corrosion attack in high temperature structural applications involving carbonaceous and other high temperature corrosive environments, particularly in syngas production and processing environments. Improved metal dusting resistance was achieved by significant additions of copper and high amounts chromium to inhibit carbon deposition, ingress, and coke formation as previously reported. The high temperature creep-rupture and tensile strength of the wrought alloy and its weldments were investigated in this paper. Weld samples produced by Gas Metal Arc Welding (GMAW) and Gas Tungsten Arc Welding (GTAW), exhibit tensile and creep-rupture strength similar to that of wrought alloy in the temperature range from 538 to 1093oC (1000 to 2000oF). In addition, the retained room and elevated temperature tensile properties of the wrought base metal after 4000-hour long-term aging at temperatures from 649 to 871°C (1200 to 1600oF) are reported.
Scale is an adherent deposit of inorganic compounds precipitated from water onto surfaces. Most oilfield waters contain certain amounts of dissolved calcium, barium or strontium salts. The mineral scale can be formed by chemical reactions in the formation water itself, by mixing of formation water with injected seawater, or by mixing of the well streams of two incompatible oilfield waters. In carbonate reservoirs, when calcium is deposited as calcium sulfate or calcium carbonate scale, a loss of production and increased maintenance expenses can result. Therefore, effective mitigation of scaling potential is of importance to the oil producers.
The alloys used as clad material for this study are members of the so-called “C-family”. It consists of Ni-Cr-Mo alloys, which are known for combining the corrosion resistance of Ni-Cr alloys in oxidizing media with corrosion resistance of Ni-Mo alloys in reducing media. As a result, these materials have proven to be extremely durable in a wide range of highly aggressive media. The development of these materials started in the 1930s with Alloy C. This alloy showed remarkable corrosion resistance in a wide spread of media, low sensitivity for pitting or crevice corrosion and virtual immunity to chloride induced stress corrosion cracking.