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An economic evaluation of a project plays a significant role in determining its feasibility. Corrosion is intrinsic to the operation of metallic assets, and the costs dedicated to its prevention and/or its consequences are unavoidable. Different corrosion strategies could be developed to address the project's needs while complying with relevant codes and standards. These various corrosion control strategies are characterized by inherently different capital expenditures (CAPEX) and operating expenses (OPEX). Careful analysis of the cost projections for each of the considered corrosion mitigation strategies is needed for project optimization and improvement of return on investment.
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The current paper deals with a thorough analysis of these newly recognized LHZ with Scanning Electron Microscope (SEM) and Electron Back Scattering Diffraction (EBSD) investigations through the wall thickness of pipes. Internal diameter (ID) surface, intermediate zone and bulk metal microstructures showed an increase of a strong misorientation while approaching the ID. Thus, LHZ is characterized by the presence of lath and especially lower bainite type microstructures associated to high local hardness above the NACE MR 0175 / ISO 15156 limits for sour service applications.
Corrosion under thermal insulations namely CUI (Corrosion under insulation) is a key degradation process in hydrocarbon facilities which poses asset integrity risks. 1 CUI is reported as the reason behind 40-60% of failures of the process piping in a typical oil refining facility. Speaking smaller-sized process piping (i.e., NPS < 4”), up to 81% of reported failures are known to result from CUI. 2 Monetary spending to inspect and fix CUI-related failures cost 10% of overall maintenance budget in a typical medium-sized oil refinery. 2 CUI risk is influenced by numerous operational and environmental factors which impedes its management in a typical AIM (Asset integrity management) program. The
Corrosion failures in the oil and gas industry are dominated by localized failures in carbon steel; however, the industry has yet to develop standards for localized corrosion specifically for low alloy carbon steels (CS) such as UNS K03014 (API) 5LX65 [X65]) or UNS G10180 (C1018). The reasons for the lack of standardization are understandable as they are not trivial. The challenges are as follows: 1) CS pitting is more complex than pitting on stainless steels (SS) and can be impacted by corrosion byproducts and other forms of scales, and 2) surface finish of a test coupon or electrode has a significant impact on the three phases of pitting: initiation, propagation, and termination.
UNS N06985 is a nickel-based alloy with additions of Mo, Cu and W. Because of its high strength and high resistance to stress corrosion cracking (SCC), cold worked UNS N06985 has been extensively used for OCTG (Oil Country Tubular Goods). The SCC initiation has been studied in Cl-H2S-CO2 containing sour environments; and the SCC resistance was often evaluated using slow strain rate testing (SSRT) for screening by short-term testing and using tensile or C-ring for verification by long-term autoclave testing exposures1. UNS N06985 showed high resistance to SCC at high temperatures in elemental sulfur containing environments with moderate chlorides2.
Offshore wind farms are important contributions to the growing need for the generation of renewable energy. The number of offshore wind farms is growing, and multiple projects are under planning and construction around the world. One key element for a profitable and sustainable operation of offshore wind farms is that the installations are protected with the most cost-effective corrosion protective solution for the entire lifetime of the offshore wind farm. In practice, this means that today’s projects are planned with an estimated lifetime of a minimum of 35 years without major maintenance of the corrosion protective solution. To achieve this it is instrumental that the entire lifetime cost is considered when a corrosion protective solution is selected.
Managing aging reinforced concrete infrastructure is a complex and capital-intensive task, particularly in harsh marine and coastal environments. Corrosion from saltwater, coupled with wet and dry cycles, are particularly problematic for long-term durability of reinforced concrete. The Gulf Coast presents a challenge for maintaining service life of concrete structures that are exposed to high levels of chlorides, either by direct contact with salty or brackish water or by indirect contact with salt spray. Chlorides induce corrosion of the steel reinforcement which initiates cracking and spalling of the concrete, reducing the service life of the structure.
Copper alloys such as copper nickel (CuNi) and Admiralty Brass (CuZn) are often successful material selections for seawater coolers. The copper alloys successes in these highly corrosive environments can be attributes to the ability of copper to form a protective scale, thus stopping corrosion of the material. On copper alloys in seawater, the protective scale formed comprises a mix of cuprous oxide (Cu2O), copper oxide (CuO) and copper hydroxy chlorides.
Safe and stable operation of the process plant through its life cycle is an ultimate target of any integrity management system. Over the last decades, a number of possible ways and systems for managing plant integrity were described and implemented.1-4 A common path for all those efforts was to control and manage corrosion processes in a more-or-less systematic way by applying certain measures (monitoring techniques, material selection guidelines, operating procedures etc.) and performance indicators (remaining time-to-failure, inhibitor usage etc.). An effective corrosion and integrity management system, in theory, should be capable to “uncover” excessive corrosion incidents before serious damage occurs. Unfortunately, unexpected corrosion-related failures are still occurring in the petroleum industry.5 This situation stems predominantly from relatively poor data organization and management, leaving corrosion and key process information spread and hidden across different refinery functions and systems.
AM brings significant benefits in better performance, inventory management, and lifecycle cost reduction to the Oil & Gas industry. Both manufacturers and users are working towards AM qualification and standardization in order to realize and sustain these benefits. Starting at the product level, the goal is to ensure the product is sound in its form, fit, and function, and free from macroscopic (surface, sub-surface, internal) anomalies deleterious to its performance. Product qualification is supported by a foundational metallurgical or AM material qualification.1
LIBS is a type of optical emission spectroscopy used to measure elemental concentrations in a material. LIBS operates by using a pulsed, focused laser that is fired at a sample with sufficient pulse energy as to create a plasma around the area struck. Bound atomic electrons are stripped from the atoms comprising the material. As the plasma cools, atoms recombine with electrons and in the process emit light in the UV, optical and IR regimes.
Cemented carbides have been widely used to make parts for wear applications due to the excellent combination of hardness and toughness. Cemented carbides represent a group of composite materials containing hard metal carbides, such as tungsten carbide (WC), bonded by ductile metallic binder agents, such as cobalt (Co), nickel (Ni), or iron (Fe).1 By varying WC grain size, weight fraction of metallic binder, and processing parameters, a wider range of microstructure and mechanical properties can be achieved.