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The importance of models for predicting carbon steel corrosion in the oil and gas production chain is undeniable. However, researchers are aware of the difficulty in extending the application range of existing data, to build a generic model. This is because the chemical and electrochemical reactions that impact the corrosion kinetics are affected by the characteristics of each process, such as: salinity, type of oil, oil/water ratio, pH, presence of organic acids.
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The range of factors affecting the susceptibility of equipment to corrosion under insulation (CUI)are numerous. Some of these factors might be controlled through better design, more robustinstallation procedures, and using better quality coatings. However, there are other risk factors such as operating temperature, material type, and environmental conditions that cannot be easily modified.
This paper, presents the isolated and common cases of failure, recounting the troubleshooting practices followed and the verified remedial actions. Much of these cases, lessons learned, and quality control measures provide valuable tools to users of this type of piping material in the oil & gas industry. This paper also sheds lights on the shortcomings of RTRP, that are usually trumped by operational benefits.
Coating systems are used in a wide variety of environments, including seawater immersion and exposure to the atmosphere, as a method for preventing corrosion. A coating system refers to the layers of coatings that are applied over one another to form a structure that performs multiple functions that cannot be provided by a single coating. For example, the initial layer of the system may consist of a surface pretreatment that thickens the oxide film of the aircraft skin material and aids in adhesion of the base coating to the substrate.
Remote monitoring is becoming an increasingly more accepted way of gathering data from test stations. Not only because the value of having continuous data often exceeds that of performing spot-wise measurements in time, but also because the cost of collecting data manually is getting higher. Still, regulations require annual surveys to document the safe operation of pipeline CP systems.
In late 2021, several leaks were observed inside the waste heat boiler coil of the steam reformer furnace at the refinery. The leaks were located in the first row of tubes of the hot bank in the vertically-oriented coil, where boiler water inside the tubes is heated via waste heat of the reformer stack. The waste heat boiler coil has a design duty of 69.59 MMBtu/hr (~20.4 MW), with design pressures and temperatures of 1010 psig (6.9 MPa) and 700°F (371°C), respectively.
The high demand for green hydrogen energy during recent decades has caused increasing research activities around energy conversion devices. Different types of water electrolyzers (WE) and fuel cells (FC) are at the core of attention for hydrogen production and electrical energy generation from hydrogen. Around 20-22% of the total cost of a WE/FC stack is the cost of bipolar plates (BPPs) materials and coatings.
Recent occurrences of high visibility structural failures have spurred interest to revisit inspection and repair of aging reinforced concrete structures. Chloride-induced corrosion can cause premature damage of structures in coastal regions. Corrosion induced by carbonation of the concrete and the concrete pore water, on the other hand can occur in many other environments including structures in both wet and dry exposures. This type of corrosion can become increasingly relevant in residential buildings as housing structures age to where sufficient carbonation occurs at reinforcing steel depths.
Alloy K-500 (UNS N05500) is concomitantly a centurial material and the very first precipitation-strengthened nickel-based alloy, then developed in the 1920s by the newly-formed International Nickel Company, or Inco. Derived from Monel 400 (UNS N04400) that was invented in 1901, Alloy K-500 shares many of the same corrosion and tribological characteristics. Being a pioneer alloy with so-called “stain-less” characteristics, AlloyK-500 also established itself as the first high-strength oilfield nickel alloy, having survived sour service conditions exceeding the capabilities of the low-alloy steels of the time. From early naval propeller shaft applications togeneral cross-industrial uses, Alloy K-500 has always been considered a corrosion-resistant alloy, or CRA. For instance, it has been included in the NACE MR1075 document right from the first 1975 edition.
Army Regulation (AR) 11-42, Army Corrosion Prevention and Control Program, requires that program managers and engineers use a risk-based approach (RBA) to identify the corrosion susceptibility on critical components and the consequence to the overall system. Department of the Army Pamphlet (DA PAM) 11-42 provides an example of generic procedures for conducting a risk-based approach. The goal of this project was to develop a detailed, standardized process for conducting a risk-based approach during CPC planning.
Over the past two decades of the Shale Revolution that completely transformed the global energy market, Fast-dissolving magnesium (DM) alloy technology has advanced significantly in both performance improvement and cost reduction through continuous optimization, which significantly reduced operational costs of hydraulic fracturing. Thousands of tons of DM are manufactured yearly worldwide to make the so-called “multi-stage dissolvable frac plugs”.
The US Army Corps of Engineers, Paint Technology Center (PTC) is a Technical Center of Expertise forall things paints and coating for the Corps and Army. The PTC has a mission, among other things, toexecute research and development directly related to the corrosion mitigation properties of commercialand experimental coatings. As part of this effort, coated panels are subjected to accelerated weatheringconditions and rust creep is quantified to determine the level of recommended mitigation.