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Wafra Joint Operations is in the west central part of the Kuwait-Saudi Arabia Neutral Zone. The oilfield produces light and heavy oil and exports it to its various customers after processing. Upstream field consists of various Sub Centres where crude, oil and water being separated, and the separated crude transported to the main gathering centre for further processing in two different trains. The produced water being disposed/injected via water disposal and injection facilities after treatment.
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Directional drilling tools for oil and gas exploration is one industrial application where Manganese (Mn)-stabilized austenitic stainless steels with different amounts of other alloying elements like Chromium (Cr), Nickel (Ni) and Molybdenum (Mo) have found extensive use in spite of the demanding requirements in terms of mechanical properties and corrosion resistance. The limited resistance of this type of austenitic stainless steels to environmentally assisted cracking (EAC) in hot chloride (Cl-)-containing environments is well known. Chloride-bearing environments at elevated temperatures are not uncommon in drilling operations and can indeed challenge the EAC-resistance of CrMn-stainless steels
Zirconium and Zirconium alloys have been used successfully in a range of corrosive environments, both as base materials and as cladding on other backing materials. Zirconium is used extensively as fuel-rod “cladding” in nuclear reactors. In the chemical process industries, Zirconium and its alloys are used in urea production, acetic acid and vinyl acetate production, and various sulfuric, hydrochloric, and organic acid services.
Metal corrosion associated with the growth and reproduction of microorganisms is known as microbiologically influenced corrosion (MIC). MIC causes damage to metal surfaces in several water-based industries including drinking water distribution, cooling water equipment, sewage treatment, underground pipes, bilges, piping, and tanks of maritime vessels. MIC is extensively seen in the oil and gas industry.
In recent years, with the large-scale construction of natural gas and metro systems, a lot of buried gas pipeline close to the metro systems have suffered from dynamic DC stray current interference. This may cause corrosion leakage of buried gas steel pipeline and bring serious safety hazards. A large number of corrosion cases from metro stray current have been reported all over the world.
Natural gas pipelines are subject to internal corrosion. Internal corrosion of steel pipelines can cause natural gas leakage, leading to wasted energy, explosion hazards, and methane emissions. The U.S. Department of Transport reported numerous case histories of corrosion problems and failures in wet gas pipelines. The National Energy Technology Laboratory (NETL) performed an incident survey from 2010 through 2018 and found that 112 (12%) of these incidents in the U.S. transmission lines were caused by internal corrosion.
Development of this strategy began after a steel pipeline, coated with Fusion Bonded Epoxy (FBE), was constructed in a collocated right-of-way (ROW) with a high voltage direct current (HVDC) Powerline. Area Cathodic Protection (CP) Technicians reported challenges in recording stable DC Pipe-to-Soil (P/S) Potentials due to rapid fluctuations observed in the DC waveform. In addition, CP technicians recorded DC line current concurrently with P/S potentials and found that there was a correlation between the two.
Longitudinal cracking had occurred in the protective ARO pipeline coating scheduled for installation. Once the cracks were discovered the cause and extent of the cracking needed to be identified before work could continue. Industry experience has shown that coating failures do not always have a singular cause and often are the result of multiple interacting variables. In addition, the interaction of these variables can be complex in nature.
For many years, sacrificial corrosion protective paint formulations based on Zinc consisted of zinc dust at approximate 80% loading and about 10% epoxy binder. This composition is necessary for corrosion protection, as direct zinc to zinc dust contact is only possible at high zinc dust loadings. This goes back to the spherical shape of the zinc dust particles with their low surface area.
Sacrificial or Galvanic Anodes Cathodic Protection System is an excellent anticorrosion solution which offers to immerse structures a long-term protection. In TotalEnergies and in the Oil & Gas Industry in general, such system provides confidence, efficiency together with little maintenance over years which is a very good point for the subsea integrity of jackets (or pipelines) when knowing all other operational constraints or corrosion issues that can be met at the surface level.
Thus, from TotalEnergies experience, it has been established that as long as:1/ the CP system is correctly designed (taking into account the applied - or not - painting on the jacket) following the recognized international codes and standards (DNV RP-B-401, ISO 15589-2.
Integrated computational materials engineering (ICME) has provided materials developers with new virtual tools for exploring the space of novel materials. ICME is typically rooted in computation of phase diagrams (CalPhaD) using thermodynamic databases as well as thermodynamic data that can be generated from first-principles. CalPhaD provides the opportunity to determine stable materials compositions that may have targeted properties, which can be predicted using other computational search techniques, depending on the criteria of interest.
Galvanic corrosion is one of the eight forms of corrosion classified in corrosion engineering. A galvanic cell is formed when two dissimilar metals are connected electrically while both are immersed in a solution electrolyte. Galvanic coupling of stainless steel and carbon steel metals in water and wastewater structures appears to be a problematic trend that the authors have observed firsthand.