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Corrosion of aircraft costs the U.S. Department of Defense (DoD) billions of dollars annually, increases demand on labor, degrades operational readiness, and is a safety issue. Coatings are the most effective means of protection from corrosion, but with time, mechanical and environmental stresses will degrade and eventually breach the coating. For a pristine structure, the coating system reacts primarily to dynamic moisture, temperature, and mechanical loads that can vary over multiple time scales.
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The company operates several thousands of kilometers of pipelines that transport oil and gas from the offshore and onshore fields. A Risk Based Inspection (RBI) approach is adopted to ensure the safe operation of the pipeline system in accordance with the design, company, and legal requirements.
During one of the many planned In-Line Inspection (ILI) programs undertaken to determine the integrity status of their pipelines, a 48" crude pipeline was reported to have significant external corrosion on one of its onshore sections with reported metal loss of up to 93% of its nominal wall thickness.
Stray current prevention, where do you start? When dealing with stray current from a DC Transitsystem it is all about building in “layers” of protection. This begins right from the start of your project through the creation of a design and maintenance guideline, through construction with inspection and testing plans and then through long range testing and maintenance plans.
Cold Spray (CS) is a solid-state deposition repair method that deposits 1-50um powder particles onto a substrate. A compressed gas acts as carrier to accelerate the particles through a converging-diverging nozzle to the substrate at supersonic speeds. Critical impact velocity is the velocity that is required to achieve sufficient bonding. CS process parameters as well as powder properties can be adjusted to achieve such velocities. The type of carrier gas will also change the spray velocity. Helium has the lowest molecular weight which allows for higher gas and particle velocity upon impact.
In many industrial applications such as oil and gas production, mining, and renewable energy systems such as concentrated solar power (CSP), solid particles impact the walls of the pipeline, piping components, and equipment resulting in wear and degradation of the component material. Erosion is the dynamic process of removing material from a solid surface due to the repeated impact of solid particles. When a single solid particle impacts the surface, the material deforms, and eventually, the material is removed upon successive impacts of particles.
Dry abrasive blast cleaning is a commonly used surface preparation method to achieve the necessary surface cleanliness and roughness for the application of high-performance protective coatings. The effectiveness of abrasive blast cleaning depends on various factors, and some studies have indicated that the blasting abrasive used to clean the surface is crucial for the performance of the coating. The previous work evaluated the performances of two liquid-applied epoxy pipeline coatings (coating A and coating B) applied to 15 different surfaces.
Spent nuclear fuel (SNF) is currently stored in stainless steel dry storage canisters (DSCs) contained within concrete cask systems with passive ambient air cooling. These systems are emplaced, either horizontally or vertically, at independent spent fuel storage installations (ISFSIs), located at utility reactor sites. The ambient air introduces moisture, aerosolized salt particles, and dust to the canister surfaces. The composition of the aerosols depends on geographical factors, such as proximity to the ocean,industrial area, rural areas, and transportation corridors that use road salt for winterization.
Corrosion under insulation (CUI) is among the key damage mechanisms in the hydrocarbon industry which mainly manifests localized corrosion on thermally insulated equipment, tanks, piping, and pipelines. CUI is a highly frequent degradation in the oil refining facilities where reportedly 40-60% of failures in the piping result from CUI. In addition, small bore piping (i.e., nominal pipe size, NPS < 4 inch. or 100 mm) are even more prone to CUI and reportedly up to 81% of failures in these piping caused by CUI.
Currently pipeline operators use coupons and other monitoring data to determine if internal corrosion is active. Coupons are relatively easy to install, typically taking 1-2 days and cost around $10,000. This makes this method for collecting data attractive to operators.
Corrosion in metallic industrial equipment, pipework, and vessels, when left unchecked, can lead to the full deterioration of wall-thickness. The presence of through-wall defects may lead to loss of production and costly shutdowns, in addition to environmental and safety hazards. One solution to this issue is the installation of a repair system using composite materials, which are durable for decades, easy to install, and a cost-effective to deploy option for bringing industrial equipment back to operation, even after a leak is detected. Internationally recognized organizations, such as ASME and ISO, set the rules for the design methodology, material testing, and training of personnel for this type of repair method.
At Savannah River Site (SRS), High-Level Waste is stored in below-grade tanks constructed of carbon steel. This waste is composed of sludge, salt cake, and/or supernate. In part, preparation of this waste for future processing involves dissolution of the salt cake layer.
As construction of an industrial plant was nearing completion, it was realized that galvanized scaffolding was used during the erection of a large furnace. There was some concern about the possibility of zinc liquid metal embrittlement (LME) of the austenitic stainless-steel tubes. LME is the loss of ductility when a metal is in contact with liquid metal while under stress. Specifically, austenitic stainless steels are known to be susceptible to LME in the presence of liquid zinc which was implicated in the Flixborough Disaster where 28 people were killed in an industrial accident in 1974.