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In the oil and gas industry, solid metal equipment such as pipelines, pressure vessels, heat exchangers and valves are susceptible to surface cracks and discontinuities attributed to cyclic loading, process environment and severe operating conditions. These anomalies affect the safety, structural functionality, reliability, integrity and life cycle of the equipment. They could lead to catastrophic incidents if not detected timely, evaluated, monitored and properly repaired.
Inspection of surface and near-surface indications has been always a challenge in the oil and gas industry due to the limitations of the commonly utilized conventional Nondestructive Testing (NDT) methods and their implementation difficulties such as surface preparation requirements, reliance on operator skills, slow deployment and inability to archive inspection data. Keeping pace with industrial revolution (IR) 4.0, Nondestructive testing (NDT) methods have been evolving to be digitized by automated data evaluation and visualization of inspection results while improving detection capability, decision making processes and speeding up the inspection activities. This paper will discuss and analyze the trials conducted to validate the capability of the new digital generation of Eddy Current Test (ECT); namely Eddy Current Array (ECA), based on comparisons made against alternate methods. The paper will also illustrate the principles, applications and benefits of ECA technology. ECA technology shows significant potential as a replacement for conventional NDT methods, i.e., Magnetic Particle Inspection (MPI) and Penetrant Testing (PT) that are used for the inspection of surface-breaking and near-surface indications including Environmental-Assisted Cracking.
Evaluating the location-based risk of corrosion is critical to a number of fields of industry. Within naval aviation, knowing the risk of corrosion from environmental factors can be used to ensure that maintenance intervals are properly planned. From a basic research aspect, understanding how different sites behave allows researchers to better correlate how performance at a standard test site can be extrapolated in future research efforts. However, a survey of literature and conversations with many corrosion experts has shown variability in how environmental factors are assessed.
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Carbon Capture and Storage (CCS) is a countermeasure for the global warming issue, and the number of CCS projects has increased. One type of CCS is Enhanced Oil Recovery (EOR), in which CO2 is injected into oil or natural gas reservoirs. Because formation water, which usually has a high concentration of chloride, exists at the bottom of these reservoirs, the injection tubing will suffer corrosion when the formation water flows back to the tubing. Stainless steels have been applied as tubing materials for Oil Country Tubular Goods (OCTG), and showed excellent corrosion resistance under high temperature and high CO2 pressure conditions. Martensite-based stainless steels bearing 13 mass% Cr to 17 mass% Cr are one of these tubing materials and are also expected to be used in CO2 injection tubing.
The manufacturing and field experience of high strength low alloy (HSLA) steel plates produced by Thermo-Mechanical Controlled Process (TMCP) are well defined in industry standards and literature. The TMCP method consists of a well-prescribed rolling pass schedule followed by accelerated cooling that leads to a fine-grain microstructure with the desired mechanical properties of the produced plates.Quite recently, this TMCP process resulted in detrimental local variations with hidden hardness variations on pipe ID, so-called Local hard Zones (LHZ).