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The total project study focused on six suction and discharge drums. Each of them was built with twohemispherical heads and a number of shells. The H2S service and Stress Corrosion Cracking (SCC) from this specific oil and gas field required the equipment to be cladded with Alloy 825 to protect them from corrosion.
The need for high-performing, corrosion-resistant alloys in oil and gas clad applications are increasing as more owner/operators move drilling operations offshore, into harsher conditions to tap petroleum reserves, which often contains more hydrogen sulphide (H2S).
Explosion Welding1 (EXW) a layer of corrosion-resistant alloys to carbon or low-alloy steel typically provides significant cost reduction for pressure vessels and other process equipment. Among all the existing nickel alloys, one specifically shows significant cost-benefit features: UNS N08825 (Alloy 825), a titanium stabilized Nickel-Iron-Chromium alloy. However, this nickel alloy is vulnerable to sensitization in a range of temperatures that is regularly used in equipment manufacturing processes.
NobelClad has partnered with VDM Metals to conduct a series of corrosion and mechanical tests throughout the manufacturing process to confirm that the cladding, head forming, vessel manufacturing, and lifecycle repair processes preserve the metals’ properties – both base and clad – from beginning to end. The study simulated and confirmed all heat treatments on the final clad product were successful.
New inventions imply that these also should be implemented into relevant standards. Sometimes also minor modifications in the standard setup of the existing procedures are needed. For duplex stainless steels one of the most important aspects is if a correct final solution annealing has been performed giving the material proper properties.
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Pipeline internal corrosion is an important issue that threatens pipeline safety operations. Catastrophic failures of pipelines and equipment due to corrosion-related shortcomings can lead to fires, explosions, and the release of toxic materials into the environment. Regulator noted that more than 9000 failures occurred due to internal corrosion from 1990 to 2012.
Material selection to get “fit-for-purpose” alloys is an important task that corrosion engineers face in their daily work. Two common ways of attacking such a challenge is by testing different alloys in environments similar to the application in a laboratory environment or installing samples in actual operating equipment. In the latter, testing is usually time consuming and might require plant turnovers to get access to the equipment for sample installation.