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Consistent coating inspections and planned maintenance are essential to asset integrity. Non-existent, delayed, and cursory inspections can allow premature coating breakdown, corrosion, and costly failures. On the other hand, improper maintenance can be ineffective, costly, and wasteful. The challenge involved in executing informative inspections and effective maintenance practices is identifying and understanding the numerous conditions that can contribute to a reduction in the lifecycle of an asset. This paper will discuss some of the aspects involved in identifying coating conditions that are likely to result in failures and developing cost effective coating repair strategies that will extend the life of the asset.
Regular coating inspections and surveys, collectively referred to as Coating Condition Surveys (CCS), provide invaluable information about the condition of existing coatings that can be used to inform effective maintenance strategies. Without routine surveys, maintenance strategies can be ineffective and can become obsolete. Regularly scheduled surveys and planned maintenance are essential to asset integrity. However, both are often neglected as the value in each task is not fully understood. The findings, recommendations, and priorities offered by a CCS not only help owners better understand their assets, but also help engineers, designers, specifiers, coatings applicators, and inspectors better maintain assets. This understanding can help owners make decisions on budgeting for maintenance, help designers plan for repairs and inspections, and provide coatings contractors a clear understanding of the repairs needed and how the repairs should be completed. This paper focuses on the inspection and repair strategies for existing coatings on steel substrates, however the plans and strategies can be applied to all assets.
Major manufacturers of protective coatings, steel fabricators, painting contractors, galvanizers, and end users, were surveyed to identify surface preparation and coating application costs, coating material costs, typical industrial environments and available generic coatings for use within those environments, and expected coating service lives (practical maintenance time).
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H2S corrosion, also known as sour corrosion, is one of the most researched types of metal degradation in oil and gas transmission pipelines requiring a wide range of environmental conditions and detailed surface analysis techniques. This is because localized or pitting corrosion is known to be the main type of corrosion failure in sour environments which caused 12% of all oilfield corrosion incidents according to a report from 1996. Therefore, control and reduction of this type of corrosion could prevent such failures in oil and gas industries, and significantly enhance asset integrity while reducing maintenance costs as well as eliminating environmental damage.
This paper will provide recent corrosion data for stored chemicals. Duplex stainless steel corrosion curves obtained in nitric, sulfuric, phosphoric acids as well as several kinds of waters will be provided. In addition, atmospheric corrosion data obtained after 15+ years of sample exposures in several geographic areas will be shown. These results will be compared to those obtained with other materials commonly used for the construction of storage tanks.