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Pipeline leak detection is emerging as a prime focus of PHMSA and other regulatory agencies in the United States as well as jurisdictions all over the world. The immense volume of buried pipelines and the fact that much of this buried infrastructure is over forty years old1 combine to present increasing risk of leaks with potentially catastrophic results. During the twenty-year timespan from 2002 through 2021, in the United States alone, the Pipeline and Hazardous Materials Safety Administration (PHMSA) recorded 42 hazardous liquids incidents resulting in 35 fatalities, 80 injuries, and over 147,000 barrels spilled. In many cases the environmental and human health and safety costs could have been reduced if the leaks were detected much earlier.
This paper presents a case study in adapting report by exception remote monitoring technology to continuously monitor leak detection sensors along a cross-country high volume liquid products pipeline system. The resulting system enables the operating company to have 24/7 visibility to their leak detection devices as well as immediate alarm notification in the event of a detected leak condition. This technology enables sensors to be distributed anywhere in the system regardless of the availability of communication connection to the central operations network, using cellular and satellite communication. The web-based data interface enables viewing of data and receipt of alarms through any authorized web-enabled device. The presentation will discuss the sensor and monitoring technology, the data interface used between the sensors and monitors, the various means of facilitating communication to the operating company, and some lessons learned along the way.
Fired heaters in coking service are susceptible to carburization damage, which needs to be predicted and managed to prevent unexpected downtime and expedited replacement costs. Carburization damage occurs when carbonaceous material, i.e., coke, is deposited on a steel surface and exposed to high metal temperatures; such are the internal conditions present in fired heater tubes in coking services. At these high temperatures, the carbon diffuses into the steel microstructure and increases the hardness while reducing ductility. At an advanced state, this reduction in ductility may lead to tube failure if a mechanical or thermal shock is applied. The diffusion of carbon can also cause the formation of deleterious chromium carbides in the steel microstructure, reducing the high temperature corrosion resistance in those areas.
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Traditionally, sour severity of high-pressure, high temperature (HPHT) oil and gas production wells were assessed by H2S partial pressure (PH2S): The mole fraction of H2S in the gas (yH2S) multiplied by the total pressure (PT). While PH2S is appropriate for characterizing the sour severity of wellbores operating at low total pressures (e.g., PT < 35 MPa) and/or for highly sour systems (e.g., yH2S > 1 mol%), PH2S usually over-predicts the actual sour severity of HPHT systems, leading to sub-optimal material selection options.
Additive manufacturing (AM) is a transformative technology that has opened areas of design space that were previously inaccessible by enabling the production of complex, three-dimensional parts and intricate geometries that were impractical to produce via traditional manufacturing methods. However, the extreme thermo-mechanical conditions in the AM build process (e.g., cooling rates ranging from 103 K/sto 106 K/s and repeated heating/cooling cycles) generate deleterious microstructures with high residual stresses, and extreme compositional gradients.