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Autonomous Healing of Smart Coating Materials for Corrosion Protection of Oil and Gas Assets

Product Number: 51324-20901-SG

Author: Norfadilah Dolmat; Azmi Mohammed Nor; Mohd Shamsul Farid Samsudin; Russel Varley; Jane Zhang

Publication Date: 2024

$40.00

Most assets in the oil and gas sector that use metal substrates e.g., pipe supports, or structures are susceptible to corrosion problems primarily because of continual exposure of damaged areas to severe environmental conditions. The proliferation and merging of corrosion issues can cause catastrophic failure of materials, resulting in a reduction in the service life of the materials. To avoid these issues, it is crucial to protect the scratch or minor crack area as quickly as possible so that it does not spread too far. In this case, self-healing as a smart material can be applied to the coating system to repair coating damage instantaneously. Self-healing works in multiple functions where it can be used to protect against corrosion and at the same time heal the damaged area itself. In this research, the experimental work includes boronic ester (BE) and polyurethane (PU) synthesis, BE-PU coating specimen preparation, characterization and performance analysis. BE was introduced in the polyurethane (PU) and applied as an additional coating layer to the existing coating system according to PETRONAS technical standard (PTS) requirement with a thickness of approximately 300-400 µm. The healing performance of the scribed coating at room and 60°C with 80% humidity level was initially evaluated using 3D profilometer microscopy and electrical impedance spectroscopy (EIS). Corrosion resistance performance was evaluated by performing long term 3000 hours salt spray and 4200 hours cyclic UV. The mechanical performance or compatibility of the self-healing with current coating system was also assessed using a pull-off adhesion test and abrasion test. The assessment of the scratched BE-PU self-healing using 3D profilometer microscopy demonstrated remarkable healing efficiency of more than 85% and has corrosion resistance performance through salt spray and cyclic UV test. In addition, BE-PU self-healing showed significant adhesion efficiency with more than 300 psi and abrasion performance.

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Avoid Potential Repeated Failure (Cracked Gas Compressor line) Through Proper Material Assessment

Product Number: MPWT19-14239

Author: Ahmed Elsharkawi, Amro Hassanein

Publication Date: 2019

$0.00

The heat treatment condition of industrial materials is a critical parameter for material evaluation and its fitness for intended service. Proper heat treatment will produce desired mechanical and physical properties, while absence or improper heat treatment may lead to major failure with huge production, Environmental, Health, and Safety (EHS) impacts. We hereby explain an actual case for cracked gas compressor (CGC) 5th stage discharge line caustic stress corrosion cracking (SCC) that caused unplanned plant shut down and resulted in noticed financial and production loss.
The proven root cause is absence of normalization. Emergency piping batch is received and supposed to be normalized to avoid failure recurrence. Many discrepancies extracted from submitted material certificates, also many physical signs observed on the material itself raising doubts about received material compatibility. Using advanced Positive Material Identification (PMI) device to verify the chemical composition of the received material, results show that the material is questionable.
As a precise test to verify heat treatment condition, microstructure analysis test (metallography) conducted to confirm normalization condition of the material, the resulted grain structure size and growth confirm that one of the received pipes has improper or absence of normalization.
The material rejected as it is proven and confirmed that it is not normalized as per the requirements to avoid further potential of hydrocarbon leakage due to improper material specification. Rejecting the material eliminate the potential of having repeated failure, in addition to 600,000 Saudi Riyal (SR) cost saving as material cost. A common recommendation shared with concerned parties to consider metallography as a mandatory test to be submitted with heat-treated material test certificate (MTC).
Key words: Heat treatment, microstructure, normalization, grain structure, failure, metallography

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Balancing the Performance and Robustness of Epoxy Intumescent Coatings

Product Number: 51324-20661-SG

Author: Ingrid Vee; James Irving; Muhammad Ahsan Bashir; Zuzanna Wierzba

Publication Date: 2024

$40.00

Intumescent coatings for hydrocarbon fires have been on the market since 1970-2019;s and have gained significant attention in recent years due to their ability to efficiently provide passive fire protection for steel structures. With oil and gas exploration moving towards arctic areas, there is a demand for intumescent coatings which can resist large temperature fluctuations during the service life without cracking. Prior acceptance within the industry of hairline cracking in such coatings is no longer acceptable. Consequently, there is a need for intumescent coatings which can withstand the severity of the service conditions without cracking while providing excellent protection in the event of fire. In the coatings industry, T-bar test is frequently used to analyze the toughness of coatings but due to its empirical nature it cannot provide information about the role of chemical structure of the coating in passing/failing the test. Therefore, by employing dynamic mechanical analysis (DMA), universal testing machine (UTM) and T-bar testing, it has been shown in this work that there is a correlation between the cracking resistance of intumescent coatings measured via T-bar test and the DMA results.

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Bayesian Modeling Coating Performance

Product Number: 51322-17612-SG

Author: James A. Ellor, Daniel Pope, Anthony Florimbio, C.Thomas Savell, Lisa A. Barker, John Repp

Publication Date: 2022

$20.00

Coating degradation on Army ground systems represents a significant maintenance cost and effort. The objective of this proposed work is to develop a predictive model for coating degradation and subsequent substrate corrosion on Army ground assets. Provided with a better understanding of the root causes, steps can be taken to reduce corrosion impacts on Army materiel.

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Benchmarking International Cathodic Protection and Alternating Current Mitigation Standards to Determine Suitable Protection Criteria

Product Number: MECC23-20206-SG

Author: Craig Botha

Publication Date: 2023

$20.00

The past 20 years in the field of Cathodic Protection (CP) have ushered in the distinct shift from the assessment of conventional Direct Current (DC) corrosion mechanisms to the more complex world of electrochemistry influenced by Alternating Current corrosion mechanisms. In fact, traditional assessment of CP protection levels without taking cognizance of the AC interference on a structure can have catastrophic consequences for pipeline operators. The most common misnomer over the past 20 years has been the idea that a pipeline under suitable levels of CP cannot corrode in a High Voltage Powerline Right of Way.

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Benefits of continuous corrosion monitoring for offshore wind structures

Product Number: 51323-19288-SG

Author: Birit Buhr, Lars Peter Løvendahl Raun, Ruth E. Sørensen, Yaser Rezania, Annika Martina Diederichs

Publication Date: 2023

$20.00

Back in 1991 the first offshore wind asset was constructed in Denmark near the coastline from Vindeby (which means windy city). This asset comprised 11 foundations with a capacity of 0.36 MW each. Since then; the offshore wind industry has been booming, and projects are becoming bigger and bigger in size (capacity), number of foundations per site and further and further offshore.

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Benefits of using zinc-rich primers in offshore environments

Product Number: 51323-18932-SG

Author: Alex Yagüe Marrón

Publication Date: 2023

$20.00

The nature and rate of corrosion of a metal depend upon –among other factors- the corrosivity of the environment to which it is exposed. The corrosivity category is a technical characteristic that provides a basis for the selection of materials and protective measures in different environments subject to the demands of the specific application, particularly concerning service life. Data on the corrosivity of the atmosphere is essential for the development and specification of optimized corrosion protection for manufactured products.

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Bio Fuel Feedstock and Finish products – Linings Case Study

Product Number: 51323-18898-SG

Author: Ravi Nagarajan, Steve Liebhart, Pedro Escudero, Shahab Soltaninia

Publication Date: 2023

$20.00

There is a sizable push for making more sustainable, renewable, and environmentally friendly fuels. One such example is the recent emphasis on manufacturing biofuels in the form of biodiesel or bio-oil. While ethanol is also considered a biofuel and likely the most widely used it will not be a focus of this discussion.

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Biocide Compatibility with Oxygen Scavenger: A Case Study from Oil Field

Product Number: 51323-19112-SG

Author: Abdul Wahab Al-Ahmad, Adel Jubar Al-Mutairi, Fatma Jassim Behbehani, Ali Mohammed Akrouf, Ashok Mathew

Publication Date: 2023

$20.00

Kuwait is among the ten top oil producing countries in the world. The state run Kuwait Oil Company produces crude oil through more than 5000 wells spread across the company’s South-East, North and West Kuwait asset areas. The crude oil produced along with saline water and gases (carbon dioxide, hydrogen sulfide & hydrocarbon gas) is received at manifold headers at Gathering Centers (GC).

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Biocide Resistance in Microbes – An Oilfield Example

Product Number: 51323-19122-SG

Author: Nazima Habibi, Saif Uddin, Abdul Hameed Al-Hashem, Anisha Shajan, Nasreem Abdul Razzack, Farhana Zakir

Publication Date: 2023

$20.00

Biocorrosion causes huge economic losses to the oil and gas industry.

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Biocide Selection Score Card: A Numerical Approach to Product Selection

Product Number: MECC23-19919-SG

Author: Juan F. Hernández; Ridha H. Abbas; Saud A. Abudaly; Subhash Nair; Sreenivas KM

Publication Date: 2023

$20.00

Secondary oil production involves the injection of water into the reservoir, generally known as water flooding, to increase the reservoir pressure to its initial levels, to maximize the oil recovery out of the ground. The injected water flows through the formation to flush the oil from the formation into the production system. Injection systems are the portion of the field that is responsible for injecting the water into the formation. Source of water may be lake, river or sea water.

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Biocide Storage Tank Internal Corrosion And A Mitigation Strategy – A Case Study

Product Number: 51322-17906-SG

Author: Ayman A. Alabdullatif, Rakan A. Al-Shebil, Wakeel Ahmad

Publication Date: 2022

$20.00

Variability of operation and practices can lead to mechanical integrity issues of equipment. A similar case was observed when an external UT survey was conducted on a biocide storage tank that showed localized areas of metal loss in the tank wall. The tank was opened for inspection and extensive internal corrosion damage was observed mainly in the form of large isolated pits. Three potential corrosion mitigation options were evaluated: upgrading the tank material from coated carbon steel to 316 stainless steel, installing a non-metallic lining, or keeping using the coated carbon steel and changing the operation practices. Each mitigation option was evaluated based integrity, feasibility, and economic factors. It was found that keeping the coated carbon steel and adjusting the operation practices can ensure the integrity of the tank while lowering the required economical investment. As such, a new operation manual was issued for the biocide storage tanks that ensured that the corrosion inducing environments are avoided.

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Association for Materials Protection and Performance