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Carbon dioxide (CO2) saturated brines containing high levels of calcium are commonly encountered across the energy sector: from hydrocarbon recovery to the harvesting of geothermal energy and re-deposition of CO2 for permanent storage. These brines originate in deep underground reservoirs at elevated pressures and temperatures. Despite susceptibility to corrosive attack under these conditions, carbon steels are the preferred choice of pipeline materials for such processes, attributable to their low cost, availability and ease of manufacture.
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TSA is mainly used to protect offshore steel structures, including atmospheric, splash and immersed zones. During installation or in service, the coating is likely to be damaged due to erosion, wear, scratch etc. TSA coatings protect by acting as a barrier and offering cathodic protection even if the substrate is exposed to seawater.
Chloride-induced corrosion of steel reinforcement in concrete structures usually experiences two stages: pitting corrosion initiation and propagation.1-2 Initiation of pitting corrosion occurs as the chloride content on the surface of a steel bar exceeds a critical value (or chloride threshold) and breaks down the passive film locally.3-4 Depending on environmental factors at the steel-concrete interface, such as temperature, moisture, and availability of oxygen, pitting corrosion initiation is not stable in the very beginning and some corrosion pits may continue to develop and become stable, while others cease.
Microbiologically influenced corrosion (MIC) is one of the most aggressive forms of corrosion leading to infrastructure and equipment damage in various industries, including but not limited to the oil and gas industry,1 water systems,2 medical devices,3 marine environments,4 nuclear waste storage facilities,5 and aviation fuel systems6 and storage.7 MIC received great attention because of the increasing cost associated with corrosion damage, particularly in oil and gas industry. The overall cost of corrosion has been estimated to be approximately 3.4% in the global Gross National Product8 which equates to approximately $2.9 trillion in 2018.9 A conservative estimate shows that 20% of all corrosion in aqueous system is MIC,10 which accounts to billions of dollars in the US.
In this paper, several cases will be showcased to highlight the contributing causes and underlying mechanisms of corrosion damage of components that resulted in significant releases of hazardous substances onto operator’s property, rights-of-way, and the environment. The objectives of this paper are to understand the causes of the failures and their consequences, to identify the risk factors involved, to discuss mitigative measures after failure, and to observe trends that may indicate the need for additional preventative and mitigative actions. The over-riding goal is to provide details in areas for potential improvement in pipeline operations to reduce risk and improve integrity management.
When two long-time operators of natural gas storage wells in southwestern Ontario merged, it was an opportune time for the combined company to evaluate the effectiveness and impact of cathodic protection (CP). Staff from both legacy operators expressed general satisfaction with the longevity of their storage wells, typically 30+ years, but they had relied on two different approaches to corrosion control: one had isolated wells from flowlines and operated without CP, while the second had resistively bonded wells to cathodically protected flowlines. For the second operator, typical well currents were in the range of ~3 A.
Alloy 625 (UNS N06625) is an austenitic solid solution strengthened nickel-chromium-molybdenum alloy containing niobium. The high alloy content of alloy 625 enables it to withstand a wide variety of severe corrosive environments. In mild environments, such as ambient atmosphere, fresh and seawater, neutral salts and alkaline media, there is almost no attack.
Alloy 182 is an austenitic (FCC) nickel base Ni-Cr-Fe-Mn weld metal that is used as a weld filler or weld pad metal to join stainless steel reactor internals, reactor instrumentation penetrations and main coolant piping to the low-alloy steel reactor pressure vessel. Stress corrosion cracking (SCC) in alloy 182 dissimilar welds is one of the most important material degradation problems and an ongoing issue in boiling (BWR) and pressurized water reactors (PWR) world-wide with potential safety concerns.Thermally activated preferential local ordering (unlike atom pairs is greater than that in a random solution) of elements within a lattice, over spatial dimensions that are typically on the order of a few nearest neighbor spacing 20 to 50 Å (2 to 5 nm) is referred as short range ordering (SRO). SRO causes lattice contraction and induces additional stress which is claimed as the driving force for SCC in the alloy 600, alloy 690, and alloy 182.
Stress relaxation cracking (SRC) is a failure mechanism known to occur in austenitic stainless steels and nickel alloys operating at moderate to high temperatures.
Typically, SRC failures tend to occur under the following conditions: 1-6 1. Susceptible material: 800H, 347H, 617, etc. (typically materials with low creep ductility) 2. High residual stresses: Hardness > 200 HV (welded thick section) 3. Specific temperature range: usually between 500 °C (932 °F) and 750 °C (1382 °F).
Under these conditions, component stresses are relieved by time dependent inelastic deformation.3 In susceptible materials, this process occurs by intergranular cracking and is essentially a creep mechanism.2-6 In this respect, materials with low creep ductility tend to be prone to this type of damage mechanism. On the other hand, materials that have good creep ductility can tolerate the inelastic strains due to relaxation without cracking.3
Opportunity crudes are generally defined as petroleum crudes bearing a high level of sulfur, metals, or total acid number (TAN). These crudes are typically offered at a discounted value. Thus, refining such crudes carries with it a lucrative incentive. However, due to the above-mentioned characteristics, processing such crudes presents numerous operational challenges as well, such as naphthenic acid corrosion, which is commonly associated with the high TAN content in these crudes. In refinery units such as the crude distillation tower, these carboxylic acids react with the iron atoms of the metal surfaces to produce oil soluble iron carboxylates.1,2 The continued formation of such complexes would then erode the metal surface. Equipment failure due to such corrosion results in shutting down a large segment or the entire refinery. Therefore, establishing a means for mitigating this type of corrosion is paramount for processing crude oils with an elevated TAN due to naphthenic acids.
Top of the line corrosion (TLC) is a phenomenon encountered in the transportation of wet gas, where temperature differences between the pipelines and the surroundings lead to condensation of water and subsequent metal degradation. This kind of corrosion occurs due to the condensation of saturated vapors present in the unprocessed gas stream which collects on the internal surface of the cold pipe wall. The condensed liquid contains hydrocarbons and water. It forms a thin film and/or droplets of liquid on the pipeline. The condensed water phase can be, at least initially, very corrosive to typical pipeline (made of carbon steel), because it contains dissolved acid gases (such as carbon dioxide [CO2] and hydrogen sulfide [H2S]) and organic acids (such as acetic acid [CH₃COOH]).1