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Corrosion Under Insulation (CUI) is the corrosion of piping or equipment under insulation that occurs when moisture ingresses the interface between insulation and piping or equipment, helping to form corrosion cells. CUI is one of the costliest problems shared by the oil and gas industries. One reason this problem has been a perennial challenge is that CUI is difficult to detect because it occurs under the insulation. And since it occurs regardless of the type of fluid in the pipe, every part of the plant would be included in the monitoring scope.
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There are hundreds of commercially available alloys in the market, which is utilized by various industries, including chemicals producers. However, depending upon the corrosiveness of the process conditions, choices of materials of construction can be limited. One of a highly corrosive condition is acidic chloride chemistry (like, hydrochloric acid) in which only a handful of alloys (like, Ni-Cr-Mo alloys) can provide a reasonable service life, which though depends upon the amount of chloride, operating temperature, and impurities level.
The hydrogen economy envisions the use of gaseous hydrogen (herein referred to as hydrogen) as an energy carrier for the reduction of carbon emissions. Transportation of hydrogen from the upstream source (generation location) to the end-user will be necessary to maximize the carbon reduction potential switching from natural gas to pure hydrogen or hydrogen blended natural gas products. A proposed, economically viable option is to utilize the existing and extensive natural gas pipeline infrastructure in the United States.
In the oil and gas industry, sand production can lead to blockage of pipelines, corrosion and erosion, which may cause the failure of the fluid transport system, pipeline leakage, and consequently environmental contamination. In the process of fluid transportation, the pipe walls are always impacted by particles entrained in flowing fluid. As a result, the corresponding erosive wear may be detrimental to pipe wall structural integrity. Although sand screens and gravel packs are frequently used to minimize sand production, technical and economic challenges or limitations with these practices are still present in the industry1.
Stress Corrosion Cracking (SCC) is a serious threat to our pipeline infrastructure. Past SCC failures have shown that both NN pH SCC and high pH SCC may lead to catastrophic pipeline failure. This is due to the formation of cracks that are difficult to detect. Moreover, SCC is difficult to predict, as multiple mechanisms must interact to lead to the formation of these cracks.
It is well understood that unless a surface is properly prepared prior to the application of a coating or surface treatment, adhesion and the expected lifetime of the material is quite minimal. Preparation generally falls under one of two options: either utilization of particle or grit-blasting, or the use of waterjetting. Typically, waterjetting of surfaces in preparation for application of coatings or surface treatments is only conducted on metal substrates that contain a previous profile from either operational wear (corrosion pitting) or previously abrasive blasted surfaces.
As facilities in the oil and gas industry age with time, corrosion mitigation and control become more important. Failure of processing equipment is likely to entail production loss, loss of containment, environmental impact, and/or human risk. Internal corrosion failures represent one of the major risks to process equipment and piping.
Atmospheric corrosion monitoring has traditionally been a lengthy and costly discipline. Visual inspection and weight loss testing is commonly applied, and this requires years of testing and on-site inspections with regular intervals. Furthermore, inspections and surveys in marine environments are troublesome, expensive and sometimes dangerous.
Corrosion costs the US Department of Defense billions of dollars annually, with the impact of corrosion estimated at $20.6B in fiscal year 2016. It continues to be one of the leading causes of aircraft unavailability and accounts for a significant portion of maintenance labor and costs. Corrosion management practices are chosen to minimize maintenance costs while maximizing the availability of an asset.
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.
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.
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.