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Corrosion Under Insulation (CUI) is a well-known industrial problem that has been plaguing asset owners for decades. CUI presents one of the costliest corrosion factors for Oil and Gas, petrochemical and general processing industries and can result in unplanned shutdowns, maintenance, repairs or even explosions while in service. Due to the risk factors present, many methods to prevent CUI have been adopted, trying to find best practices to minimize the risk of potentially catastrophic events caused by CUI.
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The hydrocarbon exploration in the ocean and deep sea was started as early as early as the 1850s, when the first drilling was carried out in California, USA. Other early oil explorations activities were later recorded in Pakistan (1886), Peru (1869), India (1890) and Dutch East Indies (1893). The development of an offshore industry is directly related to the development of subsea pipelines as well. As the industry expands towards deeper waters, the pipelines are required to have better materials, designs, operation practices and maintenance strategies to withstand the challenging environments. These pipelines are exposed to elevated temperatures, high pressures, and corrosive fluids.
Fiber reinforced polymer (FRP) and other polymeric materials are used in many ways to reduce and manage corrosion damage for industrial, infrastructure and municipal applications. It is common practice to use the term “resin” for polymers in these materials. This paper uses polymer interchangeably with resin. This paper will also only consider glass fiber reinforcements.
In most engineering and scientific applications, machine learning (ML) or artificial intelligence (AI) methods in general, are primarily oriented to design a statistical/heuristic procedure to predict the outcome of a system under new conditions. This mechanism aims at exploring non-evident correlations between inputs and outputs that are embedded in the data. However, a large body of this effort relies on black-box function approximations (e.g., neural networks) that have shown limitations to elucidate additional insights from the underlying physical process that generated the data. Thus, this type of knowledge is generated in a data-driven manner without fully explaining the physics governing the problem.
Boilers are one of the most fundamental systems in refineries or processing plants. It is very critical to assess and control the conditions of boilers to avoid the operation failure. Scale and corrosions are major problems in the boiler. Boiler chemical treatment has been considered to be a cost-effective approach to prevent deposition formation and minimize corrosion in boilers to control feeding chemicals, tracers are used for monitoring chemical dosage levels. The usage of fluorescent tracers for dosage control and system diagnostics is a recognized approach for decreasing operator workload and improving system performance.
Under current energy-market conditions, the nuclear industry must innovate and move towards a more economically viable approach for many operations and maintenance (O&M) activities. One O&M change can include minimizing labor involved and frequency of O&M activities, including shifting some manual tests to automated online testing. Changing test practices must not only consider costs but also risks and efficacy of new test approaches compared to current practice.
Historically, regulators, industry and other research organizations have performed research on materials harvested from a broad range of components, including the reactor pressure vessel (RPV), internals, and piping. Harvesting has included both service-aged materials as well as components from unfinished reactors. This harvesting and associated research has provided valuable insights into materials performance, such as flaw populations, materials properties, aging effects and non-destructive evaluation effectiveness.
Current fatigue assessments for the fatigue life of a plant component are usually based on methodologies that use uniaxial fatigue test data (i.e. ASME Section III, and are intended to be conservative for design and fitness-for-purpose assessments when applied to plant components and loading. This data is generated through cyclic loading of specimens at a constant amplitude, and failure is usually defined as when there is a load drop of 25% from steady state stress under strain-controlled conditions (or specimen separation for stress control). The corresponding number of cycles is then used as the definition of fatigue life for a particular strain amplitude. It is known that there are differences between fatigue behaviour in an idealised laboratory setting and in-service components which can contribute to excessive conservatism in plant assessments.
Aircraft representative galvanic test articles and witness coupons were placed out for atmospheric exposure testing at the U.S. Naval Research Lab (NRL) site in Key West, Florida. One set of test specimens was exposed to only ambient environment for a 62 day period; a second set of test specimens was exposed to both ambient environment (initial 62 days), and a short duration, twice daily, seawater spray protocol over a further 55 day period. Environmental loading was monitored using sensors that measured temperature, relative humidity, rainfall, and time of wetness (TOW), at 30 minute intervals. Following retrieval, the test articles were inspected in the laboratory using laser profilometry to characterize the spatial distribution and depth of corrosion damage. Mass loss measurement using the witness coupons was used to estimate relative corrosion rates for the two periods.
The coatings industry has made widespread use of a variety of accelerated test methods to quickly and effectively evaluate coating performance. Such accelerated methods are advantageous for predicting coating system performance where real-time testing is impractical. For example, it is not practical to evaluate coatings in harsh environments where coatings are expected to last for decades when the pace of innovation and new coating development is faster than the test time would need to be. Therefore a variety of test methods exist to evaluate coatings on metal substrates, such as steel or aluminum. Coatings that will be subjected to corrosive environments require testing in environments to simulate the effects of corrosion, typically involving exposure to moderate salt concentration and elevated temperatures for a specified amount of time. Such tests, testing environments, and evaluation methods include ASTM B117,ISO 9227, and ISO 12944, to name a few.
Scale is an adherent deposit of inorganic compounds precipitated from water onto surfaces. Most oilfield waters contain certain amounts of dissolved calcium, barium or strontium salts. The mineral scale can be formed by chemical reactions in the formation water itself, by mixing of formation water with injected seawater, or by mixing of the well streams of two incompatible oilfield waters. In carbonate reservoirs, when calcium is deposited as calcium sulfate or calcium carbonate scale, a loss of production and increased maintenance expenses can result. Therefore, effective mitigation of scaling potential is of importance to the oil producers.
SCC of Ni-base filler metal (FM) 82 has been reported in the nozzles and other components in Light Water Reactors (LWRs). The typical characteristics of stress corrosion cracking (SCC) of Ni-base alloys are a long incubation time followed by slow propagation, which can suddenly transition to fast propagation. Whilst there has been considerable effort expended to develop an SCC mechanism that can explain and predict SCC in Alloy 600, fewer studies have investigated SCC of FM 82. The Preferential Intergranular Oxidation (PIO) SCC mechanism of Alloy 600 proposed by Bertali et al. which is an evolution of the Selective Internal Oxidation SCC mechanism proposed by Scott and Le Calvar is considered one of the most representative primary water SCC mechanisms for Alloy 600.