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CUI (Corrosion under insulation) is among the key damage mechanisms in the process and hydrocarbon industries which results in the localized corrosion (mainly) thereby reducing the service life of the assets (pipes, equipment, etc.) CUI is reportedly known as the reason behind 40-60% of failures in the facility piping whereas small bore piping (i.e., NPS< 4”) are even more sensitive to CUI failures, where up to 81% of reported failures in small-sized piping are known to be from CUI. Monetary spending to inspect and fix CUI-related failures cost 10% of overall maintenance budget in a typical medium-sized oil refinery. CUI risk is influenced by numerous operational and environmental factors which impedes its management in a typical AIM (Asset integrity management) program.
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Molten chloride salts are one of the leading candidates for heat transfer fluids and thermal energy storage for generation IV Molten Salt Reactors (MSRs). These chloride salts demonstrate many favorable properties such as low melting temperatures, high boiling points, high heat capacity, and low vapor pressure at higher temperatures. Ternary chlorides such as NaCl-KCl-MgCl2 used in this study are particularly attractive due to their lower melting points and high decomposition temperatures.
The chemical and radioactive waste at the Hanford Site is currently stored in 131 single-shell tanks and 27 double-shell tanks (DSTs). The DSTs were built between 1968 and 1986, and each has a capacity of about 1 million gallons. Figure 1 is one typical design of the DSTs. Double shell means that each tank consists of a primary tank within a secondary tank. The primary and secondary tanks are also known as liners, and both are made from carbon steel.
With growing concern for global warming resulting from fossil fuel usage, the use of nuclear energy has provided a cleaner alternative to power generation. Radioactive fuel such as Uranium Oxide has gained significant usage today. Almost 20% of the electricity generated in the US comes from nuclear energy.
Additive manufacturing (AM) is a term that is used to describe a family of processes that adds material in a controlled way to produce a structure or product. It has been used for many years for polymeric materials and its origin can be traced to Japan in the early 1980’s. The industrial use of AM polymeric products, then commonly introduced as stereolithography, got its start from an invention using a computer-controlled laser beam to harden a liquid polymer by Charles Hull in 1983.
Organic Rankin Cycle (ORC) geothermal power plants are commonly used in low-to-medium temperature fields with temperatures below 200 °C . The utilization of geothermal fluids to generate geothermal power or heating for district systems can be difficult due to dissolved species and gasses in the fluid. The problems often encountered are due to scaling and corrosion which are dependent on the pH, salinity, and composition of the geothermal fluid (e.g., CO2 and H2S) .
The number of CCS projects (planned and in operation) is increasing, and project developers need to provide firm evidence that the proposed material is suitable for these applications.The petroleum industry has long experience with materials selection for wells, but the conditions for CO2 injection wells are somewhat different from “conventional” oil and gas wells. This is due to the high CO2 content and pressure (up to several hundred bar) which results in low pH condensed water (exact value depends on pressure and temperature, but approximately pH 3.0).
CUI (Corrosion under insulation) is among the key damage mechanisms affecting the integrity of equipment, piping, and pipelines in the hydrocarbon industry. CUI manifests (mostly) localized corrosion. CUI is a highly frequent degradation in the oil refining facilities where reportedly 40-60% of failures in the piping result from CUI.
Hydrogen embrittlement is a process that results in a decrease of the ductility of metals as a result of absorbed hydrogen. Advanced high-strength steels used in the automotive industry are materials that are considered prone to hydrogen embrittlement. Hydrogen can enter the material during steelmaking or processing steps, such as pickling, cleaning, phosphating, and electroplating.
Historically the focus has been on the adverse anions (chlorides, sulfates nitrates) with little attentionAggregated FeS and ionically bonded FeCl2 is a pervasive, difficult, and high-liability issue for pipeline,petrochemical, power, shipping, and other industries. Situational variations (meteorological, geographical,seasonal, etc.) can confound conventionally specified surface preparation attempts to achieve perfect ornear-perfect metal cleanliness, thus reducing expected coating life by 30 to 75 percent. Becauseconventional surface preparation processes have historically been unable to adequately relievemicrocontamination of metal surfaces, organizations have settled for an uneasy balance between economicand physical feasibilities that exclude the possibility of achieving ideal surface preparation outcomes andrely more heavily upon barrier coatings to supply needed corrosion control.
Long-term exposure of superheater tubes to normal operating conditions results in gradual changes inthe alloy's microstructure and properties eventually leading to creep cracking and failure. The methodused most frequently to predict the remaining life of these tubes is based on curves showing the variationof the Larson-Miller parameter (LMP) with stress needed for creep rupture. This method works well forGrades such as T11 and T22 alloy steels since the tube metal temperature can be reasonably wellestimated based on the ID scale thickness.
Pulsed Eddy Currents (PEC) is an electromagnetic inspection method for detecting thickness variations in carbon steel and cast iron through various insulation and/or protective components. It is also resilient to liftoff variations, making it a valuable technique for Corrosion Under Insulation (CUI) assessment. The technology is widely used in the energy and petrochemical industries to detect and estimate the extent of corrosion in insulated or fire-proofed components like pipes and tanks without removing the covering.