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A holiday is defined as a pinhole or discontinuity in a coating lining. These discontinuities are frequently very small and not readily visible and create a pathway for oxygen and an electrolyte to cause deterioration of the underlying substrate. These defects will tend to reduce the life expectancy of a coating in service, particularly if the service is to include immersion, such as the lining of a tank or a pipe.
In corrosive environments it is considered essential to produce a continuous protective coating for long term performance. Non continuous films provide opportunities for premature failure of the coating through isolated corrosion and undercutting. To reduce the risk of premature failure for thick film systems, high voltage holiday testing is completed using specialized equipment. High voltage holiday testing is the practice of using high voltage equipment to detect discontinuities in a coating system.
The rule of thumb throughout the US industry has typically been a minimum of 100 volts per mil of coating (1/1000 inch) as the basis of voltage settings. It is believed 100 volts/mil allows for the detection of holidays while not posing a risk of damaging the coating system. Consequences of incorrect voltage settings can range from undetected holidays to damaged coatings. The purpose of this paper will be to discuss the concept behind high voltage holiday testing, the theoretical required voltage to bridge the air gap and experimental findings of the required voltages for holiday detection on a range of thick film coatings.
In certain protective coating applications, it is vital to test the finished system for flaws and pinholes, as these defects can lead to premature coating failure in service. This is particularly important when the coating is used in an immersion or partial immersion situation such as for tank or pipe linings.
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For decades, many asset owner/operators across the O&G value chain (and other critical industry segments) of upstream, midstream, & downstream have struggled to identify the root cause of fluctuating corrosion/erosion rates due to unreliable or infrequent data during various operating intervals on their most valuable of assets. This key missing data point has forced mechanical integrity teams, corrosion engineers, inspectors, and operations to, in many cases, make the best guess or hypothesize how to operate with a limited data set of information. In almost all cases, a time-based inspection or maintenance interval is used to gauge the useful lifetime of assets based on this limited data simply because these assets couldn’t give their owners a real-time health diagnostic of how they were doing … until now.
Oil and gas wells represent a large capital investment. It is imperative that corrosion of well casings be controlled to prevent loss of oil and gas, environmental damage, and personnel hazards, and in order to ensure economical depletion of oil and gas reserve. Wells placed in external corrosive environment shall be protected by appropriate barriers such as additional cemented casing, cathodic protection and coating to assure well casing integrity.