An overview of methods for simulating and evaluating pipeline corrosion

Steel pipelines, buried under the soil and protected by the combination of protective coatings and cathodic protection (CP), are used for oil and gas transportation. These pipelines are one of the critical infrastructures for energy transportation and therefore became lifelines of modern society. The deterioration of the external surfaces of transmission pipelines is a serious problem and is caused mainly by coating and/or CP failure leading to the loss of integrity of pipelines. To avoid such damage, there is a need of techniques which are able to locate active corrosion sites, monitor corrosion, and evaluate corrosion damage. Fundamental understanding of such processes occurring on coated pipelines (with various types of defects in coatings as well as pipe) in complex soil environment is necessary for the development of such techniques. Numerous laboratory techniques, i.e., electrochemical impedance spectroscopy based, polarisation measurements based, mathematical simulations, direct observation etc. have been used to develop fundamental understanding, simulate and evaluate corrosion occurring in oil and gas pipelines under various operating conditions. Given the complex nature of the pipeline corrosion, application of these laboratory techniques in field measurements as well as in understanding the corrosion mechanisms is lacking. This paper presents an overview of investigations, based on electrochemical techniques, for simulation and evaluation of pipeline corrosion in laboratory.

Aspectos metalúrgicos de revestimentos em dutos depositados com a superliga de níquel ERNiCrMo-4 pelos processos MIG convencional e MIG com adição de arame frio

Este trabalho estuda o perfil metalúrgico de revestimentos em dutos depositados pelos processos MIG C e MIG AF. A indústria petroquímica, e outras que utilizam dutos como meio de transporte de seus insumos, depara-se com um grande desafio: como aumentar a vida útil desses dutos em um ambiente severo de trabalho. No caso específico da petroquímica, os dutos servem como meio de transporte para petróleo e gás, que são produtos extremamente agressivos às paredes internas desses tubos que sofrem degradação por corrosão causada, principalmente, pela composição química, pressão e temperatura desses produtos. Nesse contexto a soldagem de revestimentos realizada com ligas à base de Níquel, torna-se uma excelente opção para a construção, reparo e manutenção de equipamentos cuja aplicação seja voltada a ambientes severos de trabalho, tornando possível aperfeiçoar as características requeridas, como por exemplo, a resistência à corrosão. É nesse cenário que surge o mote para a realização desta pesquisa, baseada em trabalhos que indicam que o processo de soldagem MIG/MAG com o da adição de arame frio possui a finalidade de avaliar as características metalúrgicas do revestimento em dutos depositados pelo processo derivativo MIG convencional – MIG-C e MIG com adição de arame frio – MIG AF – utilizando a liga de Níquel ERNiCrMo-4 em dutos de aço carbono. As soldas foram depositadas em dutos de diâmetro de 228,6 mm, formando uma camada de revestimento interno de quatro passes, divididos em três segmentos da circunferência do duto, em três diferentes energias de soldagem: 1,1; 0,9 e 0,7 kJ/mm. Desses segmentos retiraram-se corpos de prova dos dutos para a produção das amostras. Após a metalografia, realizada nas amostras, seguiu-se com a análise e caracterização ao microscópio óptico, microscópio eletrônico de varredura e ensaio de microdureza. Os revestimentos apresentaram excelente qualidade superficial para todos os pacotes operacionais aplicados na obtenção das soldas. As análises das regiões estudadas: metal de base; zona parcialmente misturada e zona termicamente afetada, mostraram-se compatíveis com os da literatura estudada, tanto para o MIG com adição de arame frio, quanto para o convencional. Na ZTA, foram observados valores de Tungstênio em torno de 1,0%, o aumento dos níveis de dureza foi creditado a esse fato. Os resultados de microdureza indicaram que para ambos os casos, MIG C e MIG AF, nas 4 regiões analisadas ocorreram de maneira semelhante, sendo a região da ZTA a que apresentou maiores valores na faixa de 400 a 500 HV, enquanto que nas demais regiões a faixa ficou entre 250 a 350 HV. Os resultados indicam que o processo com arame frio, MIG AF, mostrou-se tão eficiente quanto o convencional, MIG C. A energia de soldagem aumentou a diluição de Fe no metal de solda. Precipitados ricos em Mo e Cr foram encontrados no metal de solda.

Procedimento de avaliação de integridade estrutural de juntas soldadas circunferenciais em tubulações submarinas rígidas submetidas à flexão.

A demanda crescente por energia tem motivado a procura por petróleo e gás natural em ambientes com condições extremas, como operações em águas profundas e o transporte de fluídos corrosivos. Avanços tecnológicos recentes favorecem o uso de tubos de aço contendo uma camada interna resistente a corrosão (comumente chamados de Lined ou Clad Pipes) para o transporte de tais fluidos agressivos. Além disso, as tubulações submarinas são sujeitas a condições de instalação muito severas e, um caso de interesse, é o procedimento de reeling que permite com que a fabricação e inspeção da tubulação seja feita em terra. Apesar de possuir vantagens econômicas, a avaliação da integridade estrutural e especificação dos tamanhos toleráveis de trinca em juntas soldadas, nestas condições, torna-se uma tarefa complexa, devido a natureza dissimilar dos materiais e ao grande nível de deformação plástica no processo. Dessa maneira, este trabalho tem por objetivo o desenvolvimento de um procedimento de avaliação de forças motrizes elasto-plásticas em tubos contendo juntas soldadas circunferenciais sujeitos a flexão, para uma extensa gama de configurações geométricas. Dois métodos distintos foram desenvolvidos e analisados: a metodologia EPRI e o procedimento que utiliza a curva de tensão vs. deformação equivalente. As análises numéricas 3D fornecem os parâmetros de fratura necessários para a resolução do problema e a acurácia dos procedimentos é verificada a partir de estudos de casos e análises paramétricas.

Investigating effects of potential excursions and pH variations on cathodic protection using new electrochemical testing cells

Excursion from safe cathodic protection (CP) potentials occurs on buried steel pipelines due to various forms of electrical interferences such as stray currents. Variations in pH can also occur over some pipeline sections such as seashore and river crossing pipes. Currently, the exact effects of potential excursion and the pH on CP efficiency have not been sufficiently quantified preliminary due to difficulties in measuring these effects. In this work, these effects have been investigated using electrochemical cells designed to mimic the high resistivity and pH conditions observable over underground steel pipes, including a new electrochemical cell that has been designed to facilitate the effective simulation and control of pH, potential excursion and other CP testing parameters. The pH has been shown to be a key factor affecting the patterns of corrosion and CP efficiency. Localised corrosion has been found to be the dominating form of corrosion under potential excursions conditions.

Electrochemical methods for monitoring localized corrosion under cathodic protection

This research proposes two new electrochemical methods for measuring corrosion rates and their distribution under cathodic protection (CP). These methods were incorporated into a corrosion monitoring sensor that grow a great interest in the Australian energy pipeline industry.

Experimental and numerical studies on protection of buried pipelines and underground utilities using geocells

This paper presents the results of the laboratory model tests and the numerical studies conducted on small diameter PVC pipes, buried in geocell reinforced sand beds. The aim of the study was to evaluate the suitability of the geocell reinforcement in protecting the underground utilities and buried pipelines. In addition to geocells, the efficacy of only geogrid and geocell with additional basal geogrid cases were also studied. A PVC (Poly Vinyl Chloride) pipe with external diameter 75 mm and thickness 1.4 mm was used in the experiments. The vehicle tire contact pressure was simulated by applying the pressure on the top of the bed with the help of a steel plate. Results suggest that the use of geocells with additional basal geogrid considerably reduces the deformation of the pipe as compared to other types of reinforcements. Further, the depth of placement of pipe was also varied between 1B to 2B (B is the width of loading plate) below the plate in the presence of geocell with additional basal geogrid. More than 50% reduction in the pressure and more than 40% reduction in the strain values were observed in the presence of reinforcements at different depths as compared to the unreinforced beds. Conversely, the performance of the subgrade soil was also found to be marginally influenced by the position of the pipe, even in the presence of the relatively stiff reinforcement system. Further, experimental results were validated with 3-dimensional numerical studies using FLAC(3D) (Fast Lagrangian Analysis of Continua in 3D). A good agreement in the measured pipe stain values were observed between the experimental and numerical studies. Numerical studies revealed that the geocells distribute the stresses in the lateral direction and thus reduce the pressure on the pipe. In addition, the results of the 1-g model tests were scaled up to the prototype case of the shallow buried pipeline below the pavement using the appropriate scaling laws. (C) 2015 Elsevier Ltd. All rights reserved.

Effect of particle concentration on erosion rate of mild steel bends in a pneumatic conveyor

Particle concentration is known as a main factor that affects erosion rate of pipe bends in pneumatic conveyors. With consideration of different bend radii, the effect of particle concentration on weight loss of mild steel bends has been investigated in an industrial scale test rig. Experimental results show that there was a significant reduction of the specific erosion rate for high particle concentrations. This reduction was considered to be as a result of the shielding effect during the particle impacts. An empirical model is given. Also a theoretical study of scaling on the shielding effect, and comparisons with some existing models, are presented. It is found that the reduction in specific erosion rate (relative to particle concentration) has a stronger relationship in conveying pipelines than has been found in the erosion tester. © 2004 Elsevier B.V. All rights reserved.

Effect of particle concentration on erosion rate of mild steel bends in a pneumatic conveyor

Particle concentration is known as a main factor that affects erosion rate of pipe bends in pneumatic conveyors. With consideration of different bend radii, the effect of particle concentration on weight loss of mild steel bends has been investigated in an industrial scale test rig. Experimental results show that there was a significant reduction of the specific erosion rate for high particle concentrations. This reduction was considered to be as a result of the shielding effect during the particle impacts. An empirical model is given. Also a theoretical study of scaling on the shielding effect, and comparisons with some existing models, are presented. It is found that the reduction in specific erosion rate (relative to particle concentration) has a stronger relationship in conveying pipelines than has been found in the erosion tester.

Investigations on Ultrasonic Transducer Array Systems for NDE of Underwater Pipelines

The main objective of carrying out this investigation is to develop suitable transducer array systems so that underwater pipeline inspection could be carried out in a much better way, a focused beam and electronic steering can reduce inspection time as well. Better results are obtained by optimizing the array parameters. The spacing between the elements is assumed to be half the wavelength so that the interelement interaction is minimum. For NDT applications these arrays are operated at MHz range. The wavelengths become very small in these frequency ranges. Then the size of the array elements becomes very small, requiring hybrid construction techniques for their fabrication. Transducer elements have been fabricated using PVDF as the active, mild steel as the backing and conducting silver preparation as the bonding materials. The transducer is operated in the (3,3) mode. The construction of a high frequency array is comparatively complicated. The interelement spacing between the transducer elements becomes considerably small when high frequencies are considered. It becomes very difficult to construct the transducer manually. The electrode connections to the elements can produce significant loading effect. The array has to be fabricated using hybrid construction techniques. The active materials has to be deposited on a proper substrate and etching techniques are required to fabricate the array. The annular ring, annular cylindrical or other similar structural forms of arrays may also find applications in the near future in treatments were curved contours of the human body are affected.

Quantifying the effects of major factors affecting the effectiveness of cathodic protection of pipelines

electrical interference signals on CP and steel corrosion using newly designed electrochemical corrosion cells; as well as to monitoring cathodic disbondment of coatings using electrochemical impedance spectroscopy. Typical results from using these new techniques for measuring stray current corrosion and for probing the cathodic disbondment of pipeline coatings have been briefly discussed.