NACEUAE - NACE International

Transcription

NACE UAE
CORROSION CONFERENCE
May 12-13, 2015 § Abu Dhabi, UAE
FINAL PROGRAM
OFFICIAL MEDIA PARTNERS
CORROSION
ThankUAEyou
to OurCONFERENCE
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UAE Corrosion Conference Final Program
C O R P O R AT I O N
Environmentally Safe VpCI ®/MCI ® Technologies
May 12-13, 2015
Abu Dhabi, UAE
Welcome to the NACE UAE Corrosion Conference
The new NACE UAE Corrosion Conference was created to identify corrosion
issues and challenges industries in the Middle East are faced with every day.
We appreciate you joining leading corrosion professionals from around the
world to address the solutions and join together to discuss preventative
actions and resources.
Conference Committee
CHAIR
TRACK
COMPANY
Fatima S. Al Mazrouei
Corrosion in Oil and Gas
Nuclear
Water/Waste Water
ADCO
Dr. Ali Noor Moosavi
Material Selection
ADCO
Elvis Sequeira
Coatings
Berger Paints
Patrick Hivert
Cathodic Protection
Pipeline Services, LLC
Usama Jacir
Corrosion Control Chemicals
Cortec Middle East
Graham Young
Inspections
Anticorrosion Protective Systems
Manea Saeed Al Jaberi
Corrosion Management
ZADCO
3
UAE CORROSION CONFERENCE
Exhibitors
EXHIBITOR
4
BOOTH #
Abdulla Fouad-Impalloy Ltd. Co.
108
Aegion
110
Berger Paints Emirates Ltd. Co LLC
113
BSS TECHNOLOGIES / SAFETRACK / DEKOTEC
118
Denso
105
Graco
101
Hempel Paints Emirates LLC
120
Maxtube Middle East Ltd.
100
Metal Samples
107
MPG Mendener Prazisionsrohr GmbH
114
Nia Shimi Trading & Producing Co.
117
Permasense Ltd
106
Polycorp Limited
104
PST Global Fzco
112
SAE, Inc.
116
STOPAQ B.V.
119
Sulzer Mixpac Ltd.
115
Trenton Corporation
109
Velosi Asset Integrity
111
20
ion
orros
Antic ctive
te
Pro
ms
Syste
d
Mid
1
t20
Eas
Prefun
May 12-13, 2015
Abu Dhabi, UAE
NACE BOOTH
Exhibit Hall Map
101
Maxtube
Middle
East
Ltd.
Graco
BVBA
114
100
MPG
Mendener
Prazisionsrohr
GmbH
Hempel120 116
Paints
Emirates
LLC
SAE,
Inc.
Polycorp
Ltd.
115
Sulzer
Chemtech
106
Permasense
Ltd
119 112
Abdulla
Fouad-Impalloy
Ltd.
Co.
PST
STOPAQ
GLOBAL
B.V.
FZCO
Denso
107
109
Trenton
Corporation
111
Velosi
Asset
Integrity
113
110
Aegion
Corporation
105
Metal
Samples
104
108
Al M
118
BSS
SAF TECHNO
ETR
ACK LOGIES
/ DE
KOT /
EC
Berger
Paints
Emirates
Ltd.
CO
LLC
117
Nia
Shimi
Trading
&
Producing
Co.
5
Networking Event
Desert Safari
Tuesday, May 12
Shuttles departing hotel at 17:15
$50 USD per person (tickets can be purchased at the registration desk)
This event gives you to the opportunity to explore the beautiful deserts of Abu Dhabi while riding on the back
of a camel. During your journey you stop to eat and be entertained by local belly dancers. Sign up at registration
to participate in this unique and memorable experience.
Keynote Presentations
NACE MR01575 Certification and Advances in Sour Service Testing
Presented by Dr. Chris Fowler C.Eng FIMMM FNACE
Group Technical Director Corrosion and Protection, Exova Corrosion Centre; Past President NACE International;
President, NACE International Institute
This presentation will outline the work of the NACE International Institute and describe the newly approved
MR0175 Certification for individuals, and briefly cover the workshop status. Further advances in sour service
testing will be described and will include the progress of a new British Standard, and the description of the
“Longitudinal” Ring test.
Nuts and Bolts of How to Build a World Class Company and Have Fun in Life
Presented by Boris A. Miksic, FNACE
President, Cortec Corp.
Boris will share the challenges, setbacks and triumphs of his journey. He fled his home country to America with
nothing but change in his pockets where he built a successful corrosion control company.
MR0175 On-Day Seminar
Thursday, May 14
Presented by Dr. Chris Fowler C.Eng FIMMM FNACE
Group Technical Director Corrosion and Protection, Exova Corrosion Centre; Past President NACE International;
President, NACE International Institute
NACE Member - $800 USD
Nonmember - $900 USD
The NACE MR0175/ISO 15156 standard is NACE International’s most referenced standard for cracking prevention
through the use of material selection. This standard helps address corrosion of metal components from sulfide
stress cracking, stress corrosion cracking, and other mechanisms of cracking caused by H2S. Complying with this
standard will help your company avoid costly equipment failures and minimize the health and safety risk to the
public, personnel, and the environment. Companies can also benefit from the increased business opportunities
that can come with proving that they are in compliance with this standard.
6
May 12-13, 2015
Abu Dhabi, UAE
Schedule at a Glance
MONDAY, MAY 11
Exhibition Set Up—Al Mudhaif 3
Registration—Pre-function Area
16:00 – 19:00
TUESDAY, MAY 12
7:30 – 8:00
Registration and Welcome Refreshments—Pre-function Area
8:00 – 8:15
Safety Talk—Al Mudhaif 2
8.15 – 8:30
Introductions by NACE International and NACE UAE—Al Mudhaif 2
8:30 – 8: 45
Opening Ceremonies—Al Mudhaif 2
8:45 – 9:30
9:30 – 10:00
10:00 – 10:25
Keynote Presentation: Nuts and Bolts of How to Build a World Class Company and Have Fun in Life
Presented by: Boris Miksic, President, Cortec
Boris will share the challenges, setbacks and triumphs of his journey. He fled his home country to America
with nothing but change in his pockets where he built a successful corrosion control company.
Inauguration of Exhibition by Chief Guest
and Morning Refreshment Break—Al Mudhaif 3
Coatings
Session Chairman: Elvis Sequeira, Berger Paints
Al Mudhaif 1
Session Chair: Usama Jacir, Cortec Middle East
Al Mudhaif 2
A Review on Self-healing Coatings Based on
Nano-containers for Active Corrosion Protection
Presented by: Efstratios Svinterikos, United Arab
Emirates University–Department of Chemical and
Petroleum Engineering
(United Arab Emirates)
Challenges of Developing Batch and
Continuous Corrosion Inhibitors to Mitigate
Localized and Under Deposits Corrosion
Presented by: Alyn Jenkins, M-I SWACO
(United Kingdom)
Developments in Dry Film Thickness Measurement
Presented by Craig Woolhouse, Elcometer
10:25 – 10:50
(USA)
10.50 – 11:15
11:15 – 11:30
11:30 – 11:55
Novel technology to Improve Adhesion of
Fusion Bonded Epoxy (FBE) Coatings
Presented by: Rezaul Haque, Dow Chemical
Corrosion Control Chemicals (Planning,
Consumption Monitoring & Effectiveness
Assessment)
Presented by: Amin El-Khatib, ADCO
Effectiveness of Vapor Phase Corrosion Inhibitors
Compared with Nitrogen Blanketing
Presented by: Philip Horsford, Cortec Middle East
Tea Break and Visit to Exhibitors—Al Mudhaif 3
Internal Corrosion Management of
Process Vessels
Presented by: Colin Bateman, Belzona Polymerics
(United Kingdom)
Internal Corrosion Prevention and
Electrochemical Studies on X60 Carbon Steel
Pipelines in CO2 Saturated Condition
Presented by: Bassam Sheriat
(Egypt)
7
11:55 – 12:20
12:20 – 12:45
Effect of Polymer Backbone on CD Resistance
of High Build Epoxy Coatings
Presented by: Rajendran Balaji, Asian Paints
(India)
Corrosion Inhibitor Micelle Detection: Case
Studies on Inhibitor Optimization
Presented by: Melanie Reid, LUX Assure Ltd.
(United Kingdom)
Busting the Myths of Wet Abrasive Blasting
Presented by: Peter Bloem, GRACO
(United Kingdom)
Corrosion Inhibition of Carbon Steel in Cooling
Water Containing Chloride and Sulfate Ions
Presented by: Amr Elsayed, Egyptian Projects
Operation and Maintenance
(Egypt)
Lunch—Al Mudhaif 1 & 2
Visit with Exhibitors—Al Mudhaif 3
12:45 – 13:35
Corrosion in the Oil & Gas Industry
Cathodic Protection
Session Chair: Fatima Al Mazrouei, ADCO
Al Mudhaif 1
Session Chairman: Patrick Hivert, Pipeline Services,
Al Mudhaif 2
13:35 – 14:00
Monitoring and Corrosion Control in Seawater
Injection System
Presented by: Abdul Hameed Al-Hashem, NACE
Kuwait Section
(Kuwait)
Set up of a Cathodic Protection Test Station in
Abu Dhabi
Presented by: Dyana Ambrose, Petroleum Institute
14:00 – 14:25
Investigating Pitting Behavior of X100 Steel
Presented by: Dr. Abdul Rauf, Abu Dhabi Men’s
College
(Belgium)
Cathodic Prevention of Steel Rebars in
Concrete: The International Outlook
Presented by: Simone Tremolada
(Italy)
Technical Evaluation of Failure of 16”# X52 Grade,
API 5L Steel Gas Pipeline, in Komsheche, Isfahan
14:25 – 14:50 Presented by: Meysam Rasooly & Ebrahim Mohseni
Homagerani, National Iranian Gas Company
(Iran)
14:50 – 15:15
Prevention of Corrosion on Interior Surface of
Metal Jacketing for Thermal Insulations
Presented by: Vishnu Dutta, ITW Insulation
(India)
ICCP Systems for the Reinforced Concrete
Structure in Union House of Etihad Museum
in Dubai
Presented by: Mohsen Mazraeh, CH2M Hill Co.
External Corrosion Direct Assessment (ECDA)
Presented by: Gerry Williams, Corrpro
15:15 – 16:55
Afternoon Refreshment Break, Visit with Exhibitors—Al Mudhaif 3
17:00-17.15
Shuttle Departs for Desert Safari
WEDNESDAY, MAY 13
8
7:30 – 8:00
Registration—Pre-function Area
8:00 – 8:15
Welcome Refreshments—Pre-function Area
8:15 – 8:30
Day 2 Opening Remarks by ADCO CEO—Al Mudhaif 2
May 12-13, 2015
Abu Dhabi, UAE
WEDNESDAY, MAY 13
Keynote Presentation: NACE MR0175 Certification and Advances in Sour Service Testing
Presented by Dr. Chris Fowler, President. NACE International Institute
Al Mudhaif 2
8:30 – 9:00
9:00 – 9:25
9:25 – 9:50
9:50 – 10:15
10:15 – 10:45
10:45 – 11:25
This keynote lecture will outline the work of the NACE International Institute and describe the newly approved
MR0175 Certification for individuals, and briefly cover the workshop status. Further advances in Sour Service
testing, will be described which will include the progress of a new British Standard, and the description of the
“Longitudinal” Ring test.
Al Mudhaif 1
Session Chair: Manea S. Al Jaberi, ZADCO
Al Mudhaif 2
Continuous Integrity Monitoring in the
Oil & Gas Industry
Presented by: Nadim Borini
(United Kingdom)
Corrosion of Below-grade RC Structures in the
Arabian Peninsula: Analysis, Evaluation
and Management
Presented by: Gul (Rose) Saridogan, Dennis Burns,
and Jorge Costa, Structural Technologies
6 Years Old Steam Reformer Outlet Headers are
Under 3rd Stage Creep
Presented by: Makram Almakrami, Sabic Arrazi
(Saudi Arabia)
Dewatering Pigging Frequency for Oil & Gas
Pipelines
Presented by: Siva Grandhe, ADCO
Increasing Pipeline Remaining Life by Assessing
for Potential Interactions between Corrosion
Metal Loss Features
Presented by: Derek McNaughtan, Intertek plc
Morning Refreshment Break, Visit with Exhibitors—Al Mudhaif 3
Coatings
Al Mudhaif1
Al Mudhaif 2
High Performance Polyurea Spray Coatings for
Pipeline Corrosion Protection
Presented by: Michael Magerstaedt, ROSEN Group
(Switzerland)
How Advances in DNA Technology Can Help Oil
Industry Minimize Risk and Cost Associated
with Microbial Influenced Corrosion
Presented by: Peter Sanders and Morten Poulsen,
Danish Technological Institute
(Denmark)
Rigid PU Coating for Pipeline Rehabilitation
Presented by: Syed Quadri, Bayer Material Science AG
11:25 – 11:50
(Saudi Arabia)
Two-Phase Modeling for Corrosion
Management in Stratified Oil-Water-Gas Flow
Presented by: Mutaz Daas, Saudi Aramco
(Saudi Arabia)
9
11:50--12:15
The Automated Field Joint Coating Process :
Providing Sustainable Coating Solutions
Through Consistency
Presented by: John Demore, Aegion Corporation
Lunch—Al Mudhaif 1 & 2
12:15 – 13:15
13:15 – 13:50
Selection Criteria for Corrosion Resistant
Elastomeric Linings
Presented by: Girish Gupta, Polycorp Ltd
Session Session Chairman: Dr. Ali Moosavi, ADCO
Al Mudhaif 2
13:50 – 14:15
Redefining Anticorrosion, Durability,
Performance, and Productivity
Presented by: Simon Daly, Hempel Paints
(United Kingdom)
The Selection of Stainless Steel for High
Temperature CO2 Environment
Presented by: Tosapolporn Pornpibunsompop, DTI
(Thailand)
Material Selection
Cathodic Protection Session
Session Chairman: Patrick Hivert, Pipeline Services,
LLC Al Mudhaif 1
14:15-14:40
Design Considerations for Complex Plant
Cathodic Protection System
Presented by: Pankaj Panchal, Abdulla
Fouad-Impalloy Ltd. Co.
(Saudi Arabia)
State of the art in Plate Making for HIC
Resistance & Beyond
Presented by: Patrick Toussaint, Industeel
(Belgium)
14:40—15:05
Innovative Corrosion Control Measures—
Internal Stray Current Corrosion
Presented by: Ali Elkordi, ADCO
Isolation Joint Material Selection:
Issues & Opportunities
Presented by: Paolo Dini, Nuova Giungas SRL (Italy)
15:05 -15:35
15:35 – 16:00
16:00 – 16:25
16:25 – 16:50
10
Afternoon Refreshment Break, Visit with Exhibitors—Al Mudhaif 3
Flexible Impressed Current Linear Anodes—
Cathodic Protection Applications
Presented by: Shailesh Javia, Matcor
(India)
Centrifugally Cast Solid CRA Duplex Grade
Pipes for Upstream Oil & Gas - An alternative to
Wrought Seamless Grades
Presented by: Shankar Venkataraman, Schmidt +
Clemens GmbH + CO. KG
(Germany)
An Investigation on the Effects of Coating
and Foundation on the External Corrosion
and Cathodic Protection Performance of
Aboveground Storage Tank’s Bottom
Presented by: Hamed Aldaghl, POGC
(Iran)
Developing Field Test Procedures for
Establishing a Chloride Stress Corrosion
Cracking Corrosion Alternative
Presented by: Hanan Farhat, University
of Saskatchewan
(Canada)
An Investigation on Parameters Influencing CO2
Corrosion of Low-Alloy Steel Pipelines
Presented by: Reza Labbaf, RGS Co.
(Iran)
May 12-13, 2015
Abu Dhabi, UAE
TECHNICAL SESSION DESCRIPTIONS
Tuesday, May 2
Keynote Presentation
Nuts and Bolts of How to Build a World Class Company and Have Fun in Life
Presented by: Boris Miksic, President, Cortec
Al Mudhaif 2
Boris will share the challenges, setbacks and triumphs of his journey. He fled his home country to America with nothing but
change in his pockets where he built a successful corrosion control company.
Coatings
Al Mudhaif 1
A Review on Self-healing Coatings Based on Nano-containers for Active Corrosion Protection
Presented by: Efstratios Svinterikos, United Arab Emirates University —Department of Chemical and Petroleum Engineering
Self-healing anti-corrosion coatings based on nanocontainers are a promising environmentally benign alternative for the
replacement of chromate conversion coatings. The idea behind these systems is the encapsulation of corrosion inhibitor in
nano-sized shells, which are incorporated in the protective coating matrix. Their self-healing properties are justified by the
controlled release of the active agent, which is autonomously triggered when the metal substrate is subject to corrosion. In
this review we provide a synopsis of the different kinds of nanocontainers, their fabrication methods and the different release
mechanisms of inhibitors upon corrosive attack. We focus on their anti-corrosion protection of various metal substrates and
highlight our suggestions for further research towards the direction of advantageous large-scale application.
Developments in Dry Film Thickness Measurement
Presented by Craig Woolhouse, Elcometer (USA)
This paper will begin with an overview of the key problems facing the coating inspection industry today, briefly review the
history of DFT measurement and then progress to explain current DFT methodology – including an short explanation of how
this technology actually works – and then focus on the new aspects of the recently launched high speed DFT scan facility and
how that product works and how it can benefit the user.
The paper would then conclude with a brief explanation of how the wider industry of coatings inspection is looking towards the
future and what we can expect. As part of the presentation I would also include a practical demo of the scan function on screen
for the participants to fully appreciate how easy and useful this technology can be to the industry.
Novel Technology to Improve Adhesion of Fusion Bonded Epoxy (FBE) Coatings
Presented by: Rezaul Haque, Dow Chemical (United Arab Emirates)
Excellent adhesion to steel substrates is one of most important performance attributes of FBE coatings and primers. However,
when FBE is exposed for long periods to hot and humid environments its adhesion can be compromised.
In addition, adhesion loss can be exacerbated by cathodic protection current as well as residual stress in three layer systems. This
work demonstrates the ability of a novel technology to enhance hot wet adhesion and cathodic disbondment of FBE coatings
without affecting other key properties such as glass transition temperature, flow, and gel time.
11
Internal Corrosion Management of Process Vessels
Presented by: Colin Bateman, Belzona Polymerics (United Kingdom)
Discover the latest developments in process vessel internal erosion and corrosion management solutions and application
techniques utilising organic lining technologies. The paper focuses on internal vessel lining solutions, flange face and small
bore nozzle protection as well as cold bonding of the vessel internals.
This novel yet proven technology ensures that each part that has a potential to corrode in high-temperature and high-pressure
conditions is effectively isolated from the environment. Materials discussed resist temperatures up to 180° C in immersed
conditions in combination with resistance to the destructive forces of explosive decompression from pressures in excess of 100
bar.
The paper discusses material acceptance and performance criteria critical to successful corrosion management and unique
application techniques that have been developed specifically for pressure vessels, designed to reduce the probability of
application failures and address issues commonly faced by the applicators and ultimately the asset owner.
Independent and comprehensive in-house testing, as well as case histories are used to support the development work. Case
studies reviewed within the paper include internal corrosion management of the process vessels for various international Oil
and Gas Majors.
Effect of Polymer Backbone on CD Resistance of High Build Epoxy Coatings
Presented by: Rajendran Balaji, Asian Paints (India)
Cathodic protection is a most efficient and widely used approach to protect buried pipelines or submerged metallic structures
against corrosion. Organic coatings applied on these metallic structures are expected to have good resistance to cathodic
delamination or disbonding (CD). Coating composition & environmental conditions both influence the CD resistance. Efforts
to generate an understanding or building simpler correlations on CD resistance of organic coatings would be very useful for
coating formulators. In this study, the effect of polymer type (epoxy & hardener) on cathodic delamination rate was studied in
a high-build epoxy coating. Relationship between residual (wet) pull-off adhesion strength and CD resistance was also studied.
Specific type of epoxy & hardener combination was found to perform better than the others used in this study.
Busting the Myths of Wet Abrasive Blasting
Presented by: Peter Bloem, GRACO (United Kingdom)
Most sandblasters experience usual inconvenient factors such as:
§§ Dust – requiring tenting and containment, requiring high PPE standards, high impact on environment
§§ High amount of blast media – causing a high clean-up and disposal cost, frequent refilling of blasting pot
§§ Many more
Eco-friendly, vapor abrasive blast equipment optimizes the current blasting process. The equipment works on the principle
that water is not compressible. All air is automatically vented from the pressure vessel and uses pressurized water as a “piston”
to force wet abrasive into the blast air stream. The precision at which the wet abrasive is forced into the blast stream elevated
the system from wet-abrasive blasting to vapor blasting. Vapor abrasive blast equipment suppresses 92% dust from open air
blasting minimizing tenting and containment. It eliminates up to 75% of blast media without slowing production times. Cleanup and disposal are drastically reduced saving both time and money as well as preserving the environment.
12
May 12-13, 2015
Abu Dhabi, UAE
Session Chair: Usama Jacir, Cortec Middle East
Al Mudhaif 2
Challenges of Developing Batch and Continuous Corrosion Inhibitors to Mitigate Localized and Under Deposits
Corrosion
Presented by: Alyn Jenkins, M-I SWACO (United Kingdom)
Corrosion in oil and gas production typically occurs due to the presence of either CO2 and/or H2S in the produced fluids. It
is common place to mitigate CO2 and H2S corrosion by applying either batch or continuous corrosion inhibitors. However,
the presence of H2S in produced fluids can cause several forms of corrosion including localized or pitting and under deposit
corrosion can also occur beneath FeS scale. Mitigating these forms of corrosion in oil and gas fields with inhibitors remains a
challenge.
When applying corrosion inhibitors in gas condensate fields, reducing the corrosion rate to acceptable levels is the primary
objective. However, corrosion inhibitors used in gas systems need to possess several other properties. It is important that the
application of the corrosion inhibitor does not affect the separation process as a result of either causing stable emulsions or
forming excessive foam. In addition, it is imperative that the inhibitors are stable under typical condensate stabilizer conditions
which can operate at very high temperatures (200°C).
This paper details the laboratory work performed to develop a continuous and a batch corrosion inhibitor for a sour offshore gas
condensate field located in the Middle East. The paper demonstrates how these inhibitors are effective in preventing general,
localized and also under deposit corrosion. In addition, these inhibitors are fully compatible with the system and are nonemulsifying, non-foaming and also stable under the high temperatures commonly found in condensate stabilizers.
Corrosion Control Chemicals (Planning, Consumption Monitoring & Effectiveness Assessment)
Presented by: Amin El-Khatib, ADCO (United Arab Emirates)
Assuring the effectiveness and availability of chemicals that are used for internal corrosion control requires a robust process.
This project discusses the proposed robust process that shall have smooth workflow with clear roles and responsibilities,
well-defined accountability & responsibilities, organized / auditable documentations and smart / analyzed database utilizing a
web-based tool; “Share Point”.
In any process safety system for oil and gas industry, internal corrosion control is an important barrier that would prevent loss
of containment. The effectiveness of this barrier shall be assured via several steps involving different stakeholders. Currently,
several areas for improvement exist such as responsibilities for planning the order of chemicals, scatter of chemicals QA/QC
documentation, fragmented records for monitoring of injection rate, comparison of actual vs. planned chemical consumption
and estimation of chemical injection availability.
This project provides a smooth process map with workflow to streamline the responsibilities among various stakeholders
involved in managing planning, monitoring of consumption and effectiveness assessment of Corrosion Control Chemicals. Clear
R&R and Well-defined responsibilities are provided for proper planning of chemical requirements in view of production demand,
secure planned chemical requirement and automatic order to avoid nil stock.
Organized/auditable Documentations is achieved via gathering all QA/QC e-documents of ordered chemicals by all stakeholders
in a web-based “Share Point”. This share point shall have “Write” access by particular discipline at relevant stage of the process
cycle, meanwhile read access is granted to all stakeholders / management for all documents. Smart/analyzed Database is
achieved via maintaining an organized electronic database for chemical injection rate monitoring in specialized system “Share
Point”, this shall enable estimation of chemical injection consumption and availability of corrosion protection level. Regular
reports comparing actual vs. planned chemical consumption provide management with feedback on production reason for
variance in chemical consumption and areas for improvement / optimization of chemical costs.
continued on next page
13
Upon assuring the QA/QC of corrosion control chemicals and estimating the continuity / availability of injection at recommended
rate, chemical injection effectiveness are assessed via comparing each chemical with its relevant KPIs such as corrosion coupons
and Lab. Analysis of process fluids. This project includes several innovative approaches towards HSE such as: developing chemical
requirement plan, enhanced business process, developing software application for data management, and systemizes data
analysis to assess availability & effectiveness
of the chemical treatment program. This project shall have positive impact on enhancing the integrity of equipment and piping
systems.
Effectiveness of Vapor Phase Corrosion Inhibitors Compared with Nitrogen Blanketing
Presented by: Philip Horsford, Cortec Middle East (United Arab Emirates)
The corrosion behavior of steel samples in various applications was investigated using two different protection mechanisms:
a Vapor phase Corrosion Inhibitor and a nitrogen blanketing system. The objective of this project was to demonstrate which
technique provides more protection in corrosive environments, especially where there are restricted geometries such as crevices,
threads, notches, and under-deposits.
The corrosion behavior of steel samples was studied under two different conditions. Two probes were placed in an environment
comprised of a 200-ppm chloride solution and 10% corrosion inhibitor. Two additional steel probes were placed in an environment
consisting of a 200-ppm chloride solution (without a corrosion inhibitor) and a nitrogen blanketing system at 10 psi (69 kPa)
applied pressure. The corrosion rate of the steel samples was monitored for ~4,000 h using linear polarization resistance (LPR) and
electrical resistance (ER) probe techniques.
The conclusions derived from the experiments demonstrated that VCIs provide effective corrosion protection for steel materials
used in storage tanks, pipe casings, and similar applications. A nitrogen blanketing system can reduce the moisture level, but it
won’t prevent corrosion and the steel will aggressively corrode.
Internal Corrosion Prevention and Electrochemical Studies on X60 Carbon Steel Pipelines in CO2 Saturated
Condition
Presented by: Bassam Sheriat (Egypt)
The aim of this research is to study the performance of typical gas and oilfield corrosion Inhibitors based on linoloeic acid (nontoxic
to the environment) in controlling internal corrosion of X-60 carbon steel pipelines under high pressure of CO2. Potentiodynamic
polarization and electrochemical impedance spectroscopy of (EIS) techniques were used to evaluate the efficiency of the prepared
compounds as corrosion inhibitors at various doses (25, 50, 75, 100, 125 and 150 ppm). The results obtained from polarization
measurements indicated that the selected inhibitors retard both cathodic and anodic reactions and act as mixed type inhibitors.
EIS data revealed that, by increasing the inhibitor consecration both the inhibitor efficiency (IE %) and charge transfer resistance
(Rt) are increased while, the electrochemical double layer capacitance (Cdl) decreased.
The high inhibition efficiencies were attributed to the simple blocking effect by adsorption of inhibitor molecules on the steel
surface. The surface active properties of the synthesized surfactants wear determined from surface tension measurements at 25°C.
The protective ﬁlm formed on the carbon steel surface is studied by scanning electron microscope (SEM), and energy dispersive
analysis of X-ray (EDX). The quantum chemistry calculations were carried out to study the molecular geometry and electronic
structure of obtained derivatives. The energy gap between the highest occupied molecular orbital and lowest unoccupied
molecular orbital has been calculated using the theoretical computations to reflect the chemical reactivity and kinetic stability
of compounds.
Corrosion Inhibitor Micelle Detection: Case Studies on Inhibitor Optimization
Presented by: Melanie Reid, LUX Assure Ltd. (United Kingdom)
The corrosion engineer has many tools available to help guide the implementation and management of a corrosion management
system. Probes, coupons, inspections and chemical monitoring all play an important role. Corrosion inhibitor management is
important for effective control of internal corrosion and better monitoring of these inhibitors can provide economic benefits. A
14
May 12-13, 2015
Abu Dhabi, UAE
tool to monitor and optimize corrosion inhibitor dosage, based on determining the presence of corrosion inhibitor micelles,
has been used in the Middle East and here we present case studies of the approach from the region and beyond.
Corrosion Inhibition of Carbon Steel in Cooling Water Containing Chloride and Sulfate Ions
Presented by: Amr Elsayed, Egyptian Projects Operation and Maintenance (Egypt)
This work studies the corrosion inhibition of carbon steel in chloride and sulfate solutions. These ions usually exist in industrial
cooling water and can cause severe corrosion. The inhibition effect of many corrosion inhibitors falls because of the presence
of these ions in the cooling water. In this study, the inhibition effect of molybdate-nitrite corrosion inhibitor was improved by
increasing the stability of the protective layer formed over the steel surface. It also designs a corrosion inhibitor mixture for
carbon steel in various environments containing up to 1000, 2000 ppm (wt) of NaCl and (NH4)2SO4 respectively at pH 5 and
matches with the environmental limits. The effect of the corrosion inhibitor components and the effect of environmental
parameters on corrosion inhibition were studied. As usually used in industry, the coupons weight loss technique was used.
The corrosion inhibitor was tested at various velocities, concentrations and temperatures. A corrosion inhibition of 99.33% was
delivered. The experiments
Use the factorial experimental design to find the interactions among a three components corrosion inhibitor. The best
combination that reduces corrosion and meets the environmental limitations was used as a starting point for the
one-factor-at-a-time approach to study the effect of each component individually on the carbon steel corrosion and find the
local minimum in corrosion rate. Various combinations of the corrosion inhibitor components are introduced according to the
required cost, environmental limitations and corrosion inhibition required.
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Monitoring and Corrosion Control in Seawater Injection System
Presented by: Abdul Hameed Al-Hashem, NACE Kuwait Section (Kuwait)
The Raudhatain and Sabriyah fields are two mature oil fields located in North Kuwait. Pressure maintenance using sea water in
KOC’s (Kuwait Oil Company) northern fields started in the year 2000. The sea water injection utilizes two main facilities project,
the Seawater Treatment Plant (SWTP) located at Subiya, and a Central Injection Plant Facilities (CIPF) located at Sabriyah; a 36
inch diameter carbon steel transfer pipeline which runs a distance of 48 km to connect the two plants, and network of injection
pipelines to transmit and distribute injection water to the injection wells. KISR has been responsible since the initial stage of
injection for the comprehensive monitoring of the water quality of the seawater injection system. Results indicate that the
corrosion rates observed in the Sabriyah field at the CIPF, and Raudhtain and Sabriyah headers are significantly influenced by
the quality of water at deaerator in SWTP at Subiya.
At the beginning of 2010, relatively high levels of dissolved oxygen were observed, due to poor performance of deaerator,
which resulted in high corrosion rate at SWTP. The corrosivity of seawater as it leaves the deaerator and the transfer pump is
much higher than it is at the pig launcher at the start of the transfer line. The corrosion rate by coupon method, installed at
the sidestream rig throughout the injection facility shows increase from monthly average 6 mpy to 9.27 mpy in the period of
March 2010 to December 2010.
And by the time, the seawater got up to the CIPF, the average coupon corrosion rate is about 1.5 mpy and 8.4 mpy with a
corresponding LPR corrosion rate of 0.29 mpy and 1.84 mpy. The significant increase in corrosion rate can be attributed to the
poor performance of deaerator and overdosing of oxygen scavenger which causes sulphide to decompose into acidic gases
15
Investigating Pitting Behavior of X100 Steel
Presented by: Dr. Abdul Rauf, Abu Dhabi Men’s College (Belgium)
An investigation of X100 steel has been performed to study its electrochemical behavior in chloride and bicarbonate containing
electrolyte. For this purpose, polarization and electrochemical frequency modulation methods were employed. The pitting
potential of X100 steel was observed around -0.14 V (SCE) in electrolyte containing equal volume of 0.1 M NaCl and 0.3 M
NaHCO3 by scanning forward polarization curve at a scan rate of 0.1 mV/s. The morphologies of pits and passive layer have been
investigated by using both optical and scanning electron microscopies.
After polarization scan, not only pits but cracks were also observed. Cracks were observed at the pit wall and near the pit mouth.
Somewhat larger cracks were observed at the pit wall/mouth as compared to the nearby passive layer on X100 steel. Cracking of
pit wall was confirmed by using electrochemical frequency modulation employing pitting potential. Cracks were also observed
inside the pits after applying pitting potential with the help of electrochemical frequency modulation. These pits and cracks
suggest that X100 steel is highly susceptible to localized corrosion when provided chloride containing corrosive environment.
Technical Evaluation of Failure of 16”# X52 Grade, API 5L Steel Gas Pipeline, in Komsheche, Isfahan
Presented by: Meysam Rasooly & Ebrahim Mohseni Homagerani, National Iranian Gas Company (Iran)
It has been shown that localized internal corrosion, such as pitting, plays a major role in the failure of buried gas pipelines
around the world. In addition to the economical aspects, i.e. direct and indirect costs due to corrosion of buried gas pipelines,
social consequences such as explosion, pollution and so on can even be more important. The aim of this paper is to investigate
the failure of 16”# X52 grade, API 5L steel gas pipe Line, in Komsheche, Isfahan, Iran. For this purpose the microstructure of
damaged and new pipe materials (having the same composition and manufacturing process) were studied using optical and
scanning electron microscopies. Also, elemental analyses of material at damage points were determined and compared with
the standard and mean chemical composition of the pipe material. In order to determine the corrosion susceptibility of pipe
material, electrochemical tests including Potentiodynamic, Polarization, and Electrochemical Impedance Spectroscopy (EIS)
were also performed. In addition the pipe condition and situation in the soil were considered. Results obtained revealed that
presence of dispersed inclusions such as MnS and/or oxide particles in the material had the main role in the failure of the above
mentioned pipe line.
Prevention of Corrosion on Interior Surface of Metal Jacketing for Thermal Insulations
Presented by: Vishnu Dutta, ITW Insulation (India)
Corrosion of metal pipe, vessel, or equipment under insulation (CUI) as well as corrosion of the outer surface of metal jacketing
have been widely studied and reported on. Often overlooked, however, is the potential for corrosion on the interior surface
of metal insulation jacketing and pipe corrosion related to this. Both crevice/pitting and galvanic corrosion can occur on this
interior jacket surface. This type of corrosion is insidious and can be quite damaging to the insulation system and even to
the underlying pipe or vessel. Interior jacket corrosion can rapidly advance to the point where it causes holes to form in the
jacketing. Once this has occurred, water can readily enter the insulation system resulting in a severe loss of insulating ability and
even corrosion to the pipe or vessel. Repairing an insulation system which has this type of corrosion usually requires replacing
much or all of the insulation system at great expense. It is much better to use metal jacketing with a proper integral moisture
barrier to prevent this type of corrosion during the original installation than to try to repair it later.
This paper will present corrosion science, lab data, and field results describing these types of metal jacket corrosion; discuss
some of the factors that can lead to this corrosion; offer suggested means of using moisture barriers on the inside surface of the
metal jacketing to minimize the likelihood this corrosion will occur; present the properties of various possible moisture barriers;
and finally draw conclusions and make recommendations on the use of these moisture barrier technologies.
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Abu Dhabi, UAE
Cathodic Protection
Session Chairman: Patrick Hivert, Pipeline Services, LLC
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Set up of a Cathodic Protection Test Station in Abu Dhabi
Presented by Dyana Ambrose, Petroleum Institute (United Arab Emirates)
Shareholders of GASCO support R&D activities in the Petroleum Institute (PI) through the Gas Research Center (GRC) project.
Another objective of GRC is to support to the education program of PI. As part of the GRC project, a Cathodic Protection test station
is designed and built at PLS premises in Mussaffah, Abu Dhabi. Even though the test station will be mainly used for education
of PI students, it will be also used for training of OPCO’s engineers, contractors’ engineers and for certification purposes. Some
studies related to cathodic protection systems will also be done (some studies related to CP inferences are already planned).
Main features of the test stations are sacrificial anodes cathodic protection and impressed current systems, two types of soils
(sand and sabkha), coated pipes with different sizes of coating defects, road crossing, buried and aboveground storage tanks
and pipeline crossings. Different types of tests stations were installed for natural and polarized potential measurements (using
permanent reference electrodes) and current measurements. A remote control system was installed in the classroom, suitable
for 20 students, to operate the unit. The design calculations of the test station has been accomplished by PI masters students,
and the installation and commissioning were done by PLS.
Cathodic Prevention of Steel Rebars in Concrete: The International Outlook
Presented by: Simone Tremolada (Italy)
The fundamental application of cathodic prevention of steel reinforcement in concrete was ideated and developed by Professor
Pietro Pedeferri. It was successfully applied since 1989 in Italy on Viaduct St. Nicholas I of the highway Rome - Aquila – Teramo
and in 1996 in the western underbroadwalk of the Sydney Opera House. Over the past 20 years it has spread throughout the
world and particularly in Northern Europe, Middle East and Australia being recognized as the most reliable technique to combat
corrosion for new buildings and infrastructure where reinforced concrete is exposed to possible contamination from chlorides.
This memory is a review of some of the most significant industrial cases reported in the international literature. Durrat Al Bahrain
and the NAKILAT shipyard in Qatar are two recent projects developed in the Middle East. Cathodic Prevention of West Swanson
Dock in Melbourne was the largest project completed in Australia in the last decade. Other significant experiences in China and
North Africa are a sign of the vitality of this technique in the developing countries. Keywords: cathodic prevention, concrete,
corrosion, chlorides, MMO titanium anodes
ICCP Systems for the Reinforced Concrete Structure in Union House of Etihad Museum in Dubai
Presented by: Mohsen Mazraeh, CH2M Hill Co. (United Arab Emirates)
This technical paper covers the minimum design requirements for the impressed current cathodic protection (ICCP) systems for
the reinforced concrete structure in Union House (UH) of Etihad Museum in Dubai.
The site survey carried by CH2M Hill has identified extremely aggressive soil conditions and atmospheric environment at the UH
location. Further to condition assessment and recommendations report produced by CH2M Hill in September 2013, ICCP system
was proposed to mitigate future degradation of the reinforcing steel bars due to corrosion.
CH2M Hill was appointed by the Roads & Transport Authority (RTA) for the design and construction supervision of the Etihad
Museum. Part of the design requirement is the integration of the existing UH with the new museum. The existing UH will be
protected by ICCP system.
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External Corrosion Direct Assessment (ECDA)
Presented by: Gerry Williams, Corrpro (United Arab Emirates)
External corrosion is one of many threats to pipeline integrity listed in ASME B31.8S. Historically in-line inspection tools and
pressure testing techniques have been employed for assessment of pipeline integrity. However, many existing pipelines cannot
be inspected with in-line tools because the pipelines were not designed to accept the in-line inspection equipment and cannot
be taken out of service for pressure testing.
As a result of regulations implemented in the United States, an alternative process was developed from traditional methods
for accessing the integrity of existing pipelines. The process is called External Corrosion Direct Assessment (ECDA) and involves
evaluating the extent of external corrosion, the effectiveness of protective coating systems and the level of cathodic protection
on buried pipelines. The ECDA process consists of the following four (4) phases:
§§ Pre-Assessment
§§ Indirect Inspections
§§ Direct Examinations
§§ Post Assessment
The ECDA process is based upon the principles of continuous improvement. A combination of test methods and inspections are
initially used to assess the pipeline condition. Subsequent testing and direct inspections increase the accuracy of the assessment.
This paper outlines the ECDA process which has been used in the US for over a decade and is being implemented by Middle
East operating companies.
Wednesday, May 13
Keynote Presentation
NACE MR0175 Certification and Advances in Sour Service Testing
Presented by Dr. Chris Fowler, President, NACE International Institute
Al Mudhaif 2
This keynote lecture will outline the work of the NACE International Institute and describe the newly approved MR0175
Certification for individuals, and briefly cover the workshop status. Further advances in Sour Service testing, will be described
which will include the progress of a new British Standard, and the description of the “Longitudinal” Ring test.
Al Mudhaif 1
Continuous Integrity Monitoring in the Oil & Gas Industry
Presented by: Nadim Borini (United Kingdom)
This paper will show how employing continuous integrity monitoring systems have better prepared oil and gas operators
in their decision-making. Corrosion is everywhere in the oil and gas industry and the extent and rate of corrosion is essential
information for safe, reliable and profitable operation of facilities.
Previously, manual inspections would reveal the extent of corrosion and erosion damage at the time of inspection. With only
manual inspections, operators are forced to guess the extent of corrosion damage between inspections without knowing
details. Since the drivers for corrosion change more regularly, it is not possible to have an up-to-date picture of how the facility
is coping with the demands placed upon it.
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Abu Dhabi, UAE
A non-intrusive, continuous integrity monitoring system that wirelessly delivers consistent and accurate wall thickness
information gives a competitive edge to companies because of the insights available to make better decisions. Extensive real
time information as well as a compilation of past and present corrosion rates affords detection and measurement of corrosion
activity all while the facility is in operation.
Ultrasonic wall thickness sensors taking measurements on-the-run deliver an accurate and up-to-date picture of pipework
integrity affording optimisation of process, corrosion mitigation techniques, shut down planning or crude selection & maximising
both plant availability and ultimately facility profit.
6 Years Old Steam Reformer Outlet Headers are Under 3rd Stage Creep
Presented by: Makram Almakrami, Sabic Arrazi (Saudi Arabia)
ARRAZI is a SABIC affiliate that produces methanol via 5 plants. Plant-1 was commissioned in late of 1980s and since commissioning
to 2012, the Steam Methanol Reformer (SMR) had been revamped twice in 1997 & 2007. In 2012 turnaround, SMR’s outlet
headers UNS N 08811 (10 headers: 48 catalyst tubes per header) had been inspected and found visually with 3rd stage creep and
scattered cracks i.e., only after 6 years of service. The immediate repair was a challenge due to huge findings versus limited time
and spare of headers but wisely it was accomplished by conducting failure analysis and fitness for service.
This paper describes the results of failure analysis and fitness for service and emphasizes on the effect of operational parameters
on the design life of outlet headers. Due to exceeding the design temperature limit, the headers consumed its 100% creep life
in 2.8 years instead of 14 years (calculated using design data). Also, the paper discuss all root causes of the failure such as filler
selection used to fabricate the header and its effect on the header integrity and the paper suggest new matching filler to be
used with statistical information. The Paper list all repair recommendations and what can be done to improve the system and
avoid such failure
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Corrosion of Below-grade RC Structures in the Arabian Peninsula: Analysis, Evaluation and Management
Presented by: Gul (Rose) Saridogan, Dennis Burns, and Jorge Costa, Structural Technologies (United Arab Emirates)
The coastal areas surrounding the Arabian Peninsula, bounded by the Red Sea to the west and the Arabian Gulf to the east, are
among the most saline and corrosive environments in the world. The ground conditions are harsh, heavily contaminated with
chlorides and often sulphates (the soil is known locally as sebkha soil). In recent times, water tables have risen dramatically and in
many of the coastal cities, are frequently close to the surface, resulting in heavily contaminated groundwater. These conditions
present many challenges for the construction of below grade structures, and particularly for the protection of steel reinforced
concrete.
In this region, the incidence of water leakage into foundations and deep basements is common. Water penetration usually
occurs when waterproofing systems fail, allowing the ingress of contaminants in solution, often under hydrostatic pressure.
The water delivers chloride and sulphate ions and deposits them within the body of the concrete. Chloride ions, in particular,
are detrimental to steel reinforcement and cause a well-documented electrochemical corrosion process which, in high
temperature and humidity conditions, results in rapid deterioration and loss of section. If left unchecked, structural integrity will
be compromised.
This presentation examines the importance of performing corrosion-based Condition Assessment to diagnose, quantify damage
and prognosticate service life. It explores the type of tests and, crucially, the means of analysis and evaluation of data using ionic
transport modelling and numerical solutions to assess durability based on a mechanistic approach. The presentation reviews
various technologies available to manage corrosion below grade, such as electro-osmotic pulse and other electrochemical
techniques, ground injection and treatments for cracks.
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Dewatering Pigging Frequency for Oil & Gas Pipelines
Presented by: Siva Grandhe, ADCO (United Arab Emirates)
ADCO operates ~165 nos of piggable Oil & Gas pipelines extending over 2500KM. These pipelines transport produced Oil & Gas
fluids from RDS, RMS`s to CDS at each interior based Assets and later the treated Oil & Gas is transported to export, distribution
terminals within the UAE. The age of these pipelines is in the range 2 to 50 yrs.
The dewatering pigging activity is performed on critical piggable Oil & Gas pipelines at specified regular intervals towards
removing the stagnant corrosive water and debris from the bottom of the pipelines, thereby reducing the internal corrosion
threat and improving corrosion inhibitor efficiency. With the aging of reservoirs associated with implementation of enhanced
oil recovery techniques such as water injection, Gas injection etc., the BS&W levels & GOR levels are continuously increasing with
the produced crude oil. This has led to high fluid velocity in many operating oil transfer lines.
There is no industry standard and or code of practice available for deciding the de-watering pigging frequency for the pipelines.
In view of risks associated with pipeline pigging activities, production deferments associated with pipeline pigging activity
with the high flow rate pipelines and the requirement for enhancing the efficiency of internal corrosion mitigation systems,
an optimized structured semi-quantitative risk based approach is developed for identifying the optimal pigging frequency
for piggable Oil & Gas pipelines, based on pipeline throughput, integrity status & operating conditions. The paper covers the
methodology for setting the optimal pigging frequency for Oil pipelines based on calculated Froude number / mix velocity & a
set of Corrosion Risk Elements.
Increasing Pipeline Remaining Life by Assessing for Potential Interactions between Corrosion Metal Loss Features
Presented by Derek McNaughtan, Intertek plc (United Arab Emirates)
When conducting pipeline integrity assessments, it is common for operators to focus attention on the sheer number of in-line
inspection (ILI) reported corrosion-based metal loss features (MLFs), assuming that a significant number of detected MLFs results
in a “long” corrosion morphology. However, in accordance with industry fitness-for-service methodologies, MLFs are required
to be within a certain minimum distance from one another before they should be considered to act as a single, larger corrosion
feature. Detailed analysis of MLF interactions during an integrity assessment in heavily corroded pipelines often precludes the
need to assume long corrosion, as many of the MLFs may be sufficiently far apart to be considered as isolated areas of metal
loss. Therefore, a possible consequence of assuming long corrosion is that the maximum safe operating pressure of a pipeline
is underestimated, resulting in repairs/replacement and/or de-rating to be carried out unnecessarily.
This paper discusses the benefits of assessing for the interaction between MLFs reported by pipeline ILI during an integrity
assessment, with a particular focus on pipelines where many thousands of MLFs have been detected. Through a case study, it
will be demonstrated how accounting for potential interactions between ILI reported MLFs during an integrity assessment can
increase the remaining life of a pipeline, in comparison to an assessment assuming long corrosion.
Coatings
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High Performance Polyurea Spray Coatings for Pipeline Corrosion Protection
Presented by: Michael Magerstaedt, ROSEN Group (Switzerland)
External pipe coatings are usually applied for corrosion protection. Modern pipe laying techniques require additional protective
properties. For example, in thrust boring applications, erosion protection is such an additional requirement. Also, in-line
inspection of older pipelines performed over recent years using novel techniques able to detect external coating disbondment
were performed. These inspections showed that coatings applied over the last decades did not always reach the specified
design life expected.
Particularly in the Middle East, where often rather harsh environmental conditions apply to buried pipelines (e.g., soils with
high salt content and tidal or seasonal salt water immersion), many older pipelines exhibit premature corrosion due to external
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Abu Dhabi, UAE
coating failure. Looking at the needs for increased bonding strength, better corrosion protection, and additional properties like
abrasion protection in thrust boring, novel coatings are being developed around the world. High Performance Polyurea spray
coatings were developed and field tested. The data give evidence that a new class of materials was designed that currently can
be considered the best existing solution to fulfill the higher needs for external coatings encountered today.
Rigid PU Coating for Pipeline Rehabilitation
Presented by: Syed Quadri, Bayer Material Science AG (Saudi Arabia)
Solvent-free two-component Polyurethane systems have been approved over decades as suitable protective coating systems.
Based on various major and minor details obtained during the many meetings with the experts of an Arabian oil & gas company,
raw material property profile was tailor-made to suit the harsh dry desert and the arid high water table regions (Subkha) of the
Arabian peninsula.
This product class comprises specifically designed Polyols in combination with Polyisocyanates (PIC) and Pre-polymers (Prep).
Because of their special properties two component Polyurethanes are favored where high performance and durability have to be
accomplished under harsh conditions of pipeline constructions. Very fast reaction times were considered appropriate to combat
the various known problems to apply liquid coatings in the field and as well the fast processing required for OEM in factories.
Special building blocks for rigid 2-K-PUR external coatings with excellent properties are being shown and the properties of prepolymers are presented.
Pre-tests of the coating system - carried out in the laboratory - showed good results especially for impact, corrosion protection,
Shore hardness formation (time factor), adhesion (without primer) and Cathodic disbondment ability. The design of the tests
was engineered to correspond to the typical ambient conditions of the region.
The importance of substrate’s surface preparation prior to the application of the coating is a pre-requisite. Special attention
needs to be given to the profile of the surface after shot blasting. These features have direct influence on adhesion and cathodic
disbonding properties. The other factors that have been studied are the dry film thickness, sag resistance and time before
backfilling and last but not the least the easy maintenance of pipelines.
Tests conducted in various situations prove this coating to with-stand the harshest weather conditions in terms of temperatures,
chemical resistance and the hardness of the coating film to with stand the so-called ‘Soil stress’ of the desert soils and as well
perform very well in temperatures between sub-zero to + 80 deg. C. These coating formulations have been shared with
local coatings companies in the Arabian Peninsula and as well application tests conducted using locally available application
companies.
The Automated Field Joint Coating Process: Providing Sustainable Coating Solutions Through Consistency
Presented by: John Demore, Aegion Corp. (United Arab Emirates)
There are many corrosion resistant coatings in the market that require a multitude of application requirements. Specifically for
field joint coatings, it is crucial to apply coatings in a consistent manner in order to promote quality in a pipelines most crucial
point. The quality of a field joint coating is directly related to the lifetime and corrosion resistant abilities of the selected anticorrosion product. Additionally, quality is not an aspect that should be affected by time. The dependability of the application
equipment can assist in the obtainment of quick cycle times as well as a way to provide assistance in forecasting project
completion dates. Examples of this type of equipment are:
§§ Coating Robotics to apply Fusion Bonded Epoxy and Plural Component Liquid Epoxies to the internal diameter of pipelines.
§§ External coating rings for the application of Fusion Bonded Epoxy and Plural Component Liquid Epoxies
To further promote the automated applications and to ensure the coatings are applied with high quality is through the use of
automated field joint coating inspection equipment. This equipment has the ability to inspect and record the many facets of the
application process. To name a few; this equipment has the capabilities to test the blast profile/cleanliness, dry film thickness,
holiday detection, and take pictures to provide a visual comparator. All of this information will be compiled into a predetermined
job report and can be issued to the necessary individuals.
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In conclusion, the utilization of automated equipment to provide quality through consistency is a crucial aspect in simulating
plant applied coatings in a field joint coating application. With the addition of automated inspection equipment, we can ensure
that acceptable quality is obtained while striving to provide sustainable solutions for the industry.
Selection Criteria for Corrosion Resistant Elastomeric Linings
Presented by: Girish Gupta, Polycorp Ltd (United Arab Emirates)
Elastomeric materials, principally natural and synthetic rubber products, have been used extensively to protect tanks and
equipment from corrosive service conditions. With the wide range of polymers available, selection of the right lining is crucial for
optimum corrosion protection. This paper will outline some of the critical parameters in assessing the suitability of a polymeric
lining for specific applications citing examples and case studies
Redefining Anticorrosion, Durability, Performance, and Productivity
Presented by: Simon Daly, Hempel Paints (United Kingdom)
Zinc rich primer coatings, both organic and inorganic, are extensively used in highly corrosive environments and they are part
of high performance coating systems to protect steel against corrosion. During the 60’s and the 70’s, zinc rich epoxy primers
dominated the market. Later, zinc ethyl silicate primers took over this role, but nowadays it appears as if zinc epoxy primers have
made a comeback. Some of the advantages of zinc epoxies compared to zinc silicates are the less demanding curing conditions
(epoxies will cure at low humidity), they are easier to overcoat and they are less demanding to substrate preparation prior to
application.
Zinc epoxies are typically formulated with high loads of zinc dust. According to ISO 12944 a zinc rich coating contains more than
80% zinc by weight in the dry film. The protecting mechanism of zinc rich coatings is believed mainly to be based on cathodic
protection provided by the zinc dust in the paint. When a coating system containing a zinc rich primer is exposed to a corrosive
environment, rust creep and blistering are amongst the most important failure mechanisms to be considered.
Many accelerated exposures will not, within their exposure time, show the defects visually on intact coated surfaces. Therefore,
behaviour of the coatings involving artificially made damages, i.e., scores, are given significant considerations in the development
of efficient anti-corrosive primers. Many prequalification tests (e.g. ISO 12944, ISO 2034, NORSOK M501 Rev.6) are based amongst
others on rust creep and blistering as well as detachment from scores. In studies presented at NACE in 2007 it was shown that
only about one third of the zinc in zinc rich epoxies is utilised for galvanic protection of the steel. The increasing demands on the
performance of zinc rich primers (low rust creep) as well as the recent developments in the market prices of zinc dust suggest
opportunities for new developments in this area.
Session Chair: Manea S. Al Jaberi
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How Advances in DNA Technology Can Help Oil Industry Minimize Risk and Cost Associated with Microbially
Influenced Corrosion
Presented by: Peter Sanders and Morten Poulsen, Danish Technological Institute (Denmark)
Industry-wide, microbially influenced corrosion (MIC) is a well-known issue, responsible for significant cost related to unexpected
production shut-down, repair, replacement and chemical treatment. Until now, the occurrence of MIC has been very difficult to
predict due to its fast-acting nature and challenges of getting reliable data.
However, recent advances in DNA-based technologies have made it possible to identify and quantify microorganisms faster and
much more reliably than previously possible. This paper presents a novel concept for monitoring, diagnosing and managing
MIC based on this technology. The concept includes handling of physical system samples, analysis for key indicator organisms
and new approaches to interpretation and modelling of MIC threat based on microbial numbers. In total, this makes it possible
to integrate MIC in conventional corrosion management programs, target and tailor mitigative action based on solid data and
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May 12-13, 2015
Abu Dhabi, UAE
hence minimize overall risk and cost related to MIC.
The paper provides a field case on how the concept has been applied for monitoring and management of MIC in interfield
pipelines off-shore and also provides further examples of applications and value creation to the oilfield operator.
Two-Phase Modeling for Corrosion Management in Stratified Oil-Water-Gas Flow
Presented by: Mutaz Daas, Saudi Aramco(Saudi Arabia)
Stratified flow in oil-water-gas pipelines occurs at low flow rates during turn down, especially in oversized pipes. The extent of
water wetting of a pipe wall, due to the presence of a continuous film of free water at the bottom of a pipe, significantly impacts
the magnitude and severity of internal corrosion, therefore pipe integrity. Wall water wettability decreases when the turbulence
in the liquid phase is sufficiently high to disperse the water film in the oil phase. Therefore, corrosion decreases significantly, and
in some cases cease to exist, when water is entirely dispersed and entrained in the oil phase.
Several models were proposed in literature to predict critical velocity to disperse water in a two-phase oil-water flow. Limited
work has been done, though, to quantify the dispersion of water and set criteria for critical velocity to fully disperse water in
three-phase oil-water-gas stratified flow. In the current study, a new approach is proposed to extend the implementation of
two-phase models into multiphase oil-water-gas stratified flow. Gas-liquid models for stratified flow are used to calculate phase
distribution in a stable stratified flow in an oil-water-gas system. Similarly, models for water entrainment in oil-water flow are used
to predict critical velocity to disperse the entire water film in a multiphase oil-water-gas stratified flow. Comparison between
calculated critical velocities in multiphase stratified flow and experimental data available in literature reveals good agreement.
Unlike current general rules of thumb, the proposed approach takes into account the fluid’s physical properties, water cut, flow
rate, and pipe size and inclination in setting criteria for critical velocity above which water is entirely entrained in the oil phase
and corrosion risk is minimized in a three-phase stratified flow.
Cathodic Protection Session
Session Chairman: Patrick Hivert, Pipeline Services, LLC
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Design Considerations for Complex Plant Cathodic Protection System
Presented by: Pankaj Panchal, Abdulla Fouad-Impalloy Ltd. Co. (Saudi Arabia)
Designing of cathodic protection (CP) systems for buried structures in a complex hydrocarbon plant is challenging due to
dissimilar metals, different types of coating systems and bare grounding systems. The CP design for all the buried structures
must be integrated. To avoid interference, the design should take into consideration the bonding for all the structures.
This paper looks at various scenarios for CP of complex plant buried structures, the types of survey to be performed and the
data collection and analysis of survey data for the design. The present paper answers questions concerning the need for an
intergraded CP system for all the buried structures and grounding systems, different type of CP systems for plants, shielding
effects and protection criteria.
Innovative Corrosion Control Measures—Internal Stray Current Corrosion
Presented by: Ali Elkordi, ADCO (United Arab Emirates)
Oil spill incidents related to Transfer line /Trunkline leaks near Isolation Joints (IJs) can be catastrophic with following consequences:
§§ Loss of life
§§ Safety and environment (fire, toxic gases & oil spill)
§§ Resource and downtime cost impact
§§ Damage to asset and company reputation
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One of the leading Middle East oil operator has 6 oil transfer lines which are cathodically protected (CP). The Intelligent Pigging
Survey (IPS) results indicated the areas near IJs with active corrosion; hence the following studies/investigations were carried out.
§§ Evaluation of past and present IPS data
§§ Ultrasonic Technique (UT) scan verification of the areas of concern.
§§ CP audit across IJs
§§ Application of Risk Based Analysis(RBA)
§§ Adequacy of current corrosion control measures.
The above investigations identified the most probable corrosion mechanism as “Internal Stray Current Corrosion”. To reduce the
failure rate and maintain integrity of Transfer lines intact the following remedial actions were adopted:
§§ Installation of resistive bond across IJs is completed.
§§ Periodic monitoring of defects by UT planned.
§§ Periodic IPS campaigns and 6 monthly pipe RBA planned
This paper critically examines the new approach and techniques which have significant HSE benefits and cost advantages of
16M USD (in terms of loss of production, Shut down and remedial actions) besides maintaining Asset Integrity, thus enhancing
company reputation and Shareholders’ confidence
Flexible Impressed Current Linear Anodes—Cathodic Protection Applications
Presented by: Shailesh Javia, Matcor (India)
Flexible impressed current Linear anodes that extend the benefits of linear anodes to the widest range of cathodic protection
applications. Along pipelines, beneath above ground storage tanks (ASTs) and congested areas. Beneath above ground storage
tanks (ASTs) with very little clearance.
§§ Horizontal directional drilling (HDD) applications Internal pipeline protection
§§ Special applications, water wells and industrial environments
§§ Marine environments, concrete and special applications
Linear anodes handle current distribution challenges by minimizing current densities and placement in close proximity to
the structure. Innovative design utilizing multiple internal anode to cable connections provides redundancy, protects against
uneven anode consumption and minimizes voltage drop.
An Investigation on the Effects of Coating and Foundation on the External Corrosion and Cathodic Protection
Performance of Aboveground Storage Tank’s Bottom
Presented by: Hamed Aldaghl, POGC (Iran)
In this research, some specific parameters affecting corrosion behavior and cathodic protection (CP) performance of aboveground
storage tank bottoms was investigated. These parameters included the application and quality of coating, tank foundation type,
and corrosive agents like sulfate and chloride ions or Sulfate Reducing Bacteria (SRB) in the foundation layer.
While the tanks had similar design, material, construction and environment, they were different in the bottom external coating
and tank foundation type. In all cases, the external surfaces of bottom plates were corroded during the time interval between
construction launch and CP system commissioning. As a result, considerable reductions in thickness of the bottom plates have
been occurred. To evaluate the extension of these damages, Magnetic Flux Leakage (MFL) technique was employed. Results
showed that, the level of corrosion in the tanks with asphalt type foundation was considerably lower than that of sand type
foundation. Meanwhile, the presence of corrosive agents in sand caused a great thickness reduction, even in the case of coated
plates.
24
May 12-13, 2015
Abu Dhabi, UAE
Results showed that the CP current distribution was better in the sand type foundations. However, the CP system was working
well in an asphalt type foundation. Results indicated that in the tanks with bare bottom plates a higher amount of current
demand was needed to achieve the protection level, while an improvement in the quality of coating decreased the current
demand significantly.
Material Selection Session
Session Chairman: Dr. Ali Moosavi, ADCO
Al Mudhaif 2
The Selection of Stainless Steel for High Temperature CO2 Environment
Presented by: Tosapolporn Pornpibunsompop, DTI (Thailand)
The stress corrosion cracking at high temperature (800 ºC) carbon dioxide surrounding of stainless steel was investigated in order
to suitably select material at such harsh environment. The stainless steels 304, 316, 310S, and 430 were chosen for investigation.
The horizontal furnace which can heat up to 1,100ºC and heating rate can set up to 7ºC per minute was used for this research.
The specimens were plastically deformed via U-bend technique with 12 mm bending radius and raised stress into them
especially tensile stress on surface. CO2 was gradually thermally increased from ambient temperature to testing temperature
(800ºC). At 800ºC with suitable holding periods and CO2 pressures, the degree of metallic compound precipitation and oxidation
at surface would very high and could be a potential course of crack initiation on specimen surface. The result of research was
aimed to identify failure environmental condition (CO2 pressure and holding time) of each stainless steel. Moreover, the cracks
were primarily examined by Optical Microscopy to reveal crack path and detailed investigated on crack type and morphology
by Scanning Electron Microscope (transgranular, intergranular, or mixed mode of cracking). The oxidation products were
investigated by X-Ray Diffraction on each layer and comparatively presented the trend of oxidation formation according to each
environmental condition. The discussion would be conducted for appropriate stainless steel selection on testing environment.
State of the Art in Plate Making for HIC Resistance & Beyond
Presented by: Patrick Toussaint, Industeel (Belgium)
The paper deals with the needs in carbon and low-alloy steel platemaking related the more and more challenging sour
service conditions encountered in oil & gas service. Features of steelmaking, chemistries of material, welding conditions,
cleanliness, sour corrosion testing, tensile and impact properties, delivery conditions and equipment farbication and post weld
heat treatments are discussed in their combined interdependent actions on the fitness of the material for its intended use,
using SA516 materials as a core example. Highlights of typically conflicting requirements are illustrated, as well as progress
towards ever increasing resistance properties like SOHIC and potential for higher strength like SA533 class 2 material towards the
progress for safe and better features of the material for the end-user while keeping safe and away from inappropriate practices.
Isolation Joint Material Selection: Issues & Opportunities
Presented by: Paolo Dini, Nuova Giungas SRL (Italy)
Monolithic Isolation Joint are simple pieces of equipment resulting from a combination of a multifactorial complexity which
combine metallic and isolating materials. It is in fact an anti-corrosion device in cathodic protection/isolation as well as a
source of potential failures leading to both mechanical and electrical leaks. The recent challenges of the new extreme ambient
(temperature range) and service condition (high pressure, high CO2, high H2S) pushes the performance to the limit making it a
key asset integrity component.
Material selection and specification are a critical activity as well as engineering and procurement. This paper discuss a series of
challenging cases from the manufacturer perspective experience and address the issue of risky project specification paradox
versus virtuous material selection and testing.
25
Centrifugally Cast Solid CRA Duplex Grade Pipes for Upstream Oil & Gas - An alternative to Wrought Seamless Grades
Presented by: Shankar Venkataraman, Schmidt + Clemens GmbH + CO. KG (Germany)
Rigid piping solutions like flowlines, gathering lines, subsea production piping are used to transport unprocessed fluids from oil
and gas wells. Depending on the field compositions, these fluids might contain corrosive species like H2S and thus necessitate
the application of sour corrosion resistant materials like corrosion resistant alloys (CRA). Among the various types of CRA used
by the industry duplex grades have found widespread usage due to their attractive combination of mechanical strength and
corrosion resistance.
Duplex pipes are supplied either in the wrought seamless or the longitudinally-welded form. Horizontal centrifugal casting
offers itself as an alternative manufacturing method of seamless pipes. The key features of this process and the possible
advantages are highlighted. Using this process, duplex pipes of standard 22%Cr as well as 25%Cr superduplex grades have been
manufactured and tested. The results of the mechanical properties, corrosion properties as well as microstructure development
in the as-cast state and the solution-annealed state are presented. It is shown that centrifugally cast duplex grade pipes meet
the requirements desired by the industry standards for line pipe applications
Developing Field Test Procedures for Establishing a Chloride Stress Corrosion Cracking Corrosion Alternative
Presented by: Hanan Farhat, University of Saskatchewan (Canada)
Oil and gas production, and petrochemical plants in offshore and onshore locations in Qatar are exposed to severe environmental
conditions. The combination of high humidity, high concentration of chloride ions, high temperature and the presence of
residual tensile stresses due to welding or other forming process make these facilities susceptible to chloride-induced stress
corrosion cracking (CSCC). High temperature causes seawater to evaporate, condensate, and dry on metal surfaces, thereby
enhancing local build-up of aggressive species, such as chloride on the metals’ surfaces. If the surface of the metal is insulated,
the condensate may be trapped under the insulation leading to high localized corrosion damage. This is complicated by
sand storms which leave sand particles with aggressive species such as chloride and sulfide on the surfaces exposed to this
environment.
A corrosion atlas for chloride stress corrosion cracking was developed in Qatar to assist for better material selection. Seven
different stainless, duplex and high nickel alloy steels were investigated. One hundred samples of each material were exposed
to a stress equivalent to 80% and 100% of their yield strength. They were then, distributed in different onshore and offshore sites
for Qatar Petroleum, and were inspected periodically for CSCC. The temperature, humidity and time to failure were recorded.
This paper describes the developed test procedures to establish high level of accuracy and repeatability. It also discusses the
design aspects and the challenges that were met.
An Investigation on Parameters Influencing CO2 Corrosion of Low-Alloy Steel Pipelines
Presented by: Reza Labbaf, RGS Co. (Iran)
CO2 Corrosion of Low-Alloy Steels has been one of the most common corrosion issues in oil and gas pipeline industry. In order
to control CO2 corrosion, many research have been conducted focusing on the effect of physical and environmental parameters
of the internal corrosion of pipeline. In this study, the influence of temperature, pH, fluid flow, and the microstructure of lowalloy steel is scrutinized. For this purpose, API 5L X65 and X70 steel were cut to the specific size and heat-treated to obtain
different microstructures. The corrosive media was a deoxygenated 3% NaCl solution, saturated with CO2 at 60°C and 80°C with
different flow rate using Rotating Cylinder Electrode (RCE). Results show that by passage of time, iron carbonate surface layer
forms and grows but the steel becomes more sensitive to localized corrosion. It is concluded that the specific microstructure
of X70 steel has a negative influence on CO2 corrosion behavior of the steel. Pits were observed on the steel surface at 80°C but
not at 60°C, showing the unusual effect of temperature on CO2 corrosion.
26
Mark Your Calendar for These Upcoming
NACE Events!
Concrete Service Life Extension Conference
June 29–July 1, 2015 | Philadelphia, PA, USA
This event will discuss proactive ways to prevent deterioration in
concrete structures that will help meet or extend the structure’s
service life.
NACE Northern Area Eastern 2015
October 18 - 21, 2015 | Ottawa, ON, Canada
NACE Western Area Conference 2015
October 28-30, 2015 | Scottsdale, AZ, USA
Top of the Line Corrosion Conference
July 27-29, 2015 | Jakarta, Indonesia
This event brings together industry professionals and leading
technology and service providers to address top of the line corrosion.
NACE East Asia and Pacific Area Conference
Pipeline Integrity Management Seminar
(PIMS) Latin America
2015 Department of Defense–Allied Nations
Corrosion Conference
July 29-31 2015 | Quito, Ecuador
PIMS will address methods and tools for making sound management
decisions that will improve pipeline integrity.
NACE Central Area Conference 2015
August 31 - September 2, 2015 | St. Louis, MO, USA
Corrosion Technology Week 2015
September 20 - 24, 2015 | Austin, TX, USA
For more information about NACE events,
visit nace.org/events
November 11-13, 2015 | Kaohsiung, Taiwan
November 15-19, 2015 | Pittsburgh, Pennsylvania, USA
Discussing corrosion control efforts for the DoD and defense ministry
partners worldwide.
*Planning for this event is subject to the receipt of official government approval.
CORROSION 2016
March 6-10, 2016 | Vancouver, BC, Canada

NACEUAE - NACE International

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