Development and Application of On-Line Corrosion Monitoring Device for Condenser Tube

This paper introduces the development and industrial application of an on-line corrosion monitoring device for condenser tubes. Corrosion sensors are made up of representative condenser tubes chosen by eddy current test, which enable the monitoring result to be consistent with the corrosion of actual condenser tubes. Localized corrosion rate of condenser tubes can be measured indirectly by a galvanic couple made up of tube segments with and without pits. Using this technology, corrosion problems can be found in time and accurately, and anticorrosive measures be made more economic and effective. Applications in two power plants showed the corrosion measurements are fast and accurate.

Effect of Ca2+ and Mg2+ on CO2 Corrosion Behavior of Tube Steel

Effects of Ca2+ and Mg2+ on the CO2 corrosion behaviors of tube steel were studied in simulated oil-field environment.The influence of Ca2+and Mg2+ on the corrosion rate and morphologies of corrosion product layer was determined by scanning electron microscope and measuring mass loss.Potentiodynamic polarization and impedance spectroscopy were used to investigate the change of electrochemical characteristic parameters of corrosion product layer and corrosion dynamic process.The results show that with Ca2+ and Mg2+ in electrolyte,the morphologies and microstructures of corrosion product layer changed obviously,thus affecting the corrosion process.

Predictive Model for Corrosion Rate of Oil Tubes in CO_2/H_2S Coexistent Environment Part Ⅰ: Building of Model

Based on an analysis of the existing models of CO 2 corrosion in literatures and the autoclave simulative experiments, a predictive model of corrosion rate (r corr) in CO 2/H 2S corrosion for oil tubes has been established, in which r corr is expressed as a function of pH, temperature (T), pressure of CO 2 (P CO 2) and pressure of H 2S (P H 2S). The model has been verified by experimental data obtained on N80 steel. The improved features of the predictive model include the following aspects: (1) The influence of temperature on the protectiveness of corrosion film is taken into consideration for establishment of predictive model of the r corr in CO 2/H 2S corrosion. The Equations of scale temperature and scale factor are put forward, and they fit the experimental result very well. (2) The linear relationship still exists between ln r corr and ln P CO 2 in CO 2/H 2S corrosion (as same as that in CO 2 corrosion). Therefore, a correction factor as a function of P H 2S has been introduced into the predictive model in CO 2/H 2S corrosion. (3) The model is compatible with the main existing models.

Influence factors on stress corrosion cracking of P 110 tubing steel under CO2 injection well annulus environment

Stress corrosion cracking （SCC） behavior of P 110 tubing steel in simulated C02 injection well annulus environments was investigated through three-point bent tests, potentiodynamic polarization and EIS measurements. The results demonstrate that SCC of P110 tubing steel could occur in acidulous simulated environment, and the sensitivity of SCC increases with the decrease ofpH, as well as increase of sulfide concentration and total environmental pressure. Both anodic dissolution and hydrogen embrittlement make contributions to the SCC. Adequate concentration of corrosion inhibitor can inhibit the occurrence of SCC on account of the inhibition of localized anodic dissolution and cathodic hydrogen evolution.

Experimental and Numerical Investigation on Erosion Corrosion of the Air Cooler Tube Bundle in a Residue Hydrotreating Unit

Corrosion leakage occurred in the 14th tube bundle in the first row of a residual oil hydrotreating air cooler after operating for two years.The failure location was 0.5 m from the outlet header box.In this paper,the erosion corrosion of the air cooler tube bundle was investigated by experimental and numerical methods.Visual inspection,scanning electron microscopy(SEM),and X-ray diffraction(XRD)experiments were performed,and the failure morphology and material composition confirmed that the damage was caused by erosion corrosion.The shear stress transport k–ωturbulence model(SST-k–ω)was then used to investigate the flow and erosion corrosion characteristics,combined with mass transfer,corrosion rate,and ionization equilibrium models.The numerical simulation results revealed that the water phase volume fraction increased with flow and heat transfer in the fluid,which increased the mass flow rate and concentration of hydrogen sulfide.The mass transfer coefficient and corrosion rate were proposed as important parameters to characterize erosion corrosion.Moreover,the local concentration of wall shear stress was found to increase the risk of erosion corrosion.The predicted high-risk area was consistent with the actual failure area,which verified that this failure incident was attributable to erosion corrosion by the water phase.

THE INFLUENCE OF RESIDUAL STRESS ON THE CORROSION RESISTANCE OF H68A BRASS TUBES IN SEA WATER

This paper reveals the morphological characteristics of the cracks formed in H68A brass tubes fully immersed in seawater, and studies the depth profiles of the residual stress of the tubes. Tbe great residual stress in the wall results in stress-corrosion cracking, and the unique morphology of the cracks is due to the uneven distribution of residual stress through the depth of the tube.

High-Temperature Corrosion of Protective Coatings for Boiler Tubes in Thermal Power Plants

High-temperature corrosion is a serious problem for the water-wall tubes of boilers used in thermal power plants. Oxidation, sulfidation and molten salt corrosion are main corrosion ways.Thereinto, the most severe corrosion occurs in molten salt corrosion environment. Materials rich in oxides formers, such as chromium and aluminum, are needed to resist corrosion in high-temperature and corrosive environment, but processability of such bulk alloys is very limited. High velocity electric arc spraying (HVAS) technology is adopted to produce coatings with high corrosion resistance. By comparison, NiCr (Ni-45Cr-4Ti) is recommended as a promising alloy coating for the water-wall tubes, which can even resist molten salt corrosion attack. In the study of corrosion mechanism, the modern material analysis methods, such as scanning electron microscopy (SEM), X-ray diffractometry (XRD) and energy dispersive spectrometry (EDS), are used. It is found that the corrosion resistances of NiCr and FeCrAI coatings are much better than that of 20g steel, that the NiCr coatings have the best anti-corrosion properties, and that the NiCr coatings have slightly lower pores than FeCrAI coatings.It is testified that corrosion resistance of coatings is mainly determined by chromium content, and the microstructure of a coating is as important as the chemical composition of the material. In addition, the fracture mechanisms of coatings in the cycle of heating and cooling are put forward. The difference of the thermal physical properties between coatings and base metals results in the thermal stress inside the coatings. Consequently, the coatings spall from the base metal.

The Hot Corrosion Performance of NiCr-Cr_3C_2 Cermet Coating to Boiler Tube

Three kinds of NiCr-Cr 3C 2 cermet coatings were designed and deposited by the subsonic velocity flame spraying, and their performances of hot corrosion performance were evaluated in comparison with 102G, 20G boiler tube steel, FeCrAl, NiCrTi, Ni50Cr and NiCrAlMoFe-Cr 3C 2 coatings, which are widely used at present for protection of boiler tubes. Meanwhile,the influence of sealer on the hot corrosion resistance of various coatings and the mechanisms of coating corrosion were explored.

Study on corrosion resistance of the BTESPT silane cooperating with rare earth cerium on the surface of aluminum-tube

Bis-3-(triethoxysilyl)propyltetrasulfide(BTESPT) silane-rare earth cerium composite coatings on aluminum-tube were prepared at 60 °C by immersion method.The performance of composite coatings to protect the aluminum-tube against corrosion was investigated with potentiodynamic polarization curves,electrochemical impedance spectroscopy(EIS),and salt spray test(SST).The results of potentiodynamic polarization curves and EIS indicated that the self-corrosion current decreased by two orders of magnitude and the i...

A Study of Water Treatment Chemical Effects on Type I” Pitting Corrosion of Copper Tubes

It is known that one of the causes of pitting corrosion of copper tubes is residual carbon on the inner surface. It was confirmed that type I” pitting corrosion of the copper tube is suppressed by keeping the residual carbon amount at 2 mg/m2 or less, which is lower than that of the type I’ pitting corrosion, or by removing the fine particles that are the corrosion product of galvanized steel pipes. The developed water treatment chemical was evaluated using three types of copper tubes with residual carbon amounts of 0 mg/m2, 0.5 mg/m2, and 6.1 mg/m2. The evaluation was conducted for three months in an open-circulation cooling water system and compared with the current water treatment chemical. Under the current water treatment chemical conditions, only the copper tube with a residual carbon amount of 6.1 mg/m2 showed a significant increase in the natural corrosion potential after two weeks, and pitting corrosion occurred. No pitting corrosion and no increase in the natural corrosion potential were observed in any of the copper tubes that were treated with the developed water treatment chemical. In addition, the polarization curve was measured using the cooling water from this field test, and the anodic polarization of two cooling waters was compared. For copper tubes with a large amount of residual carbon, the current density near 0 mV vs. Ag/AgCl electrode (SSE) increased when the developed water treatment chemical was added.

Correlation of seawater corrosion and processing of Cu Ni alloy tubes

The investigations on the effect of the initial surface and microstructure on the seawater corrosion of Cu Ni alloy tubes were carried out by processing, electrochemical methods and natural seawater exposure as well as SEM. Deformation had more impact on the final microstructure of the tubes than the annealing time did, and at the deformation of 32% and annealing temperature 550～600 ℃ for 1 h the tubes was completely recrystallized microstructure. As increasing the volume fraction of recrystallization, the homogeneity of microstructure and the corrosion resistance increased. The residual carbon film produced on the inner surface of the tubes during the processing, had higher corrosion potential than the alloy substrate and good electronic conductivity, so accelerating the dissolution of the substrate in seawater, and the non protective and loose corrosion product film formed. Immersed in natural seawater, the tubes of incomplete recrystallization, consisting of deformed and recrystallized grains, displayed intergranular corrosion, which resulted from corrosion micro cells built between deformed and recrystallized grains and the preferable transportation of electrons on the boundaries of both the grains. In contrast, the recrystallized alloy tubes formed the uniform and compact corrosion product film under which no corrosion was found.

Localized Corrosion in Copper Tubes by Volatile Organic Substance

An unusual form of localized corrsion in copper tubes was detected early in service and in leakage tests after manufacturing.The morphology of this corrosion is similar to that of an ant's nest when viewed in cross section. The corrosion mechanisms, cases ofant's nest corrosion, and preventive measures are presented.

Effect of Radial Expansion of Cr-Mo Steel Tubes on Their Corrosion Behavior in Sea Water

This paper studies the effect of expansion ratio on the corrosion rate of the expanded tubes exposed to sea water as well as the microstructure changes caused by the expansion of Cr-Mo steel tubes to large permanent deformations. 2.25 Cr-1.0 Mo steel (schedule 40 and schedule 80) tubes were subjected to various expansion ratios of 10%, 15%, 20%, and 25% by pushing conical mandrels through them using a piston. The microstructure was also studied to determine the effect of the expansion on the grain structure of the material. Microscopic examination of the expanded tubes revealed that grains elongate along the direction of the hoop stress and this elongation increases with an increase of expansion ratio. Moreover, it was found that corrosion rate and hardness increase with an increase in expansion ratio.

Ammonia corrosion analysis of copper tubes and experimental research on non-copper improvement for heat exchanger in power plant

Ammonia corrosion in copper tube will affect the safety of boiler running in power plant. Therefore, no copper in heating system has become a technical orientation in heat exchanger reconstruction, This paper analyzes the condition and mechanism of ammonia corrosion occurring in copper tube used in coal-fired power plants. Using a general steam condensation testing equipment only for horizontal single tube, with water vapor and water as working fluid, on two types of steel tube with 2-side enhancement heat transfer, namely, a spirally fluted tube and a ratchet tube with internal spiral groove （RISG tube） which was developed recently, a set of experimental tests are conducted to investigate the characteristics of heat transfer and hydromeehanics. In order to compare easily, both one copper smooth tube and one steel smooth tube are also used in the experiment. The experimental results, which get from single horizontal tube, show that the overall heat transfer coefficient of steel spirally fluted tube are improved by 10%o to 17%, and that of the steel RISG tube（22%-28%） is better than steel spirally fluted tube, its flow resistance coefficient is only increased by 22% to 66% when compared with smooth tube. Based on a lot of experimental data, the steel spirally fluted tube and the steel RISG tube were applied in a low pressure preheater and an oil-cooler of some or other power plant respectively. The field testing results showed that their heat transfer coefficient with each types of enhancement heat transfer tubes were improved by 2.5% and 21%-45% comparing with copper smooth tube heat exchangers. Both basic and field experiment indicates that the steel tube with 2-side enhancement heat transfer is an ideal choice for heat exchanger reconstruction in no copper issue in power plants.

Simple Measurement of Carbon Films on Copper Tubes and Their Effects on Corrosion

It has been reported that pitting corrosion in copper tubes occurs due to the effect of a carbon film produced by the influence of undergoing an oil and heat treatment. As a quantitative method for determining the residual carbon amount, it has been reported that the inner surface of a copper tube can be dissolved with a mixed acid to collect and analyze the adhering carbon;however, this method is dangerous and difficult. Therefore, two methods were examined as a simple quantitative method for obtaining the residual carbon amount using copper tubes with known residual carbon amounts. One method utilizes X-ray photoelectron spectroscopy (XPS), and the other method utilizes the potential difference between the carbon film-adhered surface and carbon film-removed surface. In regard to XPS measurement, a linear correlation was found between the spectral intensity of C and the residual carbon amount;therefore, XPS measurements were considered to be effective as a simple measurement method for the carbon film on the inner surface of a copper tube. In the evaluation method by measuring the corrosion potential, a correlation was observed between the potential difference ΔE and the residual carbon amount of the inner surface of the tube and the outer surface of the polished tube. It is considered possible to estimate the residual carbon amount from the prepared calibration curve. Through these studies, it is suggested that the carbon film was non-uniformly present on the surface of the copper tube. Therefore, the galvanic current was measured, and the effect of a non-uniform carbon film on corrosion behavior was investigated. As a result, in the measurement of galvanic current, the current flowed from the copper tube with a large amount of residual carbon (cathode) to the copper tube with a small amount of residual carbon (anode). In addition, the higher the area ratio of the carbon film was, the larger the galvanic current tended to be.

Corrosion performance and applicability evaluation of nickel-based alloys for oil and gas production tubing applications

The sulfide stress corrosion cracking（ SSC） performance of G3 and 028 nickel-based alloys w as studied using slow strain rate test（ SSRT） and the four-point bend（ FPB） test under simulated dow nhole conditions. The effect of high temperature,high H2 S / CO2 partial pressure,and the presence of sulfur on SSC susceptibility w as investigated. The G3 alloy w as found to have a higher SSC resistance than the 028 alloy. Presence of sulfur and temperature bear a strong influence on the SSC performance of the metals,particularly on the 028 alloy. The applicability of 028 and G3 alloys may be expanded and both could safely be used beyond the limits set by the ISO15156-3 standard.

Metallurgical Forensics: Investigating a Superheater Tube Failure in Industrial Process Plants

A metallurgical forensic investigation was conducted to determine the cause of a failed superheater tube. Analysis techniques by Visual Examination, Energy Dispersive X-ray Analysis, Mechanical Testing and Metallographic Investigation were conducted, together with a comparative study from an inlet elbow section that did not fail. The superheater tube suffered premature failure after being in service for about two years. It was concluded that the failed tube underwent overheating, corrosion-erosion, embrittlement, and eventual failure under its internal pressure by stress rupture. The analysis revealed intergranular cracks, window fracture features and spheroidization of pearlite with grain growth. A possible contribution to embrittlement was from copper. Follow-ups and recommendations were provided, as well as covering materials, inspection, and operational considerations.

Corrosion behavior of the expandable tubular in formation water

The corrosion behavior of expandable tubular materials was investigated in simulated downhole formation water environments using a series of electrochemical techniques. The corrosion morphologies in the real downhole environment after three months of application were also observed by stereology microscopy and scanning electron microscopy （SEM）. The results show that, compared with the unex- panded sample, the area of ferfite increases dramatically after a 7.09% expansion. The expanded material shows a higher corrosion current in the polarization curve and a lower corrosion resistance in the electrochemical impedance spectroscopy （EIS） plot at every studied tempera- ture. The determined critical pitting temperatures （CPT） before and after expansion are 87.5℃and 79.2℃, respectively. SEM observations demonstrate stress corrosion cracks, and CO2 corrosion and H2S corrosion also occur in the downhole environment. Due to additional defects generated during the plastic deformation, the corrosion performance of the expanded tubing deteriorates.

Effect of Rare Earth on the Corrosion-Resisting Performance of Zinc-Based Alloy Coatings

The corrosion behavior of coatings of pure zinc and Zn-Al,Zn-Al-RE alloys in NaCl solu- tions was studied by salt-spray experiments,even corrosion experiments and electrochemical measurements of bi-directional polarization curves and a.c.impedance in weak polarization region consistent regularities were obtained by these different methods,viz.,the corrosion resistance of Zn could be enhanced by alloying it with Al,and particularly with Al-RE.The causes of enhancement of corrosion resistance by RE were also discussed.

Effects of the Produced Water from a Sour Oilfield in South Kuwait on the Production Tubing

Kuwaiti oil production faces a growing challenge in the increasing quantities of produced water generated in the production of oil. The high water cut of the produced fluid from the wells and the high salinity of the produced water lead to significant degradation of subsurface equipment, specifically the production tubing. Debris generated through the degradation of the inner part of the tubing becomes a constituent of the scaling that deposits in the tubing and blocks the flow of the production fluid, inducing higher maintenance costs. This paper looks at the characteristics of the scaling in regard to the produced water and outlines the economic impact of the produced water induced degradation of the tubing structure.