Abstract

The RAMSSES project aims to show the benefits of advanced materials in maritime applications by implementing 13 market driven demo cases. The entire process chain and a wide range of applications (structural components, equipment, ship integration, repair) are covered. Installation and assessment of demonstrators on shore or on board will reveal the high technology readiness. The test program, based on risk assessment and supervised by rule making bodies, targets on ensuring relevance for commercial approval beyond the project. While demonstrators will support commercialisation of specific products, RAMSSES is also engaged strategically in enabling more rapid and agile material innovation in the European Maritime industry. The first key element is a knowledge repository for test data and best practice procedures, allowing reuse of such information for similar future cases. Secondly, standardised risk scenarios will help easing approval processes in the future, and finally a new materials innovation platform will enhance continuous technology transfer within the maritime sector and beyond.

Abstract

The nature and distribution of residual stresses are invariably critical for fatigue life with dissimilar material joints often inducing high tensile residual stresses. A fatigue-resistant concept of weld cladding process pipelines, producing compressive residual stresses, is under investigation to examine how these stresses may be influenced. Simplified weld cladding simulations have successfully illustrated the development and distribution of residual stresses through the joint. The study has highlighted the importance of accurate material data for clad and substrate materials with current analysis assumptions in a simple thick-walled pipe discussed. Experimental validation, using ICHD, measured residual stresses with depth on weld clad specimens, resulting in good correlation between simulation and experiment for a nickel-chromium-based superalloy clad on low alloy carbon steel as discussed. Future work, including a full 3D representation of the cladding process and a comparison of residual stress measurement methods, are also discussed. Document type: Part of book or chapter of book

Abstract

Ceramic multi-layer systems are the key components of solid oxide cells (SOC) to be used either for power generation or energy storage. Over the last decades continuous improvement in materials, architecture and manufacturing processes have been achieved to improve performance, durability and lifetime. The advanced concept of a metal-supported SOC where the functional ceramic layers are deposited onto a mechanically stable porous metal support is the most advanced approach for mobile application as auxiliary power units (APU) having strict requirements in terms of low volume, limited weight and improved ability for rapid start-up and thermal cycling. The paper provides an overview of the metal-supported cell development at DLR where functional layers are consecutively deposited by plasma spray technology onto a metal substrate. The current status of this development including materials aspects, stack technology and electrochemical performance is reported. When operating temperature is governed mainly by the electrocatalytic properties of the functional electrode materials and thickness of the electrolyte, thin-film electrolyte opens up the opportunity of low temperature operating SOC. Recently, further research efforts have started to develop a metal-supported cell with thin-film electrolyte. Hermetic thin films have been applied through PVD technology resulting in bilayer structured coatings. Recent results of this development are also presented. Document type: Part of book or chapter of book

Abstract

The approximately 200,000-mile fuel pipeline system in the US operates at flow rates up to 2.5 {times} 10{sup 6} gallons per hour (GPH). Most commercial technologies only provide on-line leak detection at about 0.3% of flow rate, i.e., about 7,500 GPH or larger. Detection of leaks at about 1 GPH or so is desirable both from a regulatory and leak-prevention standpoint. Brookhaven`s commercially-accepted perfluorocarbon tracer (PFT) technology for underground leak detection of utility industry dielectric fluids at leak rates less than 0.1 GPH, with new enhancements, will be able to cost-effectively detect fuel pipeline system leaks to about 1 GPH--3 orders-of-magnitude better than any on-line system. The magnitude of detected leaks would be calculable as well. Proposed mobile surveys (such as those used periodically in the gas pipeline industry) at about 110 to 120 miles per day would allow such small leaks to be detected at 10-ppb tagging levels (less than $1,500 of PFT for a 48-hour tag at the maximum transport rate) under worst-case meteorological dispersion conditions. Smaller leaks could be detected by proportionately larger tagging concentrations. Leaks would be pinpointed by subsequent conventional barholing and vapor analyses. There are no health nor safety issues associated with the use of the proposed technological approach nor any consequential environmental impacts associated with the proposed magnitudes of PFT tagging. Document type: Report

Abstract

Results of two studies conducted as part of the Strategic Petroleum Reserve (SPR) Pipeline Corrosion Control Program are reported. These studies focused on evaluation of rotary-applied concrete materials for internal pipeline protection against the erosive and corrosive effects of flowing brine. The study also included evaluation of liners applied by hand on pipe pieces that cannot be lined by rotary methods. Such pipe pieces include tees, elbows and flanged pipe sections. Results are reported from a corrosion survey of 17 different liner formulations tested at the-Big-Rill SPR Site. Testing consisted of electrochemical corrosion rate measurements made on lined pipe sections exposed, in a test manifold, to flowing SPR generated fluids. Testing also involved cumulative immersion exposure where samples were exposed to static site-generated brine for increasing periods of time. Samples were returned to the laboratory for various diagnostic analyses. Results of this study showed that standard calcium silicate concrete (API RP10E) and a rotary calcium aluminate concrete formulation were excellent performers. Hand-lined pipe pieces did not provide as much corrosion protection. The focus of the second part of the study was on further evaluation of the calcium silicate, calcium aluminate and hand-applied liners in actual SPR equipment and service. It was a further objective to assess the practicality of electrochemical impedance spectroscopy (EIS) for field corrosion monitoring of concrete lined pipe compared to the more well-known linear polarization technique. This study showed that concrete linings reduced the corrosion rate for bare steel from 10 to 15 mils per year to 1 mil per year or less. Again, the hand-applied liners did not provide as much corrosion protection as the rotary-applied liners. The EIS technique was found to be robust for field corrosion measurements. Mechanistic and kinetic corrosion rate data were reliably obtained. Document type: Report

Abstract

Centrifugally-cast concrete liners applied to the interiors of plain steel pipe sections were tested for corrosion performance in brine solutions. An American Petroleum Institute (API) standard concrete, with and without additions of a styrene-butadiene copolymer latex, was subjected to simulated service and laboratory tests. Simulated service tests used a mechanically pumped test manifold containing sections of concrete-lined pipe. Linear polarization probes embedded at steel-concrete interfaces tracked corrosion rates of these samples as a function of exposure time. Laboratory tests used electrochemical impedance spectroscopy to study corrosion occurring at the steel-concrete interfaces. Electron probe microanalysis (EPMA) determined ingress and distribution of damaging species, such as Cl, in concrete liners periodically returned from the field. Observations of concrete-liner fabrication indicate that latex loading levels were difficult to control in the centrifugal-casting process. Overall, test results indicate that latex additions do not impart significant improvements to the performance of centrifugally cast liners and may even be detrimental. Corrosion at steel-concrete interfaces appears to be localized and the area fraction of corroding interfaces can be greater in latex-modified concretes than in API baseline material. EPMA shows higher interfacial Cl concentration in the latex-modified concretes than in the API standard due to rapid brine transportmore » through cracks to the steel surface.« le Document type: Report

Abstract

Chemical treatments of paraffin and asphaltene deposition by means of cleaning fluids were carried out in this research project. Research focused on the characterization of asphaltene and paraffin materials and dissolution of asphaltene and paraffin deposits using surfactant/micellar fluids developed early in the project. The key parameters controlling the dissolution rate were identified and the process of asphaltene/paraffin dissolution were examined using microscopic apparatus. Numerical modeling was also carried out to understand the dissolution of paraffin deposits. The results show that fused chemical reaction systems are a promising way of removing paraffin deposits in subsea pipelines. The fused system may be in the form of alternate pulses, emulsions systems or encapsulated catalyst systems. Fused reaction systems, in fact, are extremely cost-effective--less than 10% of the cost of replacing entire sections of the blocked pipeline. The results presented in this report can have a real impact on the petroleum industry and the National Oil Program, if it is realized that the remediation technologies developed here can substantially delay abandonment (due to asphaltene/paraffin plugging) of domestic petroleum resources. The report also sheds new light on the nature and properties of asphaltenes and paraffin deposits which will ultimately help the scientific and research community to develop effective methods in eliminating asphaltene/paraffin deposition problems. It must also be realized that asphaltene remediation technologies developed and presented in this report are a real alternative to aromatic cleaning fluids currently used by the petroleum industry. Document type: Report

Abstract

The main objective of the study is as follows: Identify steel compositions/microstructures suitable for construction of new pipeline infrastructure and evaluate the potential use of the existing steel pipeline infrastructure in high pressure gaseous hydrogen applications. The microstructures of four pipeline steels were characterized and tensile testing was conducted in gaseous hydrogen and helium at pressures of 5.5 MPa (800 psi), 11 MPa (1600 psi) and 20.7 MPa (3000 psi). Based on reduction of area, two of the four steels that performed the best across the pressure range were selected for evaluation of fracture and fatigue performance in gaseous hydrogen at 5.5 MPa (800 psi) and 20.7 MPa (3000 psi). The basic format for this phase of the study is as follows: Microstructural characterization of volume fraction of phases in each alloy; Tensile testing of all four alloys in He and H{sub 2} at 5.5 MPa (800 psi), 11 MPa (1600 psi), and 20.7 MPa (3000 psi). RA performance was used to choose the two best performers for further mechanical property evaluation; Fracture testing (ASTM E1820) of two best tensile test performers in H{sub 2} at 5.5 MPa (800 psi) and 20.7 MPa (3000 psi); Fatigue testing (ASTM E647) ofmore » two best tensile test performers in H2 at 5.5 MPa (800 psi) and 20.7 MPa (3000 psi) with frequency =1.0 Hz and R-ratio=0.5 and 0.1.« le Document type: Report

Abstract

The two broad categories of fiber-reinforced composite liner repair and deposited weld metal repair technologies were reviewed and evaluated for potential application for internal repair of gas transmission pipelines. Both are used to some extent for other applications and could be further developed for internal, local, structural repair of gas transmission pipelines. Principal conclusions from a survey of natural gas transmission industry pipeline operators can be summarized in terms of the following performance requirements for internal repair: (1) Use of internal repair is most attractive for river crossings, under other bodies of water, in difficult soil conditions, under highways, under congested intersections, and under railway crossings. (2) Internal pipe repair offers a strong potential advantage to the high cost of horizontal direct drilling when a new bore must be created to solve a leak or other problem. (3) Typical travel distances can be divided into three distinct groups: up to 305 m (1,000 ft.); between 305 m and 610 m (1,000 ft. and 2,000 ft.); and beyond 914 m (3,000 ft.). All three groups require pig-based systems. A despooled umbilical system would suffice for the first two groups which represents 81% of survey respondents. The third group would require an onboard self-contained power unit for propulsion and welding/liner repair energy needs. (4) The most common size range for 80% to 90% of operators surveyed is 508 mm (20 in.) to 762 mm (30 in.), with 95% using 558.8 mm (22 in.) pipe. Evaluation trials were conducted on pipe sections with simulated corrosion damage repaired with glass fiber-reinforced composite liners, carbon fiber-reinforced composite liners, and weld deposition. Additional un-repaired pipe sections were evaluated in the virgin condition and with simulated damage. Hydrostatic failure pressures for pipe sections repaired with glass fiber-reinforced composite liner were only marginally greater than that of pipe sections without liners, indicating that this type of liner is only marginally effective at restoring the pressure containing capabilities of pipelines. Failure pressures for larger diameter pipe repaired with a semi-circular patch of carbon fiber-reinforced composite lines were also marginally greater than that of a pipe section with un-repaired simulated damage without a liner. These results indicate that fiber reinforced composite liners have the potential to increase the burst pressure of pipe sections with external damage Carbon fiber based liners are viewed as more promising than glass fiber based liners because of the potential for more closely matching the mechanical properties of steel. Pipe repaired with weld deposition failed at pressures lower than that of un-repaired pipe in both the virgin and damaged conditions, indicating that this repair technology is less effective at restoring the pressure containing capability of pipe than a carbon fiber-reinforced liner repair. Physical testing indicates that carbon fiber-reinforced liner repair is the most promising technology evaluated to-date. The first round of optimization and validation activities for carbon-fiber repairs are complete. Development of a comprehensive test plan for this process is recommended for use in the field trial portion of this program. Document type: Report