Embed Size (px)
Citation preview
FIELD TESTS OF DUPLEX SYSTEM AT AN OIL & GAS COMPANY IN BRAZIL
Ricardo Suplicy GoesExecutive Manager
ICZ – Non Ferrous Metals Institute
1
Agenda
1. Introduction;
2. Players;
3. Aim;
4. Test consistence;
5. Overview;
6. Features of Assessments considered;
2
3
ICZ
VISION:TO LEAD AND SUPPORT THE SECTORS OF ZINC, NICKEL AND LEAD METALS IN THE DEVELOPMENT ANDDISSEMINATION OF THEIR APPLICATIONS AND SUSTAINABLE USE IN BRAZIL.
STRATEGIES
MARKETING AND PROMOTION
CONCERNING THE ADVANTAGES OF
USING NON FERROUS METALS.
TO CONGREGATE PRODUCERS,
MANUFACTURERS AND END USERS OF NON-FERROUS METALS TOWARDS THE
COMMON INTERESTS OF THE SEGMENTS.
REPRESENT THE SEGMENTS AND THEIR INTERESTS
TOWARDS THE INTERNATIONAL INSTITUTIONS,
GOVERNMENT AGENCIES, CLASS ENTITIES AND THE
MARKET.
1. Introduction;
Players:
• Galvanizers
4
FIELD TESTS OF DUPLEX SYSTEM AT OIL & GAS COMPANY – BRAZIL
• Coatings
• Oil & Gas Company • University • Institute
2. Players;
Aim
To outline for Oil & Gas companies that they may expect higher
anticorrosion performance by using Duplex System (painted galvanized
steel) more frequently in the marine coast environment, hence
demonstrating its superior performance.
5
3. Aim;
Performance comparisons, through corrosion rates, exposing 248 (199 plates + 49 others) samples in marine coastarea:
1. Uncoated carbon steel (30);
2. Uncoated galvanized carbon steel (33);
3. Uncoated Zinc Thermal Sprayed carbon steel (03);
4. Coated carbon steel (48);
5. Duplex System (painted galvanized carbon steel) (81) (including 03 not passivated with chromate);
6. Duplex System: (painted with surface pretreatment based on sulfursilane) (02);
7. Duplex System: (painted with surface pretreatment based on hybrid coating with silanes) (02);
8. Uncoated Galvanized screws (20);
9. Uncoated Galvanized wire (01);
10. Black (04) rebars / Galvanized (04) rebars ;
11. Black rebars embedded in concrete (08) /galvanized rebars (12) embedded in concrete;
6
4. Test consistence;
Performance comparisons:
7
COATING SYSTEMS
Epoxy Isocyanate+ Epoxy
Polyamide + PU
DTM AcrylicWater Base
Powder Coating
Carbon Steel
HDG Steel
Galvanized Screws
Galvanized Wires
Galvanized/Black Rebar
Thermal Spraying
Epoxy Amine(Damp Tolerant) + Epoxy Polyamide
+ PU
Epoxy Amine + PU
Epoxy Polyamide+ Epoxy
Polyamide + PU
SURFACE PRETREATMENT
Sweep Blast
Scotch-Brite
Sulfursilane
Hybrid (Silane)
Not Passivatedwith chromate
Degreased
SUBSTRATES
4. Test consistence;
Epoxy AmineMicaceous Iron
Oxide + PU
Planning:
Assessment of those 248 samples exposed in marine environment (near the beach and inland area);
Term: 03 years (NOV 2014 – NOV 2017);
8
4. Test consistence;
Time Visual ECORR (V) * Weight LossMeasurement
Corr. Rate Determination
Pull-off AdhesionTest
Every 3 MO
Every 6 MO
1st Year
2nd Year
3rd Year
* Only for rebars embedded in concrete
ABNT NBR 6209:2007 - Atmospheric Corrosion – Metallic Material – Outdoor Test;
ASTM D1014: 2009 - Standard Practice for Conducting Exterior Exposure Tests of Paints and Coatings on Metal
Substrates;
ABNT NBR 6210:2008 - Atmospheric corrosion - Metallic materials - Preparing, cleaning and determination of
corrosion rate of specimens in corrosion Tests;
ISO 9223: 2012 - Corrosion of metals and alloys - Corrosivity of atmospheres - Classification, determination and
estimation);
ISO 9226: 2012 - Corrosion of metals and alloys -- Corrosivity of atmospheres -- Determination of corrosion rate of
standard specimens for the evaluation of corrosivity;
9
4. Test consistence – Reference Standards;
ABNT NBR 14643:2001 - Atmospheric corrosion - Classification of corrosivity of atmospheres;
ISO 12944- 1 to 6 - Paints and varnishes -- Corrosion protection of steel structures by protective paint systems - Part
2:1998 Classification of environments / Part 5: 2007 Protective paint systems
ABNT NBR 15877 - Pull-off adhesion test
ISO 4624: 2002 Paints and varnishes - Pull-off test for adhesion.
ASTM C876 - 2009 - Standard Test Method for Corrosion Potentials of Uncoated Reinforcing Steel in Concrete
10
4. Test consistence – Reference Standards;
Categ. Corrosivity Corrosion Rate of Zn (µm/a)
Corrosion Rate of Iron (µm/a)
C1 Very Low < 0,1 ≤ 1,3
C2 Low 0,1 < vcorr ≤ 0,7 1,3 < vcorr ≤ 25
C3 Moderade 0,7 < vcorr ≤ 2,1 25 < vcorr ≤ 50
C4 High 2,1 < vcorr ≤ 4,2 50 < vcorr ≤ 80
C5 Very High 4,2 < vcorr ≤ 8,4 80 < vcorr ≤ 200
We expect to confirm the C5 category in the test area. By the
Brazilian ABNT NBR 14643 standard, it may be observed a zinc
corrosion rate of 4.2 to 8.4 micrometers per year. In contrast,
carbon steel features a corrosion rate of 80 to 200 micrometers
per year in the C5 category.
11
4. Test consistence;
• Local: Atalaia beach, Aracaju city. Sergipe state, Brazil (northeast).
• Latitude of Atalaia: -10,9880;• Longitude of Atalaia: -37,0534.
12
5. Overview;
2
1
Location:
Beach
UPGN.
(Natural Gas
Processing Unit.
1
2
13
Annual Environment Features:Temperature: 22º-30º Celsius;Relative Humidity: 60%;Precipitation: 52–334 mm; Wind Speed: 08-15 km/h –east;Chlorides Analyses:
FLARE(SO2)
5. Overview - Location;
ongoing (ASTM G140 Standard Test Method for Determining Atmospheric Chloride Deposition Rate by Wet Candle Method).
1
Beach1
14
5. Overview - Location;
1. Demonstrate the performance of Duplex System in the marine coast;
2
UPGN2
15
5. Overview - Location;
The samples on the beach area:
16
5. Overview - Samples;
The samples on the beach area:
17
RebarWire Coating UncoatedCarb. Steel
UncoatedHDG. Steel
Screws
5. Overview - Samples;
The samples on the beach area:
18
3 Panels with coated steel and Duplex System
5. Overview - Samples;
The samples on the beach area:
19
1 panel with carbon steel and 1 Panel with HDG steel
Carbon Steel HDG Steel
5. Overview - Samples;
20
Beach area: Identification of Samples with Laminated Tags:
LaminatedTags
LaminatedTags
5. Overview - Samples;
The samples on the beach area:
21
Concrete samples of HDG and Black rebar in concrete 1 Panel with samples of HDG rebar
1 panel with samples of “black” rebar
5. Overview - Samples;
The samples on the beach area:
22
Sample with galvanized wire and screws:
5. Overview - Samples;
PANEL D – BEACH AREA - 15 SAMPLES OF HDG STEEL
ICZ 02.11 ICZ 02.14 ICZ 02.17 ICZ 03.05 ICZ 04.05
HDG STEEL 1º YEAR
HDG STEEL 2º YEAR
HDG STEEL 3º YEAR
HDG Steel +Incision 0.5 mm
1º YEAR
HDG steel+Incision 2.0
mm 1º YEAR
ICZ 02.12 ICZ 02.15 ICZ 02.18 ICZ 03.06 ICZ 04.06
HDG STEEL 1º YEAR
HDG STEEL 2º YEAR
HDG STEEL 3º YEAR
HDG Steel +Incision 0.5 mm
2º YEAR
HDG steel+Incision 2.0
mm 2º YEAR
ICZ 02.13 ICZ 02.16 ICZ 02.19 ICZ 03.07 ICZ 04.07
HDG STEEL 1º YEAR
HDG STEEL 2º YEAR
HDG STEEL 3º YEAR
HDG Steel +Incision 0.5 mm
3º YEAR
HDG steel+Incision 2.0
mm 3º YEAR
Beach area: Samples of Galvanized (HDG) Steel (15) – Positioned on Panel:
23
HDG Steel
6. Features of Assessments considered;
The samples in the inland area: Carbon steel (15) and of Galvanized Steel (15):
24
2
Carbon Steel HDG Steel
6. Features of Assessments considered;
All the samples were scanned before the start of the tests:
25
ICZ 01.01Carbon SteelNov. 11, 2014
ICZ 02.02Galvanized Steel
Nov. 11, 2014
ICZ 142Coated Steel – s.p.t.
sulfursilane
ICZ 143Coated Steel – s.p.t.
sulfursilanewith a longitudinal
incision.
6. Features of Assessments considered;
The samples on the beach area: Visual analyses on March 05, 2015 – After the first three months.
26
6. Features of Assessments considered;
The Carbon Steel samples on the beach area: Visual analyses on March 05, 2015.
27
6. Features of Assessments considered;
First day of exposure After three months of exposure
The Galvanized Steel samples on the beach area: Visual analyses on March 05, 2015.
28
6. Features of Assessments considered;
First day of exposure
After three months of exposure
29
The Coated (Polyamide Epoxy) Carbon Steel samples on the beach area: Visual analyses on March 05, 2015 – After first three months.
PANEL 1: Samples will be taken out after 1st year
6. Features of Assessments considered;
30
The Duplex System (Polyamide Epoxy) samples on the beach area: Visual analyses on March 05, 2015 – After first three months.
PANEL 1: Samples will be taken out after 1st
year
6. Features of Assessments considered;
The Rebar in concrete samples on the beach area: Visual analyses on March 05, 2015 – After First threemonths.
31
Corrosion PotentialMeasurement
ECORR (corrosion potential)
HDG rebar: -793 mV “Black” rebar: -368 mV
6. Features of Assessments considered;
The Rebars samples on the beach area: Visual analyses on March 05, 2015 – After First three months.
32
6. Features of Assessments considered;
The Wire samples on the beach area: Visual analyses on March 05, 2015 – After first three months.
33
6. Features of Assessments considered;
The Galvanized Screws samples on the beach area: Visual analyses on March 05, 2015 – After first threemonths.
34
6. Features of Assessments considered;
35
FIELD TESTS OF DUPLEX SYSTEM AT OIL & GAS COMPANY – BRAZILFINAL CONSIDERATIONS
• After three months of field tests, we can evaluate that the uncoated carbon steel
samples is already corroded and the coated carbon steel showed some signals of the
beginning of corrosion process.
• The idea to use Duplex System samples coated with surface pretreatment based on
sulfursilane and on hybrid coating with silanes is to analyse its performance due to the
fact that they present organic and inorganic precursors that can substitute the chrome
hexavalent as passivation in the HDG process.
• The Duplex System samples showed an extraordinary performance in this period.
Players Participants
• Galvanizer Armco Staco Ms. Renata Yuriko Ogura;
• Galvanizer Marangoni Maretti Mr. Paulo Cesar Maziero Tiano;
• Paint Company Sherwin-Williams Mr. Celso Gnecco / Mr. Roney da Silva Granja;
• Petrobras Mr. Marcelo Schultz, Corrosion Consultant (E&P Inspection Engineering);
• University of São Paulo Prof., PhD Idalina Vieira Aoki (Electrochemistry and Corrosion Laboratory).
• ICZ Mr. Ricardo Suplicy Goes – Executive Manager
36
FIELD TESTS OF DUPLEX SYSTEM AT OIL & GAS COMPANY – BRAZIL
37
Thank you for your attention!Ricardo Suplicy GoesExecutive Manager
E-mail: [email protected]: 55-11-3214-13-11
