EXPERIENCE IN TECHNICAL COOPERATION BETWEEN INDUSTRIES AND RESEARCH INSTITUTES. Carlos Alexandre Martins

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1 EXPERIENCE IN TECHNICAL COOPERATION BETWEEN INDUSTRIES AND RESEARCH INSTITUTES Carlos Alexandre Martins March, 2011

2 Petrobras experience with the Institute for Research and Technological, particularly with the Corrosion and Protection Laboratory of IPT. Some studies were done in the past, in a case by case basis. At that time, no partnership were in force. From 2001, a strong interaction between IP and Petrobras took place, due an increasing of demand for tests on new materials, ultra deep water operations and the pre-salt. Petrobras R&D Corrosion Group start to establish a partnership protocol with IPT. From that time on, about 50 projects have been developed (or in development) for Petrobras, most of them coordinated by CENPES. Some of them will be presented.

3 2001 PROTECTIVE COATING FOR METALLIC SURFACES, DEEP WATER APPLICATION Objective Since Cadmium based coating presented toxicity problems as well as environmental issues, Petrobras decided to study alternative coatings to replace cadmium on this application. It was the first project developed together with Petrobras and IPT, with Finep s sponsorship. Many other projects came

4 INTERNAL CORROSION MONITORING on PIPELINES The internal corrosion monitoring is one of the priorities of the transportation system of petroleum and its by products. The Corrosion and Protection Lab was qualified to work in this area and to support Petrobras activities Today, Petrobras and IPT technicians provide a training program for companies for carry out these activities in the field. As a result of this project, a very specialized Laboratory of Internal Corrosion for Pipelines (LACID) was conceived and established.

5 LACID - LABORATORY OF INTERNAL CORROSION FOR PIPELINES Presently, all corrosion inhibitors screening tests for Petrobras downstream pipeline system are performed at LACID. LACID is a reference Laboratory for spindle testing (based on NACE TM-0172) to evaluate corrosion inhibitors performance for derivative pipelines.

6 FLOATING LAB TO STUDY COATINGS FOR CORROSION PROTECTION IN OFFSHORE ENVIRONMENTS. New technologies for coatings including No-VOC and antifouling coatings. Today, we are able to test new technologies on coating for marine and offshore environments.

7 STUDY OF AC CORROSION IN PIPELINES INSTALLED IN CORRIDORS (Right t Of Way) WITH ELECTRIC TRANSMISSION SYSTEMS. AS RESULT, A NEW METHODOLOGY AND EQUIPMENT TO VERIFY THE PROBABILITY OF AC CORROSION IN BURIED PIPELINES WERE DEVELOPED. PATENT REQUESTED

8 STUDIES OF CREVICE CORROSION RESISTANCE OF SPECIAL ALLOYS DUPLEX SS, SUPER DUPLEX SS AND CU-NI ALLOY For application in immersion conditions

9 CORROSION CONTROL IN PETROLEUM TRANSFER SYSTEMS FOR DERIVATIVES AND BIOFUELS (ETHANOL AND BIODIESEL)

10 CATHODIC PROTECTION SYSTEM OF PIPELINES AND TANKS EXPOSED TO MEDIA CONTAINING BACTERIA According to the existing literature, the bacteria interfere in the cathodic protection systems, but the effects are not well known so far.

11 COATING TESTS FOR OIL SEPARATOR TANKS - OFFSHORE ENVIRONMENT As result, a new Petrobras standard was created and it will possibly become an ISO standard.

12 There are some reports in the literature regarding pipeline damages associated to LIGHTNING STRIKES. A Work Group was created (Petrobras and IPT), in association with IEE-USP, to study the effects of lightning strikes over the pipeline transfer system for oil and its derivatives.

13 Corrosiveness of sulfuric acid (93-98)% on carbon steel ASTM A36 and API 5L GR B and austenitic stainless steels and Alloy 20 3/6L Utilization of sulfur from the refining exhaust process to produce sulfuric acid. The Corrosion and Protection Lab is working together with Petrobras to design a system for storage and transportation of sulfuric acid.

14 TWO NEW SUBJECTS WILL SOON BE STARTED The study of metallic materials in an environment of high concentrations of CO2, H2S and O2 contamination. Selection of corrosion inhibitors for systems of oil and gas production.

15 TECHNICAL PAPERS In addition to these projects, 45 technical paper were published and/or presented, such as: Protective coating for metallic surfaces, deep water application Cadmium coating alternatives for fasteners applied in offshore oil production. Main influence factors on corrosion resistance of autocatalytic nickel-phosphorus Corrosiveness Spindle Test based on NACE Standard NACE TM-0172:2001- A Critical Analysis The influence of the added water s ph on the NACE spindle test for the determination of corrosive properties of gasoline and derivative fuels.. Proposal of mechanism and corrosion predictive criteria for AC corrosion in buried pipelines. Improvement of the NACE spindle test to determine the corrosive properties of gasoline and derivative fuels.. Effect of alternating current from high voltage lines and electric transmission systems in pipeline corrosion.

16 The effect of naphtha physicochemic parameters in its corrosivity. Corrosion by concentrated sulfuric acid in carbon steel pipes and tanks/state of the art. A new thermodynamic criterion and a new field methodology to verify the AC corrosion probability in buried pipelines. Theoretical study with macro cells corrosion on exposed carbon steel frames in concrete structures. Effect of Inert Gases (pure Nitrogen, Nitrogen and Carbon Dioxide mixtures) on the corrosiveness of anhydrous ethanol (E100). Evaluation of AC corrosion in pipelines buried using a new AC PROBE. Evaluation of organic coatings in tropical marine environment. Pitting occurrence in CS weight loss coupons for corrosion monitoring in pipelines. Coating tests for Oil Separator Tanks at Offshore Environment

17 Further, several technical meetings, training and symposiums for Petrobras are carried out in IPT facilities. Petrobras has an office in the Corrosion and Protection Laboratory. New technologies and equipments developed by industry related to corrosion monitoring are evaluated by IPT Laboratory of Corrosion.

18 Petrobras has select the IPT corrosion group as one of its partners and already invested a large amount of funds to expand IPT s infrastructure and facilities through the Thematic Network of Technology, Materials and Equipments for Corrosion Control.

19 VIELEN DANK Carlos Alexandre Martins