含水率对改输气态CO2管道焊缝接头腐蚀行为的影响及速率控制准则

Influence of water content on corrosion behavior of repurposed gaseous CO2 pipeline weld joints and corresponding corrosion rate control criterion

  • 摘要: 冗余油气管道改输气态CO2后,焊接接头因组织不均、残余应力集中及历史产物膜存在而成为内腐蚀最敏感的区域,明确不同含水率下改输管道焊缝接头的腐蚀演化规律及其控制机制,对制定改输管道的腐蚀速率控制准则具有重要工程意义。基于50 ℃、5 MPa气态CO2工况,设置含水率的摩尔分数分别为0.01%、0.04%、0.07%、0. 10%,采用失重法及显微表征手段,对新建与改输X65管道焊缝接头试样开展对比腐蚀试验,分析均匀腐蚀速率、腐蚀形貌及FeCO3生成行为,并结合腐蚀深度-壁厚比失效准则构建风险分级模型。在低含水条件下,当含水率不超过0.07% 且尚未形成连续水膜时,改输试样由于原腐蚀产物膜中存在孔隙与裂纹,易形成微电偶结构,其腐蚀速率高于新建试样。随着含水率升高至0. 10% 并形成稳定液态水膜,界面Fe2+浓度迅速达到过饱和状态,促进FeCO3沉积并填充膜层缺陷,使改输环境下的腐蚀速率反而低于新建环境。腐蚀产物形态由分散团簇逐步向连续覆盖结构演变,其中0.07% 可视为裂纹促进腐蚀向沉积控制转变的临界含水率。基于腐蚀深度-壁厚比失效准则,建立了改输气态CO2管道焊缝接头均匀腐蚀速率的风险等级标准。结果表明,为保证长期安全运行,焊缝接头腐蚀速率应控制在0. 12 mm/a以下,对应CO2含水率需低于0.07%。研究结果与现行管道内腐蚀控制标准技术要求具有一致性,可为改输气态CO2管道腐蚀控制与寿命管理提供依据。

     

    Abstract: When redundant oil and gas pipelines are repurposed for gaseous CO2 transport, weld joints become highly susceptible to internal corrosion due to microstructural inhomogeneity, residual stress concentration, and legacy corrosion product films. Establishing the corrosion evolution behavior and control mechanism of weld joints under varying water contents is essential for defining corrosion rate control criteria for these repurposed pipelines. Tests were conducted on newly-built and repurposed X65 pipeline weld joint specimens using the weight loss method and microscopic characterization. Under gaseous CO2 conditions(50℃, 5 MPa), water mole fractions were set at 0.01%, 0.04%, 0.07%, and 0. 10%, respectively. The uniform corrosion rate, corrosion morphology, and FeCO3 formation behavior were analyzed, and a risk classification model was established based on the corrosion depth-to-wall thickness failure criterion. Under low water content conditions(up to 0.07%) where a continuous water film was not yet formed, micro-galvanic coupling frequently occurred in repurposed specimens due to pores and cracks in legacy corrosion product films. Consequently, these specimens exhibited higher corrosion rates than newly-built ones. However, at 0. 10% water content, a stable liquid film facilitated rapid interfacial Fe2+ supersaturation, promoting FeCO3 deposition that healed film defects. Under these conditions, the repurposed pipeline corrosion rate fell below that of newly-built specimens. As the corrosion product morphology evolved from dispersed clusters to a continuous layer, 0.07% was identified as the critical water content for the transition from crack-accelerated to deposition-controlled corrosion. A risk classification standard for uniform corrosion rate in repurposed gaseous CO2 pipeline weld joints was established based on the corrosion depth-to-wall thickness failure criterion. The results indicated that to ensure long-term safe operation, corrosion rates must be maintained below 0. 12 mm/a, requiring CO2 water content to remain under 0.07%. These findings align with current internal corrosion control standards and provide a technical basis for the life management of repurposed gaseous CO2 pipelines.

     

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