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Prediction of Optimal Process Parameters in Tribocorrosion Inhibition of Steel Pipes Using Response Surface Methodology

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Abstract

Wear corrosion is a significant problem impacting the lifetime of steel pipes used in hydraulic fracturing operations. To improve the lifetime of these steel pipes, the present work examines the effect and optimization of three propriety corrosion inhibitors (Dynarate, DWP, and CalGuard), as well as their concentration, on the tribocorrosion behavior of AISI 4715 steels used to carry fracking liquid from their storage pool to the geological formation. The wear and corrosion behavior of AISI 4715 steel was investigated using a reciprocating tribometer integrated with a three-probe electrochemical apparatus. Response surface methodology (RSM) was applied to statistically model the effects of various concentrations of Dynarate, DWP, and CalGuard, along with their combinations, on the average coefficient of friction (COF), as well as the total wear loss of the steel and optimize them. The overall results revealed that Dynarate significantly decreased the COF (0.147) and wear rate (0.3 mm/year) with an inhibition efficiency of 480% at a concentration of 1%. To investigate the effectiveness of the regression model at predicting the wear rate, the samples were characterized using 3D optical profilometer and scanning probe microscopy to describe the effect of various additive on the surface morphology of steel. The surface topography measurements indicated the worn regions for the samples where the Dynarate additive was used were smoother compared with those having the DWP and CalGuard additives.

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Data Availability Statement

All data used in this paper are presented and any other information related to this will be made available upon request.

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Acknowledgements

The authors would like to acknowledge the financial support from the Natural Sciences and Engineering Research Council (NSERC) Engage and Discovery Grants. Additionally, funding from the Alberta Innovates Technology Futures (AITF) Campus Alberta Small Business Engagement (CASBE) is also acknowledged. B.W. would also like to acknowledge the funding through the Queen Elizabeth II Scholarship Program. The authors would also like to thank Calfrac Well Services Inc., specifically Tom McLoughlin and Keri Yule, for supporting the project, providing the test samples and additives, as well as providing valuable input on the project.

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Authors and Affiliations

  1. Department of Mechanical and Manufacturing Engineering, University of Calgary, Calgary, Canada

    Jitendra Narayan Panda, Edwin Yanez Orquera, Brandon Christopher Wong & Philip Egberts

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  1. Jitendra Narayan Panda
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  2. Edwin Yanez Orquera
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  3. Brandon Christopher Wong
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Correspondence to Jitendra Narayan Panda or Philip Egberts.

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Appendix

Appendix

Figure 12 shows optical microscope images of the sapphire counter surface. All of these images showed no wear or debris build-up following sliding experiments. Thus, the same counter surface was used in each experiment.

Fig. 12
figure 12

Optical images of two sapphire counterfaces a, b before tribocorrosion experiments and c, d after tribocorrosion experiments

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Panda, J.N., Orquera, E.Y., Wong, B.C. et al. Prediction of Optimal Process Parameters in Tribocorrosion Inhibition of Steel Pipes Using Response Surface Methodology. Tribol Lett 69, 73 (2021). https://doi.org/10.1007/s11249-021-01441-x

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