Lichti

SELECTION AND USE OF MATERIALS FOR GEOTHERMAL ENERGY APPLICATIONS

USING COMPUTER BASED TECHNOLOGY

Keith A Lichti

Industrial Research Limited

PO Box Lower Hutt, New Zealand

Key Words: materials, expert systems, database, modelling

Abstract Advice on the and use of for new and assessment has been completed and the is judged to
geothermal energy applications in New is based on outside the range of well parameters, corrosion tenting
knowledge and experience gained over several years of field testing will also typically involve the of computers for insvument
and research on exposure to geothermal fluids. Some of control, datu logging and data modelling.
this knowledge has been captured i n computer based systems, these
include: a database of metal corrosion results, a listing of archived An essential premise for capture of corrosion control technology is
publications and reports, a modelling programme which describes the need for data evaluation. (Lichti and Wilson, 1990) The process
corrosion diagrams) and an expen system of data (Anderson,
which provides interpreted materials advice for typical plant assessing accuracy and reliability
resultant computer programmes are combined
under a Windows based user interface to permit free movement . assessing techniques
comparison with other experimental
associated errors
theoretical values
between the programmes throughout a materials consultation. recalculating derived results and accepted models
. comparison with service experience
INTRODUCTION comparison with current industry practice

The of computers for transfer corrosion control technology . selective acceptance and statistical manipulation
assignment of probable error reliability.
began with abstract storage and searching programmes in the 1960's
and 1970's. The use of computers in more direct corrosion control Information and data collections require evaluated data whereas
applications also increased dramatically over this same time period computer based systems which give advice must be bared on data
and into the Table lists applications-oriented computer which has not only been evaluated but also interpreted and placed
systems for data logging, database tabulation and modelling of in context for a particular application.
corrosion data which have become standard tools corrosion
control technologists. systems, neural networks and hypertext In addition, successful development and application of computer
systems which are applications Artificial Intelligence research are based systems for corrosion technology transfer must include:
also being used for corrosion control technology. (Lichti and Wilson, models for capturing corrosion expertise
1990) quality assurance systems for assessing the validity of any
computer model results and any provided advice for a
Table Computer applications for of corrosion control defined application
technology.
. a suitable procedural modcl for of the technology
a suitable user interface to provide access to the technology
and to generate required reports.
Abstracts and Text Searching
. corrosion and materials information This paper describes the current status of a methodology for
providing advice on selection and use of materials for geothermal
Dam Logging
corrosion and calculations energy applications using computer based systems.
Database Information Systems
data storage, manipulation and reporting 2. STRUCTURE OF GEOTHERMAL CORROSION AND
Modelling KNOWLEDGE
corrosion process modelling
Expert Systems Domain knowledge for materials in geothermal energy systems must
materials selection and performance advice be drawn from differing types of data and Figure
Neural Networks illustrates the of materials knowledge relating to geothermal
data evaluation and corrosion with the central region representing which may be
Hypertext and Advisory Systems captured using computer based technology.
combined text (book) searching, case histories, databases,
and expen systems 2.1 Corrosion Results

Geothermal corrosion results are available in published papers and

reports and also in many private company archives. Published results
will have had a of data evaluation but the use of such results
The capture of geothermal corrosion expertise using computer based provision of advice for new applications generally requires added
technology can involve many of the applications listed in Table interpretation. Company archives can include:
The specification materials and limitations on use for listings and collections of published papers and conference
geothermal energy applications is a mature technology. Procedures
for assessing corrosiveness and data on which to judge the suitability
of materials are available for many situations. Where a corrosiveness
. proceedings dealing with geothermal corrosion results
listings and collections of confidential reports and
communications on geothermal materials

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Figure 1: Structure of
gmthermal corrusion knowledge
which can be captured using
computer based technology.

%,/-
In-house results from corrosion experiments can be critically 2.4 Corrosion Models
reviewed by evaluation process and tabulated i n simple
spreadsheets or they may be into a computer searchable large range of practical engineering models have been developed
database. Knowledge gained from the collected and evaluated results for describing performance i n geothermal energy systems.
be incorporated in advisory systems, but again, only after it is lhese models are based on corrosion results gained from historical
interpreted for a situation. types ofcorrosion experiments which give a snapshot of the progress
of corrosion over period of exposure wcll as results from on-
2.2 Corrosion Experience line corrosion probes which follow the progress of corrosion. (Lichti
et Lichti and Wilson, 1993, Lichti et
Geothcrmal corrosion experience includes both successes and
failures. Materials performance within an operating plant will depend Theoretical models of processes such an potential-pH
aspects of environment. plant design and operation practicer such (Pourbaix) type diagrams also available for the
as shutdown and procedures. The practical extension reactions expected to occur carbon steels exposcd to geothermal
of this experience to new situations also requires the application of environment. (Wilson and Lichti, 1982) The production these
critical evaluation and interpretation practices to reliability. diagrams can be automated using computer. The diagrams provide
Collecting and archiving experience in power stations is a useful means of equilibrium chemistry
not a exercise hut can he simplified by the application of a for corrosion reactions; for the equilibrium system the
realistic life extension programme such as that outlined by Lichti et thermodynamically stable solid specics illustrated in 2.
al The formation of solid species (such as those Seen
on the diagram i n the neutral range below the
Corrosion experience for individual plant items can he captured i n equilibrium line) next to the corrading metal surface provides the
a database or the gained can be funher interpreted for passivating mechanism which limits corrosion. et
more general application using an expen system. 1982. Wilson and Lichti, 1982)

2.3 Corrosion Environments 3. SYSTEM

Knowledge of the environment experienced in geothermal plant and A based system been developed as an in-house aid for
equipment and also the environment present in vessels used to test the provision of materiais performance advice for geothermal energy
materials performance is critical of corrosion applications. The system consists the fallowing: an
results and corrosion experience to new environments. In many expert system for provision of interpreted advice selection and
situations the measured environmental parameters such as a programme for calculating data for
gas content of steam cannot be directly related to potential-pH diagrams and a database of surface results
corrosion processes and calculation of theoretical corrosion obtained in tests at Broadlands well Access is also provided
chemistry is required. Direct measurement of corrosion parameters to of company archived reports and published papers. These
such as condensate and corrosion potential in pressurised systems are accessed via a user interface, which
are difficult. New techniques are being developed to provide provides selection buttons for the programmes in a single window
more direct measurement of corrosion parameters to reduce reliance and gives help and guidance the of the
on theoretical models. et 1992 screen design for is shown in Appendix (The
system has not been developed for sale but as research
of high temperature corrosion chemisuy is based on and consulting aid.)
chemisuy models which can be automated using computers. Models
may be implemented in stand alone applications or into
other programmes such expert systems. (Lichti and Wilson, 1990)
The results of these models can be used to compare differing Research Limited, New Zealand
geothermal systems and plant with the proviso that
means of independently verifying the validity of the results is
Windows, Microsofr USA
available. (Lichti and Wilson, 1993)

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3.2 Potential-pH Puurbaix Prugramme

A programme by Chen et for calculating

potential-pH Pourbaix diagrams has bcen adapted for use in this
system. The programme uses a data input file which the
calculation temperature, total sulphur concentration, a listing of the
solid and dissolved spccics to be cansidered together with their
thermodynamic data. input data files are unique for each
combination of conditions which is to he considered.
Thermodynamic data for normally encountered in geothermal
applications have k e n researched, tabulated and reviewed. (Johnson,
1993) The programme generates two output files; one containing a
listing of the reactions considered with those having the lowest
free highlighted, second provides set of coordinates for
drawing the diagram.

A developed programme, reads the Pourbaix

output files and gencrater graphic of the diagram
on computer screen. T h i s is captured using the
programme, and can be further
to providc a report quality diagram.

3.3 Relational Database Fur Data

Corrosion testing results available in New Zealand for

geothermal fluids derived from
Kawcrau and for a high environment typical
of the Ngawha geothermal field. Corrosion have k e n
calculated for these and other fields. Much of this data has k e n
incorporated into engineering and models which allow
results and to new applications.

The basic building blocks for these model, is the data. It is

essential that this data be evaluated and archived in a formal manner
which permits other scientists review the data and allows new
data to be added without revision of the bare system.

A database systcm has developed using ParadoxT' 4.5 far

Windows". The original DOS-based user interface (Mcllhone and
Lichti, was been abandoned in favour of the Windows bascd
system with a small of searching and reponing options. The base
system has been loaded with surface corrosion results for ASTM
type coupons exposed at Facilities capturing
historical corrosion results from an-hne corrosion monitors have
been added to date.

3.4 Archived Publications and

Published literature describing New research and experience

materials selection has been and
"Corrosion File". and Lichti, A listing of authors
and titles is available for simple word searching. Copies of the
are bound to provide ready access for system users.
Reports generated in the course of providing advice an materials
selection and use for energy applications provide a
valuable history of problems and solutions. "corporate"
information company records of this type is seldom
collated, summarised published because of its confidential
nature. In this instance a separate collection of these
reports has been made, however, has of necessity k e n
restricted.

3.5 Knowledge and Computers

Selection of a computer based technology for capture and transfer of

knowledge will depcnd on (Lichti et al, 1993):
the nature of the technology
the available expertise
the needs of the
SNAP, USA
the time and budget available for development
Corporation. U S A
. the versatility and complexity of the software
the cost of the software
Paradox, Inc, USA the requirements for development and delivery.
 Lichti
No single method provided the scope of knowledge capture required description of planned engineering plant
for the system and a combination of products anticipated utilisation environments.
evolved to meet the needs the application.
When differences exist which are beyond the scope of the current
The pmesses used for the capture of knowledge in computer based knowledge, corrosion testing or examination of existing plant is
systems differ for differing applications. Procedures for developing required before advice be provided.
databases (Mcllhone and Lichti, and knowledge capture
models for the development of expert systems are available. (Lichti 4.2 Consider knowledge base
and Cradwick, et al, 1992) The use of
based systems aids users through pmvision of graphical user The knowledge base for geothermal materials selection and use is
interfaces which simplify access to the extensive. Published and unpublished results can be searched for
relevant data, Broadlands well BR22 are
The systems described here were developed using a team approach. accessible from user inrerface window as a
Team contributions are required from domain experts, (Lichti and searchable listing of geothermal and reports. Existing
Page, system engineers, 1994) models describing corrosion mechanisms can be reviewed to
and programmers (Cmdwick and Lichti, 1994). In this instance the establish their relevance. Theoretical
principal are also the system users but systems developed d i a g r a m are included in rhe expert system bur where rhe
for use by non-experts would require user input the have not been previously defined user action rhe for
development. calculating and diagram from user
inrerface window. Practical experience gained in solving similar
4. PROCEDURES FOR PROVIDING ADVICE plant metallurgical and corrosion problems provide "rules of
which can be applied to the new problem. Rules of rhumb and
A philosophy for provision of advice on materials in geothermal derived advice for many are in expert system.
energy systems has been documented and used in practice for a Whenever possible existing corrosion models and mechanism are
number of applications. (Wilson and Lichti, 1982) The procedures used to describe the new environment. The experr provides
followed assess new environments and to evaluate the validity of hisrorical of planr and marerials as well as on rhe
current knowledge for new applications have been partially use of rhe or the control of rhe environment. The work
automated using the computer based systems described above. of providing some means of quality assurance for the advice
Appendix 1 describes these in greater detail with reference to the provided by the expert system and making an initial lifetime
programmes being used, The procedure is based on knowledge of prediction must he made by the system user by for example
common materials selection and usage practices such as one would consulting all referenced documents contained in the "Corrosion
find in a materials standard as well as an extensive database of File" archives. (Lichti et In theory, all of the information
results and models corrosion developed to describe the used by the system will be essible for the user to independently
mechanisms of corrosion. (Lichti and Wilson, 1993) The computer review if any aspects in doubt.
programmes have becn developed to assist experienced corrosion
engineers to provide the required the advice. (Attempts to promote Recommendations must of necessity be based on the best available
the development of a materials standard for geothermal energy information at the time of the consultation. In those instances where
applications have not been successful. (Wilson 1987)) this is of a questionable quality then it be necessary to monitor
the progress of corrosion in full size plant or to conduct additional
Firstly, a theoretical assessment of the likely corrosion chemistry in field or laboratory research to further define the corrosion
the proposed energy utilisation system is advocated, mechanisms.
testing being undertaken only where the new environment is
significantly different from those for which corrosion data 5. CONCLUSIONS
available. Secondly a critical review of the existing knowledge base
is required define the materials advice which can be recommended A series of computer based aids for selection and use of materials
as well as any additional caveats which apply to the new field. for geothermal energy systems, have been brought
together in a single Windows based user interface:
4.1 Assess corrosiveness expert system for chemistry calculations,
corrosiveness assessment and historical materials advice
Initial assessment of corrosiveness of a geothermal field can be potential-pH Pourbaix diagram programme for modelling
based on the reported and on the corrosion chemisny corrosion and to draw the diagram
calculated derived from the geochemistry. Comparison of ParadoxTM database of evaluated surface corrosion
corrosion of new fields with those of existing fields for searchable listings of corrosion publications and reports
which corrosion data is available, can permit an estimate of the relating to selection and use of materials for geothermal
corrosiveness of the new system. The chemistry and energy applications.
comparison of corrosiveness done using rhe expert
sysrem. In many instances the corrosion data available for previously The custom user interface provides ready access to the required
tested geothermal environments can be applied the new programmes and gives guidance on their use. Experienced corrosion
environments, with suitable caveats, and additional corrosion testing engineers can use the system without the need to be intimately
is not required. The experr system provides series known familiar with the large database of results and knowledge
where significant differences exist there may available for geothermal energy applications.
justification in conducting tests which aid in determining the caveats
which must be applied to the existing knowledge base. 6. ACKNOWLEDGEMENT

The experr system is based on The author acknowledges the financial assistance of the New
calculated steam chemisnies Zealand Foundation for Research Science and Technology in the
condensate preparation of this paper.
total in solution
separated water chemistry
high temperature
7. REFERENCES
corrosion on carbon steels
corrosion product type Anderson, D.B. corrosion data. ASTM
properties of corrosion products Symposium Corrosion Testing and Evaluation.
 Lichti

M., Lichti, K.A. and Wilson, P.T. (1982). The Lichti, K.A.. P.G.H., Cradwick, P.D. and Page. G.G.
relationship between corrosion products and corrosion rates in system for materials performance advice.
geothermal steam. in Proc of Pacific Conference No Computers in Corrosion Control.
incorporating 4th New Zealand Geothermal Workshop, Geothermal Volume 3, NACE
Institute, of Auckland, pp
Lichti, K.A., Cmdwick, P.D. and Aldous, K.J. Guidelines for
Chen, C.M., K. and G.J. the of applications for expen systems. 5th New Zealand
diagram Power Research Institute Materials Symposium. Engineering Materials Group, IPENZ. Lower
Repon by and Co, June. New Zealand, paper no

Cradwick, P.D. and Lichti, K.A. The role of the Lichti. K.A., D.M. and Wilson, P.T. (1993). Lifetime
in expen systems development. Paper N o 379 in predictions for critical plant in geothermal energy systems. in
Computers in Corrosion Knowledge Based Systems, eds of 15th New Zealand Geothermal Workshop, of Auckland, pp
P.R. Roberge, P. Mayer and W.F. NACE International. 81-86.

Inman, M.E., Sharp, R.M., Wright, G.A. and Wilson, Lichti, K.A. and Page, G.G. The role of the expen in
Development of erosion-corrosion test facility for geothermal devrlopment of materials expen systems.
steam condensate. in 14th New Geothermal Workshop. Paper No 369 in Corrosion Control Knowledge
Geothermal Institute, of Auckland, pp Based Systems, eds P.R. Roberge. P. Mayer and W.F. Bogaens.
NACE International.
Inman, M.E., Sharp, R.M., Wright, G.A. and Wilson, P.T. (1993).
Predicting protective film behaviour on carbon steels. i n Proc Lichti, K.A. (1994). The role of the system
15th New Zealand Geothermal Workshop. Geothermal Institute, engineer in the development of materials performance expen
of Auckland. pp systems. Paper No 383 in Computers in Corrosion
Knowledge Based Systems, edn P.R. Roberge. P. Mayer
Johnson, C.A. (1993). guide 'Pourbaix' for and W.F. Bogaens, NACE
Pourbaix diagrams. Industrial Research
Internal Repon 18013.31. Lichti, K.A., Johnson. C.A., Mcllhone, P.G.H. and Wilson, P.T.
of iron-nickel base and titanium alloys in aerated
Lichti, K.A., S. and K.D. geothermal fluids. submined to World Geothermal Congress,
Geothermal corrosion and corrosion products. in Roc New Zealand Florence, Italy, May.
Geothermal Geothermal Institute. of
A.N. and Lichti, K.A. Corrosion File,
Revision 4. Confidential DSIR Development Repon
Lichti, K.A. and Wilson, P.T. Materials testing i n geothermal No June.
steam. in Proc of Symp on Solving Corrosion and Scaling
Problems in Geothermal Systems, Francisco, USA, NACE P.G.H. and Lichti, K.A. Database for materials
International, pp in geothermal fluids. 13th New Zealand Geothermal
Workshop, Geothermal Institute, of Auckland, pp
Lichti, K.A. and Wilson, P.T. Geothermal materials advisory
system. 12th New Zealand Geothermal Workshoo. Geothermal Wilson, P.T. and Lichti. K.A. Assessment of corrosion
Institute, of Auckland, pp Performance of construction materials. in Proc of Pacific Geothermal
Conference incorporating 4th New Zealand Workshop,
Lichti, K.A. and Cradwick. P.D. Expen systems Institute, of Auckland, pp
technology transfer. Proc of 7th Asian-Pacific Corrosion Control
Conference, International Academic Pub, China, pp Wilson, P.T., Lichti, K.A. and Wells, D.B. Materials
selection for geothermal developments, the need for materials
standard. in New Zealand Workshop,
Appendix I: System Consultation Procedure Geothermal Institute, of Auckland, pp

Appearance

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System Consultation Advice Displays
Risk of corrosion
1. Known Chemistry Materials options
Historical listing
Experienced users of rhe system will know rhar besr An indication of the need for more expertise
resulrs are obtained georhermal phase gas chemistry is
known. gas phase chemistry is not known, expert system 3. Potential-pH Pourbaix Diagram Programme
will accept of corrosion characteristics.
Steam Phase Gas mol The data be and evaluated for rhe desired
The and species io be considered
be specified input file
NH,, H,, HCI, Residual gases ie
and N,, 0, to judge the risk of the sample having been . Input Data File
exposed to air Total T,
Temperature Data (he-Evaluated)
Pressure
While Pourbaix programme is running generared
2. Expert system operation is displayed on rhe
Output Data Files
Clicking rhe expert burton the expert . List of equations and co-ordinates for lines on the
inrerface programme. of knowledge base requires diagram
access. Expert the User. A separate listing of co-ordinates for lines on the
User enters area and plant of interest diagram
User enters physical conditions
User enters gas phase 5. PBpaint

uses a model to determine chemical This programme takes the output files the
composition in equilibrium wirh programme, birmnr graphic of and sends
phase. output of steam condensate chemisrry and Windows''' Clipboard ir be picked by
parameters used to chemistry paramerers
are on screen. from Pourbaix output files
Summary Of All On Request Output diagram in bitmap window on screen
Required Parameters: Total T, Transfer diagram to Clipboard

The above required parameters used to assess rhe tendency of 6.

rhe high temperature firm corrosion products
on carbon steel through an poienrial-pH diagram. The user is offered use to add
Sir diagrams which describr New Zealand geothermal are and change the of species labels.
available within rhe experr sysrem.
. diagram Cliphoard
Add comments and revise text
is similar to one rhese, diagram Print the diagram (see Figurc 2 i n text)
is presented to user screen. If the conditions are outside
the range into rhe then The added the expert using rhe
values and rhe experr run the expert
programme generare required diagram.
Potentid-pH diagram built into expert system or 7. Database
Potential-pH diagram generated for the conditions (see Step
3 below) The can be at any time throughout
consultation.
built into the expert are provided wirh a set of Surface corrosion of metals and alloys tested at Broadlands BR22
mouse operated cross to assist user in determining the materials tested
corrosion for and read. standard alloy composition
from rhe diagram, the of solid corrosion . exposed allay analysis
products and the free corrosion region the theoretical test type descriptions
corrosion (see Figure 2 in The requires surface corrosion
this detail approximate the and the coupons
tendency for erosion-corrosion. resistance probes
Input Pourbaix diagram Linear Resistance
Corrosion potential at the calculated test environments
Corrosion product stability vessel designations
of free corrosion area at corrosion potential physical conditions
chemical conditions
The risk of corrosion is defined by experr and relevanr exposure times
advice files are displayed to rhe user. The user is able to enter corrosion results
custom advice which will be displayed rhe system advice description of corroded samples
whenever same of rules are corrosion product analysis

.
Output and Displays
Summary Option
User entered Values
material gain due scale or corrosion product formation
material loss due corrosion
corrosion based linear extrapolations
System inferred values description of form corrosion
Internal calculations pitting and crevice corrosion depth attack
Model outputs maximum depth
Definition corrosiveness mean of deepest pits

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