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The life of offshore jacket structures can be extended up to 30 years towards the end of their design life by retrofits. For larger structures, and in unusual cases, semi-remote ICCP anode sleds are a favorable option compared to sacrificial anode cathodic protection (SACP) due to the high current output from each individual installation, reducing the time to install substantially. Anode sled locations are determined based on site plans, experience, survey data, and equations evaluating “remoteness” or “voltage rise” criteria.
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Safe and stable operation of the process plant through its life cycle is an ultimate target of any integrity management system. Over the last decades, a number of possible ways and systems for managing plant integrity were described and implemented.1-4 A common path for all those efforts was to control and manage corrosion processes in a more-or-less systematic way by applying certain measures (monitoring techniques, material selection guidelines, operating procedures etc.) and performance indicators (remaining time-to-failure, inhibitor usage etc.). An effective corrosion and integrity management system, in theory, should be capable to “uncover” excessive corrosion incidents before serious damage occurs. Unfortunately, unexpected corrosion-related failures are still occurring in the petroleum industry.5 This situation stems predominantly from relatively poor data organization and management, leaving corrosion and key process information spread and hidden across different refinery functions and systems.
Stress corrosion cracking (SCC) of Type 304 stainless steel (304 SS) in elevated temperature (288 °C) high purity water is typically an intergranular (IG) process with cracks propagating along grain boundaries, which are mesoscopic entities relevant on the grain scale. It follows then that the nature of the grain boundaries plays a significant role in SCC. In fact, for IG SCC to occur three things must be present: 1) stress; 2) a corrosive environment; and 3) susceptible grain boundaries. SCC growth rate (SCCGR) equations for 304SS in high temperature, high purity water, test orientation, temperature, material composition, and sensitization.
In Corrosion/2021, the authors introduced a molecular mechanistic model that quantifies and predicts SNAPS corrosion rates. During Corrosion/2022, we presented the mechanistic corrosion prediction framework describing the molecular basis of the model’s reactions, kinetics, and mass transport of ROSC to vessel walls. In this molecular model, sulfidation corrosion is calculated for direct heterolytic reaction of ROSC with solid surfaces.
In Corrosion/2021, the authors introduced a molecular mechanistic model that quantifies and predicts simultaneous naphthenic acid and sulfidation (SNAPS) corrosion rates. During Corrosion/2022, we presented the mechanistic corrosion prediction framework describing the molecular basis of the model’s reactions, kinetics, and mass transport of reactive organic sulfur compounds (ROSC) to vessel walls. In this molecular model, sulfidation corrosion is calculated for direct heterolytic reaction of ROSC with solid surfaces.
The gap between fully immersed and ultra-thin film electrochemical measurements is wide, which suggests that the two conditions are independent of one another. There is a lot of work describing experiments, results, and trends regarding completely immersed electrochemical tests. However, in corrosion tests under thin electrolyte films, the information is not so abundant. A classical three-electrode cell used in conventional electrochemical tests cannot easily be scaled for immersion in electrolytes of micron thickness.
As previously reported, the gap between electrochemical measurements for systems under bulk conditions and those under thin film layers of electrolyte is still important. Under thin film layers, it is not straightforward to take advantage of the typical three-electrode cell to electrochemically characterize a metallic surface under corrosion. Only a few localized electrochemical techniques are able to achieve measurements under thin films of moisture. It is important to bear in mind that the mechanism for corrosion under thin films is fully different from corrosion on bulk electrolytes and it is not valid to predict the behavior of the former system by extrapolating the latter.