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This paper focuses on the risk of corrosion of austenitic stainless steels following exposure to oxygenated chloride containing waters, such as during hydrotesting or commissioning activities.
Hydrotesting is an activity typically occurring during construction intended to confirm the component's structural integrity for the design and operating pressure. The commissioning phase can use the same water in multiple systems for dynamic commissioning.
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Thanks to their good corrosion resistance and ease to shape and weld, austenitic stainless steel grades (e.g. UNS S31603) are used as standard materials for the construction of municipal wastewater treatment plants (WWTP). The main factors influencing the corrosiveness of the fluids in WWTP are halides concentration (more specifically chlorides), H2S content, low pH, temperature and their combined effects.
In municipal wastewater streams, chloride content, known to be one of the critical agents affecting the stability of protective passive layers for stainless steels2, is usually around 50-200 mg/L and in this content range does not present major issues for the austenitic grade.
The recent development of ASTM D8370-22 provides a field-applicable technique for measuring impedance on protective coatings. The test method expands the use of electrochemical impedance spectroscopy (EIS) beyond the laboratory and standardizes the approach for various applications to polymeric coatings on conductive substrates, e.g., barrier coatings on steel structures. Example applications include condition assessments and quality control testing.
There have been several studies and publications over the past decade that clearly illustrate how initial assumptions about monopile interiors being perfectly sealed compartments were not correct in practice. Oxygen ingress through various points in the monopile contributes to persistent internal corrosion, and planned inspections are also opportunities to introduce fresh oxygen into the monopile. The replenishment of oxygen has been found to continue the corrosion reaction between the monopile wall and entrapped water.
Scaling is an important factor affecting oilfield production. The main reasons for scale formation are usually either the mixing of incompatible waters in production flow systems, for example, a formation of brine and seawater injected for maintaining downhole pressure, or changing thereservoir conditions such as temperature, pressure, and brine pH, among others1,2. Carbonate scaling is dependent upon the equilibrium between bicarbonate, carbonate, and carbon dioxide relative to changes in the temperature and pressure3,4. Scale can deposit on almost any surface,so that, once a scale layer is formed, it will continue to become thicker unless treated. Scale can block pore throats in the near-well bore region or in the well itself, causing formation damage and loss of well productivity.
The Passaic Valley Sewerage Commission (PVSC) in Newark, New Jersey is one of the most extensive modern wastewater facilities in the Eastern United States and is the sixth largest in the country. Established in 1902, PVSC began operating the Newark Bay Treatment Plant in 1924 to mitigate pollution in the Passaic River. The sprawling facility contains miles of access roads, utility tunnels, sewers, storm drains, and process pipes.
Three platforms in the Santa Ynez Unit (SYU) field in the Santa Barbara Channel, platforms Heritage (HE), Harmony (HA), and Hondo (HO), were installed between 1979 and 1989, approximately 19 km (12 miles) west of Goleta, California in water depths between 259 m (850 ft) to 365 m (1200 ft). These platforms were previously retrofitted with ICCP sleds which were in decline, requiring additional Impressed Current Cathodic Protection (ICCP) anode output. Therefore, they were all retrofitted with additional ICCP systems in a single campaign to provide a 25-year life extension.
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.
The Santa Ynez Unit (SYU) consists of three offshore platforms and an onshore oil and natural gas processing facility in Goleta, California. The platforms are located between five to nine miles offshore in federal waters. The construction of SYU began in 1976 in the Santa Barbara County in California with the platform Hondo (HO) which, started operations in 1981 to supply the domestic California market.
Aircraft reliability and maintainability are critical to their availability and operation. One of the biggest threats to aircraft availability is corrosion of aircraft systems. The annual cost of corrosion for Air Force aviation and missiles is estimated to be $5.67B dollars, or 23.6% of total maintenance costs for this equipment, and 2.1 million non-available hours. It is estimated that for defense acquisition programs 60 – 80% of the total life cycle cost is associated with the operation and support (O&S) phase.
The most dangerous phrase in business, “We’ve always done it that way”, has never been more apt. It cannot be assumed that these linings, with proven track record in storage and processing fossil fuels, will provide the same level of asset protection in biofuels storage and biorefining processes. Likewise, the use of “generic” equivalents offers greater risks as the technology used does not define the performance.
Liquid Metal Embrittlement (LME) phenomenon occurs when the certain molten metals wet the specific alloys, causing drastic ductility reduction that normally is associated with the formation of an intergranular crack that is sudden and brittle in nature. High tensile stress is also known to promote cracking; however, cracks may develop merely by contacting molten metal with a susceptible alloy as there is only a small amount of low-melting-point metal required to cause LME.