Crevice corrosion on stainless steels in oil and gas industry: a review of techniques for evaluation, critical environmental factors and dissolved oxygen

Seawater desalination infrastructures require a careful material selection with high corrosion resistance. The high seawater temperatures in warm regions, where many desalination plants are developed, must be clearly considered regarding the corrosion of materials. To comply with the operational characteristics of seawater reverse osmosis (SWRO) process (high pressure, high chloride content and dissolved oxygen content at saturation values), the conventional material selection was stainless steel with sufficient pitting resistant equivalent number. However, many cases of corrosion failures of stainless steel in SWRO desalination units have been reported. In most cases the cause of the failures was attributed to the use of not enough alloyed grades. However, high alloy stainless steels are also susceptible to crevice and pitting corrosion in seawater. The operational corrosion risk will highly depend on the stainless steel composition, on the metallurgy (i.e. cast or wrought), on the service conditions, an...

Review of material selection and corrosion in seawater reverse osmosis desalination plants

Failure analysis of a flange of superduplex stainless steel by preferential corrosion of ferrite phase

To comply with the demanding operational conditions of seawater reverse osmosis (SWRO) process, both in terms of corrosion resistance and mechanical properties, the conventional metallic material selection was often stainless steel for seawater and brines handling units (e.g. pumps, valves and piping). However, many cases of corrosion failures of stainless steel in SWRO desalination units have been reported often attributed to un-adapted stainless steel grade selection and/or to the particular aggressive conditions in “warm” regions where many recent desalination plants are built (high ambient temperature, severe biofouling, etc.). The operational corrosion risk will actually highly depend on the material composition, on the metallurgy (i.e. cast or wrought), on the service conditions and on the geometrical configuration of the concerned units in contact with seawater. Considering all these parameters, a proper material selection should avoid corrosion issue. For existing corrosion, cathodic prot...

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Corrosion and corrosion management investigations in seawater reverse osmosis desalination plants

With increasing environmental awareness follows demands for handling of brines that remain after use in a variety of applications. For this reason, stainless steels are being used in increasingly c ...

Corrosion of Stainless Steel in Sodium Chloride Brine Solutions

Since contradictory data can be found in the literature, it is often difficult to assess the susceptibility of crevice corrosion of stainless steels in service conditions for a given marine application. The initiation and propagation of crevice corrosion in natural seawater were evaluated for five different duplex stainless steel grades together with some austenitic grades. A CREVCORR-type assembly was used to simulate crevice configurations involving the use of plastic crevice formers. The standard pressure applied on the crevice assembly was 3 N/mm2 . Pressure of about 20 N/mm2 was also applied on some selected specimens in order to assess the effect of crevice geometry on crevice corrosion. The effect of environmental parameters (i.e. temperature, flowing conditions, residual chlorine, and dissolved oxygen content) and of surface roughness on the crevice corrosion initiation and propagation were investigated, allowing the assessment of limits of applications for some tested stainless steel grades. The less alloyed duplex stainless steels were evaluated in stagnant seawater at 5 °C and 20 °C. The duplex stainless steel UNS S32205, with PREN = 37, was also evaluated under the same conditions of exposure. The high alloyed stainless steels with PREN above 40 were evaluated in the expected most severe conditions of exposure, namely in 0.5 ppm-chlorinated seawater at 20 °C, in seawater at 30 °C (not chlorinated and with 0.5 ppm of residual chlorine) and in seawater at 50 °C (not chlorinated and with 0.5 ppm of residual chlorine). As expected the less alloyed duplex stainless steels showed limited crevice corrosion resistance in the tested media while UNS S32205 showed better resistance in the less severe tested condition of exposure. In demanding media it was shown that the limits of application of highly alloyed stainless steels are highly dependent on the crevice geometry (i.e. specimen roughness and applied pressure at gasket location).

Crevice corrosion of duplex stainless steels in natural and chlorinated seawater

Abstract: Tungsten carbide based spray coatings are widely used in industry for application requiring abrasion, sliding, fretting and erosion corrosion resistance. High velocity oxy-fuel (HVOF) flame spraying was used for producing high quality carbide composite coatings. In this study, a WC-CoCr and WC-CoCrNi powders were thermal sprayed using a HVOF process. The spray parameters were varied in order to investigate their influence on microstructure and mechanical properties of coatings. It is possible to produce homogeneous coating by controlling the flame temperature, the velocity of the gun transverse, the powder feed rate and the nature of the powders. The mechanical properties and the porosity rate could be optimized in order to improve the functional properties.

Influence of Spray Parameters on the Metallurgical and Functional Properties of HVOF WC Based Cermets Deposited onto Low Alloy Steel

Electrochemical Characterization of Low Carbon Steels During Long Term Immersion in Natural Seawater

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Crevice corrosion of duplex stainless steels in natural and chlorinated seawater

Influence of Spray Parameters on the Metallurgical and Functional Properties of HVOF WC Based Cermets Deposited onto Low Alloy Steel

Electrochemical Characterization of Low Carbon Steels During Long Term Immersion in Natural Seawater