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<p>Localized corrosion failure was observed in a coated carbon steel seawater pipeline connected to a plate and frame heat exchanger (PFHE). The failure occurred as a perforation near an internal weld reinforcement despite the presence of an epoxy coating. This study investigated the underlying mechanism through an integrated approach combining field inspection, surface characterization, microbiological analysis, corrosion rate testing, and computational fluid dynamics (CFD) simulation. Macroscopic and microscopic observations revealed coating degradation, localized corrosion morphology, and heterogeneous corrosion deposits. Microbiological analysis confirmed the presence of sulfate-reducing bacteria (SRB), indicating potential microbial involvement. Standard corrosion rate measurements showed no significant increase in uniform corrosion under SRB conditions, suggesting that corrosion was localized rather than uniform. CFD results demonstrated that the weld protrusion significantly altered the local flow field, producing strong wall shear stress gradients and non-uniform hydrodynamic conditions. These included both high-shear regions and localized low-velocity zones that may support biofilm formation. The findings indicate that corrosion initiation was governed by the interaction between coating degradation, microbial activity, and weld-induced flow disturbances. This study highlights the importance of considering coupled mechanisms in failure analysis of seawater pipeline systems.</p>

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Weld-Induced Flow Disturbance and MIC in a Coated Seawater Pipeline

  • 期刊论文

  • 发表日期：

    2026年6月20日

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  • Sepfitrah,
  • A. T. Joenoes

摘要

Localized corrosion failure was observed in a coated carbon steel seawater pipeline connected to a plate and frame heat exchanger (PFHE). The failure occurred as a perforation near an internal weld reinforcement despite the presence of an epoxy coating. This study investigated the underlying mechanism through an integrated approach combining field inspection, surface characterization, microbiological analysis, corrosion rate testing, and computational fluid dynamics (CFD) simulation. Macroscopic and microscopic observations revealed coating degradation, localized corrosion morphology, and heterogeneous corrosion deposits. Microbiological analysis confirmed the presence of sulfate-reducing bacteria (SRB), indicating potential microbial involvement. Standard corrosion rate measurements showed no significant increase in uniform corrosion under SRB conditions, suggesting that corrosion was localized rather than uniform. CFD results demonstrated that the weld protrusion significantly altered the local flow field, producing strong wall shear stress gradients and non-uniform hydrodynamic conditions. These included both high-shear regions and localized low-velocity zones that may support biofilm formation. The findings indicate that corrosion initiation was governed by the interaction between coating degradation, microbial activity, and weld-induced flow disturbances. This study highlights the importance of considering coupled mechanisms in failure analysis of seawater pipeline systems.