Jet Impingement Corrosion Testing: Advancing Flow Corrosion Analysis for Industry Applications

by: Suresh Divi, PhD, PE, APMP

In industries where materials are subjected to aggressive flow conditions—such as oil and gas, chemical processing, and power generation—understanding the impact of flow on corrosion is critical. Corrosion not only compromises asset integrity but also leads to costly downtime and maintenance.

Stress Engineering Services (SES) specializes in jet impingement corrosion testing, a method designed to analyze the effects of fluid flow on material degradation and corrosion inhibitor performance. By simulating real-world flow conditions, our system provides highly relevant data that can be directly correlated to industrial processes.

What is Jet Impingement Corrosion Testing?
Jet impingement testing is a technique that exposes materials to high-velocity fluid flow, mimicking the stresses experienced in field conditions. This method measures wall shear stress, which quantifies the interaction between a moving fluid and a solid surface. Wall shear stress is a key factor in determining corrosion rates and evaluating inhibitor performance under dynamic flow conditions.

At SES, we have optimized this technique for both scientific investigations and routine corrosion evaluations. Our system enables precise control overflow dynamics, allowing us to analyze a wide range of operating scenarios.

Key Features of our Jet Impingement Testing System

Our system offers several advantages over conventional corrosion testing methods:

1. Corrosion Inhibitor Performance Analysis: We evaluate corrosion inhibitor efficiency across varying wall shear stress conditions, capturing transient effects that influence inhibitor effectiveness.
2. Real-World Correlation: Test results are directly linked to field flow regimes, allowing for accurate prediction of material performance in operational systems.
3. Instantaneous Corrosion Measurements: Our setup enables real-time corrosion rate monitoring in complex multiphase environments, such as water with entrained oil and gas, gas with entrained water, and low water cut oil.
4. Flexible Flow Testing: We perform both recirculating and once-through flow experiments, simulating a range of industrial process conditions.
5. Slug Flow Intensity and Frequency Determination: We assess the impact of slug flow—a common issue in pipelines—on corrosion severity and identify critical slug frequency thresholds.
6. Precise Corrosion Inhibitor Assessment: Our system accurately measures the minimum effective concentration of corrosion inhibitors, ensuring optimal dosing strategies.
7. Corrosion Inhibitor Persistency Testing: We determine how long an inhibitor remains effective under continuous exposure to flow stress.
8. Batch and Continuous Inhibition Evaluations: We analyze both batch and batch/continuous inhibitor applications to optimize protection strategies for industrial systems.
9. Acidizing and Spent Acid Flow-Back Testing: Our method assesses the impact of acid treatment flow-back on material integrity, crucial for well stimulation and cleaning processes.

The Benefits of Jet Impingement Testing for Industry

By employing jet impingement testing, industries can gain valuable insights into corrosion mechanisms under realistic flow conditions. This leads to several key benefits:

• Enhanced Material Selection: Understanding corrosion behavior in dynamic environments allows for better material choices, reducing failure risks.
• Optimized Corrosion Control Strategies: Accurate inhibitor performance data ensures efficient chemical usage, minimizing costs while maximizing protection.
• Reduced Downtime and Maintenance Costs: Predictive insights help mitigate unexpected failures, improving system reliability and operational efficiency.
• Regulatory Compliance and Risk Reduction: Reliable data supports compliance with industry corrosion standards and enhances safety protocols.

Conclusion

Corrosion is a complex challenge that requires advanced testing methodologies to fully understand its behavior under flow conditions. Our jet impingement testing service provides industries with the critical data needed to develop effective corrosion mitigation strategies, optimize inhibitor performance, and extend asset lifespan.

With our scientifically validated and field-correlated approach, we deliver high-quality insights that drive better decision-making and improved operational outcomes. Contact us today to learn how our jet impingement testing can help protect your assets from flow-induced corrosion.