CORROSION AND

ITS PROTECTION
IN OIL & GAS PRODUCTION

CORROSION IN OIL FILED :

INTERNAL AND EXTERNAL THREATS

INTERNAL THREATS

CORROSION CAUSES
WELL TREATMENT
INFLUENCED
WATER CARRY OVER
UNDERDOSING
DEMULSIFIER
INJECTION PUMP with
LOW
CAPACITY
UNDERDOSING
CORROSION
INHIBITOR
WATER SETTLE OUT

Typical E&P process

conditions

Temperature
Typical E&P process
temperatures range from
-100C to >200C
Corrosion rates increase
with temperature
Pressure
Pressure: up to 10,000psi
Increase partial pressure of
dissolved gases
Flowrate & flow regime
High-flow: erosion and
corrosion-erosion.
Low-flow or stagnant
conditions promote
bacteria
5

Internal corrosion
Hydrocarbon phase
Not normally corrosive
at temperatures
experienced in
production systems
Corrosivity depends on
extent and distribution
of the aqueous and
hydrocarbon phases.

Aqueous phase
Responsible for corrosion
Corrosion exacerbated
by acid gases & organic
acids
CO2, H2S and O2 are the
most aggressive species
Chlorides increase
corrosion
Generally,
no water, no
corrosion
6

Internal (process-side) damage

mechanisms

H 2S

CO2

Solids & velocity effects

Chlorides pitting, stress corrosion cracking
Oxygen (crevice / under deposit / differential
aeration)
Galvanic corrosion
Preferential weld corrosion (PWC)
Microbially induced corrosion (MIC)
Liquid metal embrittlement (LME)
Chemicals

TYPICAL REACTIONS

Corrosion Rate of Carbon Steel

Dissolved gas - effect on corrosion

Corroded seawater i
25
20
15

O2
CO2
H2S

10
5
O2
H2S
CO2

00
0

50

100

150

1100 2 200 3 3004

4
5
400
200

6
500

7600 8 700

250

300

350

8
800
400

Dissolved Gas Concentration in Water Phase, ppm

There is no species more corrosive on a

concentration basis than oxygen!
9

H2S CORROSION

10

H2S corrosion metal loss

Formation of a thin protective FeS surface film often
means general corrosion rates are low on steels
Main risk is localised pitting corrosion where film is
damaged
Pitting will be galvanically driven

11

Wet H2S corrosion

H2S is soluble in water
Produces a weak acid and lowers the pH
H2S H+ + SH At low concentrations, H2S helps form protective
FeS film
Main risk is localised pitting corrosion which can be
rapid
H2S also poisons combination of atomic hydrogen into
molecular hydrogen
Atomic
+
H +eH
hydrogen dangerous to
H + HX
H2
steels!!

12

Cracking in sour service

H2

H+
H
H

Applied Stress

Higher Strength Steels YS > 500 MPa

H H
HH
H

S2-

Fe2+
FeS Film
Metal Matrix

No Applied Stress
Low Strength Steels YS < 550 MPa

H2
H2
13

Sulphide stress cracking

(SSC)
Key parameters:
pH and pH2S
Domain diagrams for carbon
steel
Material hardness
High strength steels and areas
of high hardness susceptible.
Temperature
Maximum susceptibility at low
temperatures for carbon
steels (15-25C), higher for
CRAs (5-70C).
Stress
Cracking promoted by high
stress levels e.g. residual
welding

HAZ

WELD
HAZ

Hardness
readings

14

Protection against SSC

Avoid wetness
Minimise hardness
Guidance on limits
in ISO 15156
Optimise
microstructure and
minimise residual
stresses

Upgrade to CRAs
Martensitic and duplex
stainless steels have
limited resistance
H2S limits for duplex and
super-duplex steels are
complex
Function of
temperature, pH,
chlorides, pH2S
Nickel-base alloys such as
625 and 825 have high
resistance
Testing: NACE TM0177
15

ISO 15156 SSC zones for

carbon steel

0.0034bar
a 0.05psia

Servic
e
Domai
n

Max hardness
(parent metal,
HAZ, weld
metal)

No requirements

300HV

280HV

250HV root
275HV cap

16

SSC limits for selected

CRAs
Alloy

pH2S limit (bara)

13% Cr martensitic

0.008

22% Cr duplex

0.10

25% Cr super-duplex

0.25

Alloy 825

No limit

Alloy 625

No limit

17

HIC / SWC / blistering

Laminar cracking in
plane of inclusions or
blistering (HIC).
Transverse cracking
between laminar
cracks on different
planes (SWC).

Step-wise cracking

Hydroge
n
blisters

Blistering of CS
plate

18

Avoiding HIC / SWC

Avoid plate steels (rolled)

otherwise qualify by HIC
test
Control impurities e.g. S, P
Uniform microstructure
Use internal coatings
isolate steel from process
fluid
Testing: NACE TM0284

Banded

Uniform

19

ISO 15156 (NACE MR0175)

ISO 15156 combination of
NACE MR0175 and NACE testing requirements TM0177 & TM0284
European Federation of Corrosion Guidelines No.16 & 17
Part 1: General principles for selecting crack-resistant materials
Part 2: Cracking resistant carbon & low-alloy steels & cast iron
Part 3: Cracking resistant corrosion resistant alloys (CRAs)
Covers all cracking mechanisms
Goes beyond application of the 0.05 psia pH 2S threshold for sour
service
It is the equipment users responsibility to select suitable
materials
HIC/SWC of flat rolled carbon steel products for environments
containing even trace amounts of H 2S to be evaluated
BP ETP: GP 06-20 Materials for Sour Service

20

Designing for H2S service

Materials requirements
Reference ISO 15156 and GP 06-20
pH2S and pH
Temperature
Chlorides
Hardness limits

Welding QA/QC (HIC)

Maintain hardness limits
HIC testing for plate products

21

CO2 CORROSION

22

CO2 - containing
environments

CO2 always present in

produced fluids
Corrosive to carbon
steel when water
present
Most CRAs have good
resistance to CO2
corrosion.

Mechanism
CO2 + H2O H2CO3
H2CO3 + e- HCO3- + H
2H H2
Fe Fe2+ + 2eFe + H2O + CO2 FeCO3
+ H2

23

Types of CO2 damage

General & pitting

corrosion

Mesa corrosion

Flow-assisted-corrosion
(CO2)

Localised weld
corrosion

24

CO2 corrosion in a production

flowline

6 CS production flowline (Magnus,

1983)
25mm thick, 90bar, 30C, 2%CO2
Heavily pitted pipe wall and welds
(not necessarily uniform corrosion)
Didnt fail removed due to crevice
corrosion of hub sealing faces
25

Factors in CO2 corrosion

Main factors
pCO2, temperature, velocity, pH
- CO2 prediction model

For an ideal gas mixture, the

partial pressure is the pressure
exerted by one component if it
alone occupied the volume. Total
pressure is the sum of the partial
pressures of each gas
component in the mixture

Temperature, (C)

pCO2
(bar)

Carbon steel
corrosion rate
(mm/yr)

130

0.6

75

0.6

149

30

>50

26

Effect of sand on CO2

corrosion

Produced sand can affect inhibitor efficiency

Inhibitor adsorption loss
Sand (and other solid) deposits give increased risk of
localised corrosion;
Prevent access of corrosion inhibitor to the metal
Provide locations for bacteria proliferation
Galvanic effects (area under deposit at more negative
potential than area immediately adjacent to deposit)
Formation of concentration cells/gradients

27

Mitigation of CO2 corrosion

Internal CO2 corrosion of carbon steel needs to be managed

Usually mitigate by chemical inhibitors
Simple geometries only (mainly pipelines)

Assume inhibitor availability (90-95%)

Inhibited corrosion rate of 0.1mm/year
Remaining time at full predicted corrosion rate
Apply a corrosion allowance for the design life
If calculated corrosion allowance >8mm use CRAs

28

CO2 corrosion inhibition

Filming type
Retention time
Continuous injection
Adsorption onto clean
surfaces

Clean steel

29

CO2 + H2S corrosion metal

loss

CO2/H2S > 500

CO2 dominates

500 > CO2/H2S > 20

mixed CO2/H2S

20 > CO2/H2S > 0.05

H2S dominates

H2S corrosion (CO2/H2S < 20)

Initial corrosion rate high
Protective FeS film quickly slows down corrosion to low
level
The corrosion rate is much less than the Cassandra
prediction

30

Partial pressure CO 2 (bar)

H2S + CO2 materials

selection guide
Duplex SS
13% Cr SS

Nickel-based alloys

Carbon/low alloy steels

Partial pressure H2S (bar)

EROSION & EROSIONCORROSION

32

Flow regimes
Various multi-phase
flow regimes possible;
erosion
characteristics
distribution of
phases
carrier phase for
solids
Flow regimes with
particles in the gas
show higher erosion
rates than those with
particles in the liquid
phase.

Liq
uid
Bubble (bubbly)
flow

Ga
s
Liq
uid
Stratified

G
as

Plug flow

Ga
s
Liq
uid
Wave (wavy)
flow

flow

Gas
Liq
Annular
uid

Ga
Liq
s
uid
Slug flow

flow

Churn flow

Mist (spray) flow

33

Erosion & erosioncorrosion

Erosion
Caused by high velocity
impact & cutting action of
liquid and/or solid particles
Erosion failures can be
rapid
Erosion-corrosion
Occurs in environments
that are both erosive and
corrosive.
Erosion and corrosion can
be independent or
synergistic.

Erosion of tungsten
carbide choke trim

34

Typical vulnerable areas for

erosion

Areas wherever flow is restricted

or disturbed
T-pieces, bends, chokes, valves,
weld beads

Trinidad

Areas exposed to excessive flow

rates
Sand washing
Washing infrequently allowing
sand to accumulate
High pressure drop during
washing of separators

Sea water systems

High flow areas in water
injection / cooling systems

Algeria (duplex)
35

Erosion in piping

Sand accumulation
Build up of sand in a test
separator

Pressure drop
Large pressure drop across
sand drain pipework during
washing

Rapid failure
Occurred within 2 minutes
of opening the drain

Erosion at bend
36

Erosion in a vessel
Sand allowed to accumulate in
separator
Wash nozzles embedded in sand
PCV not working properly
High pressure / flowrate
Nozzle not erosion-resistant
Erosion of wash nozzle
Spray changed to a jet causing
erosion of shell
Local changes to operating
procedures not communicated
Frequency of sand washing
Risk not captured or assessed in
RBI

Water
spray

Water
jet

37

Erosion of sandwash nozzle

Progressive

nozzle

damage
38

Erosion-corrosion
Occurs in environments that can be erosive and
corrosive.
Erosion and corrosion can either be:
independent of each other;
wastage equals sum of individual wastage
rates
synergistic;
wastage rate > sum of individual rates
localised protective film breakdown at
bends, elbows areas of turbulence

39

Impingement

Water speed or local turbulence damages or removes

protective film
90-10 Cu-Ni susceptible to internal erosion-corrosion
(impingement) at velocities >3.5ms-1
Water-swept pits (horse-shoe shaped)
40

Cavitation

Occurs at high fluid velocities

Formation & collapse of vapour
bubbles in liquid flow on metal
surface.
No solids required
Typical locations
Pump impellers (rapid change in
pressure which damages films)
Stirrers, hydraulic propellers

Use erosion resistant materials

Stellite, tungsten carbide

41

CORROSION IN SEAWATER

42

Raw seawater

Composition of raw seawater varies around the world

Temperature, pH, salinity, dissolved oxygen, marine
life
Very corrosive to unprotected carbon steel, other
materials susceptible to pitting and crevice corrosion
Select seawater resistant materials
Super-duplex grades, 6Mo, CuNi, titanium
Consider galvanic corrosion
Most seawater resistant grades of stainless steel and
Ni-Cr-Mo alloys are compatible with each other in
seawater.
Seawater can cause SCC of 300-series, duplex grades
and 6Mo
43

Pitting resistance of stainless

steels

Pitting Resistance Equivalent

Number (PREw)
Formula for comparing
relative pitting resistance
Applicable to stainless steels
& Ni-Cr-Fe alloys
Typically PREw 40 required
for exposure to raw sea
water <30C
Alternatively, use titanium or
GRE

Alloy

PREw

13Cr

13

316ss

23

Alloy 825

28

22Cr duplex

33

25Cr superduplex

40

Alloy 625

46

PREw = %Cr + 3.3x (%Mo + 0.5%W)

+ 16%N

44

Internal & external pitting

Internal pitting

Section of 3 316L pipe fitting

Failed due to internal corrosion (pinhole leak)
Poor hydrotest practice - seawater left within spool
45

Failure of a seawater pump

cooling coil

Indication on coil

External surface of
coil

Internal surface of
coil

316 SS coil, raw seawater service, hypochlorite added

Shellside: lube oil up to 50C
Tubeside: seawater inlet ~6C, return ~18C
Failed due to localised internal pitting
316 SS has low PREw
Material upgrade required

46

Oxygen - concentration
cells

Crevice
corrosion
under baffle

Crevice corrosion
O2 is consumed in the crevice
and becomes the anode
pH decreases in the crevice
increasing attack
Differential aeration cells
Air/water interfaces with attack
below the water line e.g. splash
zone
Pipelines in soils containing
different amounts of oxygen
Under deposit corrosion
Deposits of scale, sand or sludge
Produces differential
concentration
SRBs thrive - H2S pitting
47

Galvanic corrosion
Three conditions are required for galvanic corrosion;
A conducting electrolyte (typically seawater).
Two different metals in contact with the electrolyte.
An electrical connection between the two metals.
Relative positions within the electrochemical series (for
given electrolyte) provides driving potential and affects
rate.
Corrosion of base metal (anode) stimulated by contact
with noble metal (cathode).
Relative area of anode and cathode can significantly
affect corrosion rate.
Higher conductivity increases corrosion e.g. presence of
salts

48

Galvanic corrosion firewater

piping

Firewater CuNi / super duplex

stainless steel connections.
4CuNi pipe with a 550mm
isolation spool (i.e. 5x OD)
Leaks experienced on CuNi
spools at welds
Same problems with CuNi / 6Mo

49

Galvanic corrosion - seal

rings

ETAP platform
Techlok joints in a
firewater piping system
Piping: super-duplex
Seal rings: 17-4PH

50

Dealloying of brass
Brass tubesheet in
seawater service
Brass is Cu-Zn alloy
Cu is more noble than
Zn
Zn dissolves
preferentially leaving
Cu behind
Result
Loss of strength
Difficult to seal
Remedy
Add arsenic to the brass
51

Mitigation of galvanic
corrosion

Avoid dissimilar materials

in seawater system
designs
MoC for later changes
Avoid small
anode/large cathode
Avoid graphite gaskets &
seals
Avoid connecting carbon
steel to titanium alloys
Galvanic corrosion or
hydrogen charging of
titanium may occur

Electrical isolation between

different alloy classes
Install distance spools,
separation of at least 20x pipe
diameters
Solid non-conducting spool
e.g. GRP
Line the noble metal
internally with an electrically
non-conducting material e.g.
rubber
Apply a non-conducting
internal coating on the more
noble material. Extend coating
for 20 pipe diameters.
52

Example : CuNi-Super duplex

Distance spool: solid, non-conducting material e.g. GRP

Distance spool: noble metal internally lined with an

electrically non-conducting material such as rubber

Apply a non-conducting internal coating on the more noble

53
material.

Cathodic protection (CP) what

is it?
By connecting an external anode to the component to be
protected and passing a dc current, it becomes cathodic and
does not corrode.
External anode may be a galvanic (sacrificial) anode, the
current is the result of the potential difference between the
two metals
External anode may be an impressed current anode,
current is supplied from an external dc power source.
CP is mostly applied to coated, immersed and buried structures
The coating is the primary protection, acting as a barrier
between the metal and the environment
CP protects steel at coating defects
Coating + CP is most practical and economic protection
system.
Primary principle in GP 06-31
54

Cathodic protection how

does it work?
CP works by making the component to be protected the cathode in an
electrolytic cell
When two metals are connected in an electrolyte, electrons flow from
the anode to the cathode due difference in the electrical potential
ANODIC

Magnesium
Zinc
Aluminium
Iron (steel)
Copper
Stainless steels
Titanium
Graphite
CATHODIC

Corrosion of
steel by copper
plating

Cathodic protection
of steel by zinc
55
plating

Galvanic (sacrificial) CP
Aluminium anodes: require alloy
additions to become active e.g. Zn + In,
high efficiency (>90%).
Typically used in seawater applications.
Zinc anodes: ambient applications only.
Alloyed with Al or Cd to improve efficiency.
Typically used on coated pipelines in
seawater
Magnesium anodes: large driving
potential, alloyed with e.g. Al or Zn to
reduce rapid activation, limited efficiency
Sacrificial anodes,
(50-60%)
new and wasted
Used in soils and other high-resistance
(therefore working!)
environments (risk of overprotection/rapid consumption in
seawater).
56

Applications of internal CP

Anodes in shell & tube

seawater cooler water boxes

Oil storage tanks (in water

bottom)
Water tanks

Stainless steel piping systems in warm/hot chlorinated seawater.

To avoid high anode consumption rates, resistor controlled CP
(RCP) systems should be considered.
E.g. RCP + 25Cr super duplex piping instead of titanium or
other higher-alloy CRA.
Used on Greater Plutonio
57

Chloride stress corrosion

cracking (SCC)

Susceptibility varies
considerably (no absolutes);
Material grade, strength,
residual stress, chlorides,
oxygen and temperature
300-series austenitic stainless
steels susceptible to at temps
>50C
Highly-alloyed austenitic and
duplex SS have improved
resistance
Nickel-base alloys with Ni
42% are highly resistant, e.g.
825
58

Chloride SCC (22Cr duplex

vessel drain)

22Cr duplex drain ex-production separator

heat-traced to 60C (vessel temp up to 105C)
Internal chloride SCC (cracking in parent metal, HAZ and
weld metal)
Contributory factors:
Susceptible material
Local stress concentration (weld toe and lack of support)
Environment (elevated temperature, chlorides).

59

Water injection systems

(deaerated)

Oxygen:
Trace amounts corrosive to
carbon steel. As a guide:
<20ppb O2 maintains general
corrosion rates <0.25mm/yr
Stricter limits often applied
e.g. <10ppb if 13Cr
completions
Microbial-induced Corrosion,
MIC
SRB require anaerobic conditions
deaerated water
conditions within and under
biofilms
SRB use sulphate in water in their
metabolisms to generate H 2S

Fluid Velocity:
Areas of high fluid velocity
or turbulence and O2
O2 from poor deaeration
or air ingress
susceptible areas include
pump discharge piping,
bends tees and reducers.

60

Mitigation & monitoring

Deaeration and supplementary O2
scavenging
Monitor O2 concentrations on-line
(orbisphere) or colorimetric
analysis
Maintain oxygen scavenger
residual to mop-up oxygen spikes.
Chlorination u/s of deaerator, biocide
applied into or d/s of deaerator
Effective biociding based on;
Type, frequency, dosage, duration
Bacterial monitoring (sidestreams,
scrapings or bioprobes)
Corrosion monitoring

Leaking deaerator

Seawater injection
tubing

61

Preferential weld corrosion

(PWC)

The selective corrosion of weld zones (WM/HAZ)

Relevant factors include;
Electrochemical properties of the materials and any
corrosion cell forming around the weld joint
Water phase liquid film thickness and conductivity
Temperature and tendency to form protective scale
Corrosion inhibitor effectiveness, (film formation,
composition)
Weld joint metallurgy
Flow pattern and flow induced shear stress
PWC rate of attack can be high, up to 12mm/yr
observed
62

Preferential weld corrosion

(1%Ni)
Water Injection:
Wet hydrocarbon service:
1% Ni-containing welds
beneficial for avoiding
PWC in WI systems.
Weld cathodic to parent
metal, protected by large
area of parent metal.

Lower conductivity, no benefit of

selecting cathodic weld metal
Reliant on intrinsic corrosion
resistance of the weld metal
Require corrosion inhibitor for
protection (test against WM and
PM)
Attack of weld metal promoted
by under-dosing of inhibitor (WM
needs more inhibitor than PM)

Welds exposed to hydrocarbon service

63

Lomond drains - PWC

TEG contactor scrubber drain

pipework (hydrocarbon)
Carbon steel parent metal
~2%Ni deposited in weld
metal
Groove along 6 oclock
position
Accelerated corrosion at the
weld
Large number of isolations,
extensive inspection and
repair
64

MIC &

DEADLEG CORROSION

65

Microbially induced corrosion

(MIC)
Anaerobic environments often
support development of biofilms.
Sulphate reducing bacteria
(SRB) thrive in anaerobic
conditions
SRB biofilms generate H2S
FeS corrosion product cathodic
to bare steel, increasing
corrosion rate.
MIC of carbon steel usually
localized pitting under biofilm.
Corrosion rates of 5-10 mm/yr
seen
CRAs also susceptible
66

Bacterial growth factors

pH
MIC growth in pH 5-9.5
range
Temperature
SRB can grow in temps of
5-100C. Optimum
temp <45C.
Sulphates
Necessary for SRB
activity.
Growth restricted if
<10 ppm

Carbon source
SRB growth restricted if
organic carbon (volatile
fatty acids) not
available (<20ppm)
Nitrogen
Important but at levels
which are difficult to
detect
Flow
Highest corrosion rates
in stagnant conditions.
Biofilms unstable at
high flows.
67

Deadlegs types &

locations

A deadleg is a section of pipework or vessel which

contains hydrocarbon fluids and/or water under
stagnant conditions (permanent or intermittent)
or where there is no measurable flow.
Permanent or physical deadlegs (long term stagnation
by design)
Operational deadlegs (stagnant for operational
reasons)
Unprotected mothballed items (plus those temporarily out
of service)

68

Examples of deadlegs

69

Deadlegs assessment
factors

Consequence of failure
Location of pipework
Nutrients replenished by regularly opening /closing
valves?
Is draining of pipework possible?
Is removal of deadleg possible?
Presence of SRBs, deposits, biocide?
Material of construction
Wall thickness
Fluid type (aqueous phase, sulphates, nutrients, oxygen
ingress)
Temperature
Stagnant permanent/intermittent
Prior history of corrosion
70

Example of deadleg
corrosion

Pin Hole leaks

Releasing water

Crude oil recycle cooler bypass

Scale-inhibited seawater left in line after leak test (of u/s
valve)
Severe corrosion rate at and around pinhole.
Fortunately, a leak of water not crude.
Two week shutdown

71

Root causes
Failure to identify the bypass
line as an operational
deadleg
No deadleg register
Failure to recognise
introduction of new corrosion
hazard
No mitigation measures.

Corroded area approx 80mm x72

110mm.

Mitigation & inspection

Flush system of deposits and
treat with biocide, nitrate
Out of service items
Biocide treat or mothball
procedure
Use treated water
Hydrotest & washing
Profile radiography or UT
scanning
low points, bottom of vertical
sections etc.
Lowest parts of vessel bridle
together with any associated
level gauges.
73

OTHER CORROSION
MECHANISMS

74

Corrosion due to chemicals

Chemicals can be corrosive

Carbon steel OK for non-corrosive
chemical piping, e.g. methanol
Corrosive chemicals (e.g.
concentrated solutions of inhibitors
and biocides) require CRAs vendor
will specify
316 SS is typical

Notable exceptions:
Hypochlorite: very corrosive, titanium
or GRP piping required
Avoid titanium alloys in dry methanol
service due SCC

SCC of a titanium
seal exposed to
pure methanol
instead of 5%
water content

75

Corrosion due to chemicals

Carbon steel open drain
pipework.
Seepage of scale inhibitor
(passing valve)
Scale inhibitor pH <2.
Chemical entered drains, not
flushed

76

Injection point issues

Inadequate mixing
corrosion
Intermittent use
switch off when not
flowing
Areas affected
Impingement / turbulent
areas
Bends and low points
Use quill/other mixer
Upgrade material
Thicker schedule
Valve arrangement
Make self-draining
Enable quill removal

Injected Fluid

Main Flow

Impingement

77

High temperature
corrosion

Environments less common in E&P

Flare tips, fired heaters, boilers
Oxidation
Oxidation significant >530C
Oxidation rate varies with temp,
gas composition and alloy Cr
content
Firetubes: usually CS, but CrMo alloys needed for high
temps
Flare tips: 310 SS, alloy 800H
Other high temperature mechanisms
sulphidation (H2S and SO2)
carburizing, metal dusting, hot
salt
thermal fatigue and creep
78

Amine stress corrosion

cracking

Material: carbon/low-alloy steels

Environment: aqueous amine
systems
Cracking due to residual stresses
at/next to non-PWHTd weldments
Cracking develops parallel to the Intergranular cracking
weld
Mitigation:
PWHT all CS welds including
repair and internal/external
attachment welds.
Use solid/clad stainless steel
304 SS or 316 SS
Amine piping welds require
PWHT to avoid SCC

79

Corrosion in glycol system

Glycol usually regarded as benign

Corrosion in glycol regeneration
systems usually due to;
Acid gases absorbed by rich
glycol or
Organic acids from oxidation of
glycol and thermal
decomposition products
Condensation of low pH water
giving carbonic acid attack.
Risk recognised in design
On-skid: CRA piping & clad
vessels
However, off-skid piping mix of
regular CS and LTCS
80

Corrosion fatigue
Combined action of cyclic tensile
stress and a corrosive
environment
Fatigue is caused by cyclic
stressing below the yield stress
Cracks start at stress raisers
Can occur due to vibration e.g.
smallbore nozzles & with
heavy valve attachments
Presence of corrosive
environment exacerbates the
problem
Can lead to pitting, which acts
as stress concentrators

81

Example of corrosion
fatigue
2 A106 GrB carbon steel piping
Wet gas service, 1.2%CO2 and
160ppm H2S
Operating @ 120C and 70bar
Elbow exposed to vibration (used
in a gas compression train)
Crack located at 12 o'clock
position
Crack initiated internally

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EXTERNAL CORROSION
SURFACE FACILITIES

83

External corrosion

External corrosion of unprotected steel surfaces

External corrosion of coated surfaces
Corrosion under insulation (CUI)
Corrosion under fireproofing (CUF)
Pitting & crevice Corrosion
Environmental cracking

84

Where does it occur?

Bare steel surfaces

At locations of coating breakdown
Under deposits such as dirt, adhesive tape or nameplates
Mating faces between pipe/pipe support saddles &
clamps
Isolated equipment not maintained or adequately
mothballed
Water sources include:
sea spray and green water (FPSO or semi-sub)
rain
deluge water
leaking process water
condensation
downwind of cooling towers.
85

What does it look like?

Damage can be extensive or localised.

Corrosion can be general attack, pitting or cracking.
Seen as flaking, cracking, and blistering of coating
with corrosion of the substrate.

86

Appearance
Carbon/low alloy steels usually
covered in compact scale/thick
scab
Stainless steels have light stains on
the surface possibly with stained
water droplets and / or salts.
Corroding copper alloys covered in
blue/green corrosion products.

87

Piping, supports & clamps

88

Not just carbon steel

25Cr super-duplex (PREN 40)
Seawater service
12 months exposure in tropical
climate
External corrosion along welds
Poor quality fabrication

89

Corrosion of bolts and

fasteners

Bolted joints
Onshore and offshore: exposed to frequent
wetting
Low alloy bolts
General or localised corrosion
Galvanic corrosion in stainless steel flanges
CRA bolts susceptible to pitting and/or SCC
Crevice corrosion under bolt heads and nuts
Hydrogen embrittlement possible
Fatigue

90

Corrosion of bolts and

fasteners

General corrosion

Crevice corrosion

Galvanic corrosion

Stress corrosion
cracking

91

Flanged connections
Corrosion
General surface corrosion
Galvanic corrosion
e.g. 316 SS / carbon steel
Use of graphite gaskets
Potential problems
Failure of flanged connection
due to corroded fasteners
Joint leak
Corrective actions
Change gasket/fastener
materials
Replace graphite gaskets
with non-asbestos or rubber
material
92

Corroded fasteners (seawater

service)

Location of graphite gaskets

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Structures / valves
Valves
Valve handles
Chain-wheels
Valve body
Structures
Stairways and
walkways
Gratings, ladders,
handrails
Cable trays and
unistruts
Threaded plugs
Valve bodies, xmas
trees, piping
Dissimilar metals
94

Coating damage and

breakdown

Deterioration of coating with time

All paints let water through - continuously wet areas
will fail
Poor original surface preparation / paint application
Mechanical damage
Small area of damage can lead to major corrosion

95

External cathodic
protection

Types of structures with

external CP
Buried pipelines / structures /
piping / tanks
Floors of above-ground
storage tanks
Submerged jetty structures

Factors affecting corrosion

Extent of wetness
Oxygen depends on depth
Resistivity of soil & presence
of salts
Equipment temperature

96

Impressed current CP
Adjustable dc source
Negative terminal
connected to the
steel structure
Positive terminal
connected to the
anodes
Typically used on
larger structures
where galvanic
anodes cannot
economically deliver
enough current.

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Corrosion under insulation

(CUI) and Corrosion under
fireproofing (CUF)

CUI
Water seeps into insulation
and becomes trapped,
results in wetting and
corrosion of the metal
Carbon steel corrodes in the
presence of water due to
the availability of oxygen.
CUF
Same mechanism except
water gets behind the
fireproofing.

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Insulation

Typical insulation
types;
Process
Personnel protection
(PP)
Winterisation
Acoustic
Challenge the need
Remove
unnecessary
insulation
Replace PP with
cages

Mitred joint

Lobster-back
joint

Pre-formed bends

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CUI incident

4 gas compression recycle

line
Operating pressure, 35bar
3 bar pressure surge
Temperature: 50C
6.02mm nominal WT
Rockwool insulation
Extensive corrosion
rupture
Unusual, burst rather than
leaked

100

CUI gas leak

2 fuel gas piping outside

edge of platform - exposed
CS, heat-traced, Rockwool
Operating @ 5bar, 45C,
5.4mm NWT
Failed during plant start-up
External corrosion scale, CUI

Focus on internal corrosion

Previous survey found
defect in an adjacent line.
Failed line in survey but
not failed area.
Features selected from
onshore not site survey

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piping CUI
4 CS hydrocarbon line
55C, inlet to PSV (153 bar)
Thermally-sprayed aluminium
(TSA)
CUI found, radiographed ok
to refurbish.
Found during needle-gunning
(paint removal)
Max pit depth 10mm
Insulation permanently
removed
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CUI on pressure vessel

CS offshore vessel
Operating at 85C and 11
bar
PFP coating (passive fire
protection)
Extensive corrosion
scabbing on both sides of
vessel.
Scaling runs in two
horizontal distinct lines
along each side.
Scaling directly above
lower seam of insulation
location of water
retention.

400x300x30mm

400x100x25mm

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External pitting & crevice

corrosion
Stainless steels in marine
environments (chlorides, O2)
316L stainless steel
commonly used for
instrument tubing
Particularly susceptible at
supports and fittings.
Primary mitigation is materials
selection (higher PREw)
Tungum, 6Mo, super-duplex
Alternative mitigation
methods (coating, cleaning),
not easy or practical.

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Instrument tubing
(316 SS and super-duplex)
316 SS tubing

super-duplex tubing

316 SS (pitting/crevice corrosion)

pitting)

super-duplex (no

105

Crevice corrosion under

clamps/supports
Pitting and crevice
corrosion of 316ss
piping
Clamps
Plastic retaining
blocks

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External chloride stress

corrosion cracking

Mechanism same as internal chloride SCC however:

Numerous variables influence susceptibility therefore
guidance differs
Material, stress, chlorides, oxygen and temperature
No absolute guidance available, seek expert advice

Chloride SCC is
characterised by transgranular crack paths

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External stress corrosion

cracking

UK HSE:
Coat 22Cr duplex >80C
NORSOK M-001 SCC temp limits:
22Cr duplex >100C
25Cr super-duplex >110C
Recent testing has shown failures at
80C
now recommend 70C as limit
Reliant on external coatings to act as
barrier (isolate from environment)
Beware solar heating - can raise
external temperature above
threshold limits!
SCC failure of 316L
108