DESIGN AND CHANGE OF Date: 09.09.

2005
Institutt for Produktutvikling og ENVIRONMENT Rev.: 01
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DESIGN AND CHANGE OF

ENVIRONMENT
Important elements in reducing
corrosion and erosion

Prepared by

Professor Roy Johnsen, Inst. of Engineering Design and Materials - NTNU

E-mail: [Link]@[Link]

Trondheim September 2005

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AGENDA Page

1 INTRODUCTION ........................................................................................ 3
2 DESIGN AGAINST CORROSION .............................................................. 3
2.1 Introduction.......................................................................................... 3
2.2 Corrosion allowance ............................................................................ 4
2.3 Galvanic corrosion ............................................................................... 4
2.4 Replacement components/spools........................................................ 6
2.5 Flow velocity ........................................................................................ 7
2.6 Avoid possible leakage in critical areas ............................................... 7
2.7 Self drainage ....................................................................................... 8
2.8 Vibration and fatigue............................................................................ 9
2.9 Insulation ........................................................................................... 11
2.10 Summary ........................................................................................... 13
3 CHANGE OF ENVIRONMENT ................................................................. 14
3.1 Introduction........................................................................................ 14
3.2 Removal of water............................................................................... 14
3.3 Reduction of oxygen .......................................................................... 15
3.4 Reduction of velocity.......................................................................... 16
3.5 Reduction of solid particles................................................................ 16
3.6 Temperature ...................................................................................... 16
3.7 Temperature ...................................................................................... 17
3.8 pH adjustment ................................................................................... 18
3.9 Corrosion inhibitor ............................................................................. 19

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1 INTRODUCTION
There are several ways to prevent or reduce the susceptibility of corrosion for a construction.
The most important are:

1. Select the most appropriate material and material combination.

2. Corrosion protection by coating
3. Cathodic Protection
4. Anodic Protection
5. Design
6. Change of environment

In this document corrosion prevention by Design and Change of environment will be

described. However, during design other threats like vibration and fatigue will also be shortly
desctibed.

2 DESIGN AGAINST CORROSION

2.1 Introduction
Selection of material and design are linked close together. In complex construction individual
components, the interaction between them and the relation to other structures and surroundings
have to be taken into account. During design all phases in the life of a construction needs to be
taken into account:

o Production
o Storage
o Transport
o Operation
o Shut down
o Repair/Maintenance

Each design needs to be based on the properties of the actual material.

In the following sections are giving a short description of important elements to be used to
reduce the probability of corrosion.

Figure 2.1 Examples of “bad” design causing serious corrosion.

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2.2 Corrosion allowance

Most components like pipes, vessels, containers, piles are normally designed with a corrosion
allowance (CA (mm/y)). The basis for this is the assumption that the component is exposed to
general corrosion with an average corrosion rate CRave (mm/year) and a design lifetime of LD.
The necessary corrosion allowance is calculated according to:

CA = CRave * LD (2.1)

Assuming a wall thickness TS to withstand the load the theoretical minimum design wall
thickness tD of the construction will be, see Figure 2.2:

tD = CA + TS (2.2)

CA

Ts

Ts : Thickness due to strength

CA : Corrosion Allowance – based on
corrosion rate and life time

Figure 2.2 Corrosion Allowance (CA) added to the wall thickness TS needed for the
load/strength.

2.3 Galvanic corrosion

Galvanic corrosion is one of the biggest threats to the integrity of a construction. During the
material selection process, it is important to use galvanic series to control the possibility of
galvanic corrosion. By selecting materials within a potential difference less than 50 mV, serious
galvanic corrosion is normally avoided.

The area ration between the noble material (cathode), AN, and the less noble alloy (anode), ALN,
in the galvanic coupling, is an important factor. Assuming the use of two different metals can
not be avoided, it is of vital importance that:

ALN >> AN (2.3)

In this situation the corrosion on the less noble alloy will be restricted – but it can still be
serious. The potential drop between the two metals also plays an important role for the
galvanic corrosion.

To achieve galvanic corrosion, the following requirements need to be fulfilled:

1. The two metals are in direct electrical contact.

2. The two metals are exposed to the same electrolyte.

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One way to avoid galvanic corrosion is to insulate the two metals from each other. When
using this solution it is important to secure 100% insulation. In piping systems this can be a
problem due to possible metallic contact through the supports and the metal frame. Figure 2.4
shows two examples of how to avoid galvanic corrosion:

Upper: Insulation gasket Î not a preferred solution

Lower: Internal coating of noble alloy Î preferred solution

Hole

a) b)
Figure 2.3 a) Galvanic series in seawater, b) hole due to galvanic corrosion in 90/10 CuNi
coupled to Titanium seawater cooler.

90/10 CuNi Titanium

Gasket Support

Metal frame

Coating

90/10 CuNi Titanium

Gasket Support

Metal frame

Figure 2.4 Galvanic connection between 90/10 CuNi and Titanium pipes for transport of
seawater.
Upper figure: Gasket to prevent galvanic corrosion
Lower figure: Internal coating in noble alloy to prevent galvanic corrosion

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2.4 Replacement components/spools

Some components are exposed to corrosion during operation without any possibility to change
this exposure during the design. For such components it is important to design with
components/spools that can be easily replaced during operation. Figure 2.5 shows one
example that is often seen in the field: A piping system with a less noble alloy (e.g. 90/10 CuNi)
is connected to a heat exchanger made from a more noble alloy (Titanium). The designer
knows that galvanic corrosion will occur on the less noble alloy after a certain exposure time.
To prepare for an easy (e.g. less expensive) repair, a replacement spool is installed. By having
this replacement spool in stock, the repair can be done quickly.

Figure 2.6 shows another example with a bend exposed to corrosion and/or erosion during
operation.

Titanium plate
heat exchanger

90/10 CuNi Replacement

pipe spool

Steel frame

Figure 2.5 Construction prepared for easy repair by designing a replacement spool into
the system.

PIPE
900 BEND

900 bend flanged into the pipe

system – easy to replace if
corrosion-erosion problems occur

PIPE

Figure 2.6 Bend exposed to corrosion and/or erosion; Designed for easy replacement
during operation.

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2.5 Flow velocity

Corrosion and/or erosion are a threat to the integrity of a piping system. The different metals or
alloys can withstand a certain flow velocity without suffering erosion-corrosion or plain erosion.
In water systems (without solids) the following critical velocities, Vcr can be used as a “rule-of-
thumb”:

Carbon steel: 5 – 6 m/s

Copper: 2 m/s

90/10 CuNi: 3 – 4 m/s

AISI 316L: 20 – 30 m/s

Titanium: 20 – 30 m/s

If solid particles are present these values will be reduced. The simplest way to reduce the
velocity of a piping system is to increase the piping diameter DP. The following connection
exists between the flow velocity, V, and the pipe diameter assuming the same flow rate QP:

QP = VP*(πDP2/4) (2.4)

Î VP1 = VP2*(DP1/DP2)2 (2.5)

DP1 VP1

DP2 VP2

Figure 2.7 Schematic comparison of flow velocity in two pipes with different diameter but
equal flow rate.

2.6 Avoid possible leakage in critical areas

Some areas are more critical than others. One typical example is possible water spray from a
leakage in an area with electronic equipment. Another example is routing of piping with high
safety consequence to personnel. In both these cases special precautions should be taken (if
possible) during design. Figure 2.8 shows one example with a vessel and a piping system
located over an electronic unit. A leak in the valve will cause water spill to the electronic unit
that can be damaged. To avoid this problem, a drip tray is mounted under the piping system to
collect possible water spill and guide it away from the electronic unit.

Figure 2.9 is taken from information sent out by Statoil after an accident on their Sleipner A
platform. The cost for this accident was 200 MNOK. One way to avoid this failure could have
been to re-route the piping system outside this unmanned room.

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Vessel Valve
Pipe

Leak in the valve

Electronic unit

Vessel Valve
Pipe

Drain tray
Drain tray

Drain pipe

Electronic unit

Figure 2.8 Example of water spill damaging electronic unit and a way to avoid this.

Seawater piping made from 90/10 CuNi passed in the ceiling of one
electronic room on Sleipner A. The room was normally unmanned.
Leakage in the piping occurred and seawater wetted the electronic
equipment. This resulted in shut down of the production for several
days. The total cost of this incident was close to 200 MNOK.

Figure 2.9 Copy from information from Statoil after an accident offshore.

2.7 Self drainage

Stagnant water in piping systems and vessels can cause high corrosion rates. During the
design it is important to secure that areas with stagnant water can occur. Figure 2.10 and 2.11
shows two important design rules related to this:

Rule 1: Design always piping system with an angle to secure drainage

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Rule 2: Install always drainage valves at the lowest point in a pipe or a vessel.

α>0

Figure 2.10 Preferred piping design with an angle α > 0 to secure self drainage of the
piping.

Outlet

Drain valve 1

Drain valve 2

Inlet

Figure 2.11 Preferred installation of a drain valve (green) in a piping system (low spot).

2.8 Vibration and fatigue

Vibration is a big threat to the integrity of a piping system. If the system is not supported
according to accepted design rules, see Figure 2.12, vibration will occur and after a certain time
in operation, fatigue will start followed by fracture.

PIPE

PIPE SUPPORT
Pipe support distanse L

Figure 2.12 Schematic of pipe support to avoid vibration.

The following pipe systems are exposed to vibration:

o Small bore protruding pipes

o Thin walled pipes
o High pressure and high velocity pipes
o Thermo wells/probes
o Stress critical lines

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o Pipes connected to pumps and compressors

o Internal pipes in coolers/heat exchangers

Figure 2.13 shows two examples of a construction of valves connected via a small bore pipe to
a main pipe. In both cases a relatively “big” mass is connected. In a) the unit is not supported
at all, while in b) the small bore pipe is supported, while the bigger pipe is not supported and are
able to move (up, down, side ways). The most likely result is fatigue crack in the welds on the
small bore pipe.

Free pipe

Problem area Problem pipe

Support
a) b)

Figure 2.13 Components with big mass connected to a main pipe through a small bore pipe
(© MainTech as).

Figure 2.14 a) Fracture after 11 years in operation due to vibration b) Mechanical damage
on small bore pipe due to elongation (± 100 mm) during start up and hammered
against a steel support (© MainTech as).

During the design it is possible to reduce the exposure to vibration and fatigue. Figure 2.15
shows an example how the complex valve arrangement have been redesigned to a much
simpler and robust design still fulfill the same requirement (double “bleed and blind valve”).
Instead of stiff pipes, a flexible pipe connection is used.

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Old ”blind & bleed valve” New ”blind & bleed valve”

Figure 2.15 Redesign of valve arrangement to avoid vibration and fatigue cracks
(© MainTech as).

2.9 Insulation
Different types of insulation are used on piping systems and vessels. The most frequently used
insulation systems are:

o Heat preservation
o Freeze prevention
o Personal protection
o Fire protection

Figure 2.16 shows pictures of corrosion under insulation (CUI) close to the bottom of a column
for gas treatment. Temperature is 900C. Max. wall thickness reduction 10 mm.

Figure 2.16 Corrosion under insulation on a column for gas treatment.

Figure 2.17 shows a schematic view of a carbon steel tank with internal volume 200 m3 external
insulated. The tank is not coated under the insulation. After 10 years in operation, an external
inspection identified serious corrosion in connection with one stiffener ring. More than 90% of
the wall thickness was corroded away. The reasons for this problem were:

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1. Damage in the mantel on top of the tank (hole)

2. Stiffener rings with orientation that collects water.
3. Insulation that keeps the carbon steel surface wet.
4. No coating on the steel surface beneath the insulation.

Hole Water

Mantel

Insulation

Carbon steel tank

Stiffener
ring

Figure 2.17 Carbon steel tank exposed to corrosion under insulation due to bad design.

Corrosion under insulation is among the most frequently failure mechanism in a plant. The
following general rules are important to follow:

1. Avoid the use of insulation where it is possible

2. Replace insulation for personnel protection with protection shielding
3. Use insulation that do not collect water (foam instead of rock wool)
4. Always use coating beneath insulation (Figure 2.18)
5. Install drain holes in the insulation to secure water that comes in will escape (Figure
2.19)

Insulation

Pipe to be insulated

Coating
Figure 2.18 Coating is necessary under insulation.

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Insulation

Pipe to be insulated

Drain holes in insulation

Figure 2.19 The importance of drain holes in insulation in the bottom of a pipe.

2.10 Summary
The following summary is important to follow:

o When designing with carbon steel add corrosion allowance to the thickness calculated
for strength
o Secure easy replacement of components exposed to corrosion and/or erosion
o For constructions exposed to the atmosphere: do the design in a way that secure moist
to drain so that the construction most of the time is kept dry
o Design in a way that make the unit/component/system easy to maintain and inspect
o Use welding instead of bolting (if possible)
o Avoid local hot and cold areas
o If you do not need insulation – remove it!
o Use simple geometries and rounded corners
o Design in a way that the flow velocity is below critical values for the actual material
o Avoid solid particles (sand) in the fluid. If not possible, the flow velocity needs to be
adjusted based on max. acceptable erosion
o Use “flange pressures” that prevent water to penetrate into the flange crevice
o Drain point should be installed on all vessels and pipes on the lowest point
o Use the galvanic series actively when selecting materials for a design
o Select the most suitable material for the actual use – remember that process conditions
can change during operation!

The most important rule to follow is:

Contact the corrosion expert in advance for verification of design to avoid

problems during operation.

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3 CHANGE OF ENVIRONMENT
3.1 Introduction

3.2 Removal of water

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3.3 Reduction of oxygen

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3.4 Reduction of velocity

3.5 Reduction of solid particles

3.6 Temperature

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3.7 Temperature

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3.8 pH adjustment

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3.9 Corrosion inhibitor

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