3050 Using This Manual

Abstract
This section tells you how this manual is organized. Abstracts of each section are
included along with a list of other Company manuals. The index at the end of the
manual will also help you find particular topics.

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Scope and Application

The Corrosion Prevention and Metallurgy Manual, Volume 1, consists of Engi-
neering Guidelines that cover a wide range of corrosion topics. The General Guide-
lines are concerned with the chemical and metallurgical bases for corrosion. In
addition to explaining basic corrosion mechanisms they provide guidance in
avoiding, recognizing, detecting, and mitigating the specific types of corrosion that
are a problem in our industry. The General Guidelines also address certain specific
equipment corrosion problems.
Volume 2 of the Corrosion Prevention and Metallurgy Manual, Cathodic Protec-
tion, covers specific applications of impressed current and sacrificial anode cathodic
protection. The applications discussed include pipelines, tanks, offshore structures,
well casings, vessel internals, piling, submerged manifolds and submarine pipe-
lines. Included are sections explaining the fundamental principles of cathodic
protection, methods of determining criteria for cathodic protection, basic equations
and data used in system design, and system maintenance.
Volume 3 of the Corrosion Prevention and Metallurgy Manual covers corrosion
control practices specific to large plants and refineries.
It consists of nine Engineering Guidelines, each covering corrosion problems and
corrosion prevention in one type of refinery facility. Each guideline reviews the
basic process in question and identifies the corrosives typically associated with the
process as well as plant areas, equipment, and materials susceptible to each type of
corrosive attack. Design, operating, and materials choices are discussed in view of
their role in mitigating corrosion.
The intent of this manual is to make available useful information based on Company
experience. Therefore, forms for suggesting changes have been included at the
front. Your input and experience are important in improving subsequent editions and
keeping this manual up-to-date.

Organization
The colored tabs in the manual will help you find information quickly. In summary:
• White tabs identify general purpose topics.
• Blue tabs denote Engineering Guidelines.
• Gray tabs (if any) are used for Specifications and related drawings and forms.
• A Red tab is included for local documents.
Change bars, vertical black lines in the margins of this manual, indicate information
has been added, changed, or deleted from the last edition of the manual.
Where a paragraph(s) has been deleted, a single change bar will run from the last
line of the first paragraph to the first line of the next.

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Engineering Guidelines — Abstracts

The following paragraphs comprise abstracts of each section of the manual.
Section 100, “Fundamentals of Corrosion Mechanisms,” describes some basic
corrosion mechanisms of concern to the petroleum industry and serves as an intro-
duction to those sections of the Corrosion Prevention and Metallurgy Manual that
discuss specific types of corrosion and the practices that have been developed for
their control.
Section 200, “Corrosive Environments,” discusses corrosion caused by corrosive
environments, and recommended metallurgy. Section 210 covers general and local-
ized corrosion of steel, stainless steels, nickel alloys, copper alloys, titanium, and
aluminum alloys in sea water and brine. It also covers internal and external corro-
sion and specifically discusses offshore platform corrosion. Section 220 discusses
corrosion by cooling water.
Section 300, “Metallurgy,” discusses several general corrosion phenomena that
affect both upstream and downstream units. It includes alternatives for material
selection to remedy commonly encountered corrosion problems.
Section 400, “Characteristic Corrosion Phenomena,” describes various types of
corrosion monitoring or test methods. These methods include the use of electronic
devices comprised of meter and probe, corrosion specimens (weight loss coupons)
in field equipment, probes to detect the presence of hydrogen, and nondestructive
test methods.
Section 500, “Corrosion Monitoring Methods,” discusses the use of corrosion
inhibitors in various environments. It also provides a guide for the use of polysul-
fide corrosion inhibitors and a guide to evaluating corrosion inhibitors in the
laboratory.
Section 600, “Corrosion Inhibitors,” discusses the use of corrosion inhibitors in
various environments. It also provides a guide for the use of polysulfide corrosion
inhibitors and a guide to evaluating corrosion inhibitors in the laboratory.
Section 700 concerns specific corrosion problems associated with specific equip-
ment, as follows.
Section 710, “Corrosion of Tank Shells and Roofs,” presents data on corrosion
rates of storage tank shells and roofs in black oil and crude, light oily stock, and
light non-oily stock services. Recommended design corrosion rates are given for
each type of service. Variables which influence corrosion rates are also discussed.
Section 720, “Corrosion of Storage Tank Bottoms,” discusses internal and
external corrosion of tank bottoms. Inspection techniques and design alternatives to
reduce corrosion are included.
Section 730, “Corrosion Under Insulation and Fireproofing,” discusses causes
and prevention of corrosion under insulation and fireproofing.
Section 740, “Corrosion in Steam Condensate Systems,” covers corrosion in
steam condensate systems. Topics include causes of condensate corrosion, sources

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of dissolved oxygen and carbon dioxide, corrosion inhibitors, and corrosion evalua-
tion techniques.
Section 750, “Corrosion of Heat Exchangers” addresses corrosion concerns and
corrosion damage mechanisms specific to heat exchangers. Refinery services which
have had the most significant corrosion-related problems are discussed. This section
lists additional sources of information regarding corrosion of heat exchangers.
This section also provides information on four classes of high alloy tubing mate-
rials. The discussion covers advantages and limitations of each alloy, service infor-
mation and history, and design considerations. Finally, this section briefly describes
current issues of concern regarding inspection, repair, and replacement strategies for
heat exchanger tubes.
Section 800, “Corrosion Control Practices,” covers two corrosion control prac-
tices: mothballing and chemical cleanup. Various methods for mothballing are
given, as well as techniques for specific items of equipment. Typical short-term and
long-term mothballing schemes are summarized.
The fundamentals of chemical cleaning are outlined with emphasis on hazards to
personnel and equipment. This section is not a detailed guide to specific chemical
cleaning procedures. Such procedures are very site-specific and beyond the scope of
this manual.
Section 1100, “Fundamentals of Cathodic Protection,” discusses mechanisms of
cathodic protection and types of cathodic protection available to engineers for corro-
sion control. This section also discusses the corrosion of metal in contact with moist
soil or water, and the tendency of some metals to corrode preferentially with respect
to other metals when located in the same environmental conditions.
Section 1200, “CP for Pipelines,” covers cathodic protection systems for onshore
and offshore pipelines. Important subjects considered include protection criteria;
insulation and testing of joints, flanges and casing; test lead requirements and instal-
lation; current requirements and their calculation for single and multiple drain point
systems; and system selection, design, and installation.
Section 1300, “CP For Tank Bottoms (Underside),” covers sacrificial anode and
impressed current cathodic protection systems for tanks. It discusses soil tests, foun-
dation types, design parameters, and cost analysis. Step-by-step design examples are
given for protecting single tanks, and larger systems that protect many tanks are
discussed briefly. Retrofits for existing tanks are discussed, along with their
limitations.
Section 1400, “CP of Offshore Structures,” covers the types of systems used in
cathodic protection of marine structures. It includes calculations and selection
criteria based on performance and cost. Design guidelines for fixed equipment used
to monitor the cathodic protection system are also included.
Section 1500, “CP of Onshore Well Casings,” covers the basic design concepts
and criteria for protection of well casings. System design and limitation are
discussed, along with economic factors influencing the decision to use cathodic

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protection. Emphasis is placed on the problems of anode bed design and interfer-
ence. Guidelines for system energization and maintenance are also included.
Section 1600, “CP for Special Applications,” currently discusses cathodic protec-
tion of vessel internals only. Future work will expand the section to include galvanic
current cathodic protection of submerged manifolds, submarine pipelines, and ways
to protect ships, boats, barges, and process equipment.
Section 1700, “CP Measurements and Testing,” discusses some of the measure-
ments made and testing techniques used most commonly in cathodic protection. It
does not include detailed procedures covering all types of tests under all conditions.
The discussion covers basic principles which, once understood, may be modified for
use with various other specific cases.
Test procedures covered include level-of-protection tests, soil resistivity measure-
ments, current drain tests, current flow in pipelines, interference tests, and miscella-
neous measurements and tests. Also discussed are instruments and equipment used
for cathodic protection testing.
Section 1800, “Maintenance of CP Systems,” discusses the need for and methods
of obtaining effective routine, monitoring, and maintenance procedures; and good
record keeping in diagnosing and resolving cathodic protection problems.
Section 1900, “Design Data for CP Systems,” includes charts, equations, and
figures used to calculate cathodic protection parameters for pipelines, tanks, heat
exchangers, well casings, offshore platforms, and marine craft.
Section 2000, “Introduction to Specifications,” collects Operating Company
drawings that show examples of corrosion prevention methods.
Section 3100, “Crude Distillation Units,” covers materials of construction and
other controls used to minimize corrosion in furnace tubes and transfer lines, atmo-
spheric and vacuum columns, column overhead systems, and other crude distilla-
tion facilities. Corrosive agents include high-temperature H2S, naphthenic acid,
and HCl.
Section 3200, “Fluid Catalytic Cracking Units,” discusses the major corrosion
and erosion problems in a fluid catalytic cracking (FCC) unit. Included in this
section are discussions on mechanism and methods of control for erosion, oxida-
tion, hydrogen sulfide corrosion, hydrogen damage, overhead stress corrosion
cracking, and graphitization.
Section 3300, “Isocracking and Hydrotreating Plants,” gives an overview of the
hydrotreating and isocracking processes is followed with descriptions of the types of
corrosion associated with these processes, including high-temperature hydrogen
attack, high temperature H2S corrosion, stress corrosion cracking by chlorides,
sulfur acids, and sulfides, and aqueous corrosion by sulfitic water condensates.
Section 3400, “Catalytic Reforming Units,” covers corrosion in catalytic
reformers by hydrogen attack, H2S, and HCl corrosion. It includes a discussion of
stress corrosion cracking in specific equipment.

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Section 3500, “Sulfuric Acid Alkylation Plants,” discusses materials design

considerations for handling concentrated sulfuric acid and corrosion in the distilla-
tion system.
Section 3600, “Hydrogen Manufacturing Plants,” pure hydrogen for refineries
and ammonia plants is usually produced by steam-hydrocarbon reforming. This
section covers material failure problems associated with this process, including high
temperature creep-rupture failures of reformer furnace tubes, high temperature fail-
ures of pigtails, headers, and transfer lines, and corrosion failures of carbon and
stainless steel equipment in carbon dioxide (CO2) removal facilities. Materials used
to minimize these problems are also discussed at length.
Section 3700, “Acid Gas Removal Plants,” three types of amines are commonly
used in acid gas removal plants: monoethanol amine (MEA), diethanol amine
(DEA), and methyl diethanol amine (MDEA). Hot potassium carbonate systems
(Benfield and Catacarb) are primarily used for CO2 removal. This section covers
corrosion problems found in CO2 and H2S removal plants that use these processes.
Section 3800, “Sour Water Strippers,” covers both sour water strippers and
Chevron WWT plants. The emphasis is on ammonium bisulfide corrosion and
cyanide corrosion.
Section 3900, “Sulfur Plants,” corrosion problems in sulfur plants include high
temperature sulfidation, sulfur acid attack, stress corrosion cracking, and aqueous
corrosion. This section describes the Claus sulfur plant process along with material
and equipment corrosion problems likely to be encountered, and recommends mate-
rials and process control choices that will mitigate their effects.
This section does not cover tail gas plants. Consult a materials specialist if assis-
tance is needed.
Section 4100, “Corrosion Considerations in Upstream Operations” is intended
to provide a basic overview of corrosion principles for upstream production and
drilling facilities that use both carbon steel and corrosion resistant alloys. The
discussion is limited to oil and gas production, although most of the information is
relevant to water injection. Salt water facilities are not covered. The reader is
encouraged to review other sections of the Corrosion Prevention and Metallurgy
Manual and contact CRTC Materials and Equipment Engineering for additional
information.
Section 4200, “Materials Selection for Completion Equipment” discusses mate-
rials selection for upstream completion equipment. The section focuses on corro-
sion resistant alloys and covers very specific equipment for oil and gas well drilling
operations.
Section 4300, “Materials Selection for Surface Equipment” discusses materials
selection for corrosion resistant alloys in typical production facilities. The discus-
sion is limited to five basic facilities: gathering systems, primary separation
systems, gas compression systems, gas dehydration systems, and produced water
handling.

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Other Company Manuals

The text sometimes refers to documents in other Company manuals. These docu-
ments carry the prefix of that manual. The prefixes and their referents are:
Prefix Company Manual
CIV Civil and Structural
CMP Compressor
COM Coatings
CPM Corrosion Prevention and Metallurgy
DRI Driver
ELC Electrical
EXH Heat Exchanger and Cooling Tower
FFM Fluid Flow
HTR Fired Heater and Waste Heat Recovery
ICM Instrumentation and Control
IRM Insulation and Refractory
MAC General Machinery
NCM Noise Control
PIM Piping
PMP Pump
PPL Pipeline
PVM Pressure Vessel
TAM Tank
UTL Utilities
WEM Welding

To Get Help
Call CRTC Materials and Equipment Engineering at CTN 242-5139.

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August 1999 3050-8 Chevron Corporation