Corrosion Engineering (Practical)

Name: Farwa Naeem Roll No: 16MME-S2-317

Semester: 6th Session: 2016-20

Date of Submission: 04/02/2020

Experiment No. 13
Calculate the weight loss in steel sample due to erosion corrosion in 3.5% NaCl solution with
10% silica sand particles as per ASTM G-184.

Lab Instructor Signature: ________________

Grade/Marks: _______________
Figure 1: RC Apparatus

Figure 2: Pipe Failure on Bending Areas due to Erosion Corrosion

Experimental title
Calculate the weight loss in steel sample due to erosion corrosion in 3.5% NaCl solution with
10% silica sand particles as per ASTM G-184.

Objective
To understand erosion corrosion phenomena through rotating cage.

Principle
This practice provides a method of evaluating corrosion inhibitor efficiency in a RC
apparatus. The method uses a well-defined rotating specimen setup and mass loss
measurements to determine corrosion rates in a laboratory apparatus. Measurements are made
at a number of rotation rates to evaluate the inhibitor performance under increasingly severe
hydrodynamic conditions.

Background
Petroleum institute fabricate an apparatus to measure weight loss of a sample in less time
(See Figure 1). Apparatus was named Rotating Cage (RC), which work on Fluid
moments/particle moments phenomena i.e. is a dynamic system. As speed increase,
depolarization within a structure increase. Weight loss time duration shrunk down. 3.5%
NaCl with 10% silica sand is added into the electrolyte. Silica sand particles strike steel
sample and cause erosion corrosion. Hitting can be Impingement or striking.
Striking: solid – solid interface
Impingement: liquid – solid interface (due to particles).
We can also evaluate erosion corrosion, by adding inhibitor with 3.5% NaCl in Rotating
cage, as inhibitor work in dynamic motion. Standard ASTM G 184 is designed for both,
inhibitor and 10% silica sand. And will provide complete guideline regarding “Hole
diameter”, “Number of slots” and “dimension”.
Erosion corrosion mechanism
No substrate has uniform surface. There are always some defects present on surface of
sample. High speed liquid cause widening of already present hole/defect. That is called
erosion corrosion. Rougher the surface, more will be the erosion corrosion effect. Erosion
corrosion is mostly on elbows/bending areas as shown in figure 2. Elbow leakages are due to
erosion corrosion because fast moving material (fluid) strike at elbow, widen defect, cause
hole/leakage point formation.
As at low pressure speed is high. For example, Turbine blades/ repeller. Cause enhanced
erosion corrosion.
Figure 3: Schematic Diagram of Rotating Cage

Figure 4: Photo of Rotating Cage Containing Coupons

Figure 5: Photo of Rotating Cage (Top View)

Construction (Please See Figure 3)
1. Rpm controller/inverter:
Drive motor at different frequencies.
2. Motor (0.5 Horsepower):
Rotate shaft.
3. Rotating cage:
To attach sample, carry slots that secure sample. Typically, eight coupons (each of 75
mm length, 19 mm width, and 3 mm thickness, and a surface area of about 34.14 cm 2)
are supported between two PTFE disks (of 80 mm diameter) mounted 75 mm apart on
the stirring rod (Fig. 4). Holes (10 mm diameter) about 15 mm away from the center
are drilled in the top and bottom PTFE plates of the cage to increase the turbulence on
the inside surface of the coupon (Fig. 5).
4. Vessel/Slurry pot:
The vessel (typically 150 mm diameter) is manufactured from an inert material. PTFE
have been used. Carry liquid (electrolyte).
5. Teflon base:
For alignment purpose. At the center of the base, a hole is drilled into which the lower
end of a stirring rod is placed. This arrangement stabilizes the stirrer and the coupons.
6. Lid:
To cover the vessel.
7. Rotating Shaft/Stirring rod (stainless steel):
Stirring purpose.
8. Impeller:
A fan that create tornado which prevent sand from settling at the base and add more
impact towards sample.
Sample should not be touched after operation as it damages impressions present already, that
we need to observe afterward. Should be dried as it is.
Materials
The coupons shall be made of the material (such as carbon steel) for which the inhibitor is
being evaluated. The coupon should have the same metallographic structure as that used in
the service components
Test Solution
All solutions (oil and aqueous) should be obtained from the field for which the inhibitor is
being evaluated. These are known as live solutions. It is important that live solutions do not
already contain corrosion inhibitor. In the absence of live solutions, synthetic solutions
should be used, the composition of which should be based on field water analysis. The
composition of the solution should be determined and reported. Alternatively, standard brine
should be employed. The solutions should be prepared using analytical grade reagents and
deionized water.
 (a) (b)

(c)

(d) (e)
Figure 6: Show (a) As received Sample (b) After Grinding (c) Stereo Micrograph (d)
Roughness of grinded sample (e) Weight of grinded Sample
Standard for experiment
ASTM G-184-06:
Standard practice for evaluating and qualifying oil field and refinery corrosion inhibitor using
rotating cage.
Apparatus
1. Rotating Cage Apparatus
2. Surface Profilometer (Mitutoyo SJ-201)
3. Stereo Microscope (Magnifying Glass)
4. Vernier Caliper
5. Weighing Balance
Materials
1. Carbon steel strip
2. Cleaning Solution
Procedure
1. Take sample (See Figure 6 (a)) and do rough grind, using emery paper P 100. Clean
whole surface (See Figure 6 (b)).
2. Place the sample under Stereo Microscope (Magnifying Glass) and observe the
prepared surface of sample (See Figure 6 (c)).
3. Calculate average roughness (Ra) of sample using Surface Profilometer as shown in
figure 6 (d).
4. Take dimensions (Length, Width, Thickness), calculate surface area and measure
weight of given sample (Figure 6 (e)).
5. Put sample in Rotating cage (Figure 7). Rotating cage parameters are;
a) Solution (3.5% NaCl)
b) 10% Silica sand (60 Mesh size)
c) 1800 RPM (frequency = 30 Hz)
d) Time = 1 hour

6. After 1 hour, take the sample out and dry it using dryer, as shown in figure 8 (a).
7. Place it under Stereo Microscope and observe the surface (See Figure 9). Calculate
average roughness (Ra), see difference, as shown in figure 8 (b) and clean (remove
corrosion product) it as shown in figure 10 (a), using cleaning solution (Water).
8. Again, do Stereo Microscopy (See Figure 11). Calculate average roughness (R a) as
shown in figure 10 (b) and weigh it.
9. Using formula, calculate weight loss

Δm
Wt. loss =
At
Figure 7: RC running

(a) (b)
Figure 8: Shows (a) Dried Sample After Process (b) Roughness of Processed sample

Figure 9: Stereo Micrograph of processed sample

Results
Conductivity of Electrolyte = 61.7 mS
pH of Electrolyte = 6.5
Table 1: Dimensions of as received sample (After grinding)

Average
Length 75.087 mm
Width 19.053 mm
Thickness 2.943 mm
Surface Area (A) 3,415.373 mm2
Table 2: Difference in Parameters, before and after the process

Before Process After Process

Weight (m) 31.894 g 31.903 g
Before After
Roughness 0.83 μm cleaning cleaning
0.82 μm 0.51 μm

Calculations
Δm
Wt. loss =
At

m1 = 31.903 g
m2 = 31.894 g
Δm = m1 – m2 = 31.903 – 31.894
Δm = 0.009 g
= (0.009/3.4 x 10-3 x 1 hr) x (24hr/1day)
Wt. loss = 55.911 gmd
 (a) (b)
Figure 10: Shows (a) Processed sample after cleaning with cleaning solution (water) (b)
Roughness of cleaned sample

Figure 11: Stereo Micrograph of cleaned sample

Figure 12: Pourbaix Diagram of Iron-water system

Discussion
From data gathered through experiment (RC apparatus) it can be seen that weight loss is very
small. This may be due to less time exposure. Erosion is a dynamic phenomenon, that require
small time to destroy a structure. But too small-time duration may not effect the structure to
that extent. Silica sand present in liquid electrolyte just remove a rough layer from the sample
surface. It can be noticed in table 2 that roughness decreases. During operation sand
bombardment cause upper defective, rough layer weakening. Which upon cleaning, removed
and hence roughness decreased down to 0.51 from 0.83 μm, see table 2.
Stereomicrograph Figure 9 show little brownish material over the surface of specimen. This
is corrosion product plus sand accumulation. On cleaning using cleaning solution, a smooth,
shiny surface is visible which represent little or no corrosion.
Figure 12 represents pourbaix diagram of iron-steel system. From diagram it can be seen that
at low potential, pH 6.5 remain in immunity region. On increasing potential it may enter the
corrosion region but continuous increase in potential lead to passivity region, which is again a
safe place.
Conclusion
Steel sample corrode to some extent due to erosion corrosion phenomenon.
References
1. Corrosion Technology Volume 1 by Prof. Dr. Ijaz Hussain Khan
2. Principles of Corrosion Engineering and Corrosion Control by Zaki Ahmad