Corrosion Overview Online - 1

A SABIC Affiliate
CORROSION OVERVIEW
Prepared by:
Muazu Mohammed – AED
Classification: Internal Use
COURSE OVERVIEW
• Lecture Objectives
• Corrosion, Its Effects & Key factors
• Types of Corrosion
• Corrosion Control & Mitigation
• Corrosion Assessments (Loops & Circuits)
• General Discussion
2
OBJECTIVE
Objectives: the objective of this lecture is to provide:
• Understanding of Material Degradation due to corrosion
• Understand key factors in failures due to Corrosion
• Corrosion & Mitigation
3
CORROSION, ITS EFFECTS & KEY
FACTORS
4
CORROSION, ITS EFFECTS & KEY FACTORS
• The huge annual loss due to corrosion is enormous (5% of

a GDP), this can be minimized by:
 Proper understanding of the basics of corrosion
 Proper Materials Selection
 Operating within IOWs
 Quality Inspection
80% of corrosion loss can be eliminated
With the above controls
 Proper Monitoring & Control
5
• The consequences of corrosion are many!11!!!!!11 The question is the loss of metal
itself very consequential?
 Safety & Environmental The answer is often : ……………..
But the major repercussion
 Business disruption – Downtime of equipment
 Escape of fluids & product Contamination

 Reduced value of goods & Repair Cost
 Lost surface properties
 Reputation
6

Corrosion
 When metals are refined from natural ores
 Energy absorbion is necessary duirng steel making.
 Different materials absorb energy in different amounts.
 The driving force that causes corrosion
 the natural tendency for them to revert to their more stable
(lower energy) oxide form as originally found in nature.
 What is Corrosion?
 Practically
The tendency of a Metal to Revert to its Native State
 Scientifically
The destructive attack of a metal by a chemical or by Ore Metal Product Rust
electrochemical reaction with its environment”.
Energy
 does stable metal corrode??? released
Energy input
7

PRACTICAL GALVANIC SERIES
Electromotive Series
Material Potential*
Pure Magnesium -1.75
Common elements listed in the Magnesium Alloy -1.60
order how much energy will be Aluminum Alloy -1.10
needed to extract metals from their Zinc

Cadmium
-1.05
-0.80
ores Mild Steel (New) -0.70
Mild Steel (Old) -0.50
Or how much energy will be Cast Iron -0.50
released during the corrosion Stainless Steel

Copper, Brass, Bronze
-0.50 to + 0.10
-0.20
process Titanium -0.20
Gold +0.20
Carbon, Graphite, Coke +0.30
* With Respect to Saturated Cu/CuSO4 Electrode
8
 Anodic Reactions produce;

 Cations reacting metal becomes more
positive
 Oxidation occurs
 Produce Electrons
 Equation:M0 Mn+ + ne-
Anode Cathode
-600mV - -550mV
575mV
9
All Present
Metallic
Overall Corrosion Reaction
Metallic Corrosion Remove
Path Occurs Path Metallic Path by This illustration demonstrates
isolation /
Cathode
separation, the four essential elements
Anode
corrosion
Cathode
required for corrosion to occur:
Anode
minimal
 Anode
Electrolyte  Cathode
 Electrolyte
Electrolyte
 Metallic Path
Remove
Remove any one element and
Metallic
Path
Electrolyte
Metallic
Remove anodic
areas by
corrosion will not occur. This is
by coating,
corrosion Path applying CP, the principle of corrosion
Cathode
minimal Inhibitors,
Anode
Cathode Material control.

Anode
selection,
corrosion
minimal
Electrolyte Electrolyte
10
Acceleration of Corrosion Acceleration of Corrosion

Factors that affect the rate of corrosion Physical Characteristics
 Metallurgy  Exposed area (less, increases corrosion
 Electrode Potential rate)
 Temperature  Time of exposure (more time, more
 Concentration of Electrolyte, corrosion)
 Water chemistry, pH, Moisture content, Chemical  Others
Salts  Agitation (Flow Velocity)
 Environment;
 Solids
 Humidity, Oxygen,
 Pressure
 Acidic environment
 Dissolved Gases (CO2,H2S, O2)
 Sulfur gas environment
 Chemicals and airborne gases  Microbial Activity
11
TYPES OF CORROSION
12
TYPES OF CORROSION
Uniform corrosion of a single metal
 Usually an electrochemical reaction at granular ( pits of micrometer) level
 Uniform and continuous thickness loss over entire surface, quasi-uniform, or uneven,
 Relatively slow and predictable
 Easily corrected with coatings and regular mitigation
What causes uniform Corrosion
 It is often as a results of exposure to polluted industrial environments
 Exposure to fresh, brackish, and salt waters, or exposure to soils and chemicals
What are the Critical Factors of Uniform Corrosion?
 The corrosive environment must have the same access to all arts of the metal surface
 The metal itself must be metallurgically and compositionally uniform
 Interface potential is in active corrosion region
 The corrosion rate predictable and thus acceptable in design
13
TYPES OF CORROSION
 Relative uniform corrosion rates used in design
Rate mpy mm/yr µm/yr Nm/h Pm/s

Outstanding <1 <0.02 <25 <2.5 <1
Excellent 1-5 0.02-0.1 25-100 2.5-10 1-5
Good 5-20 0.1-0.5 100-500 10-50 5-20
Fair 20-50 0.5-1 500- 50-150 20-50

1000
Poor 50-200 1-5 1000- 150- 50-200
5000 500
Unacceptable 200+ 5 5000+ 500+ 200+
14
TYPES OF CORROSION
Localised Corrosion
It the selective removal of metal by corrosion at small areas or zones on a metal surface.
Usually the small local attack sites, much higher than the rest of the surface.
Pitting corrosion
 This is a localized type of attack,
 Pits are localized corrosion forming holes or indentations
 Deep pit when attack acting as anode are appreciable relatively to other part of metal, .
 If the area of attack is relatively larger and not so deep, the pits are called shallow.
 It is difficult to initially detect localized corrosion or pits – measure or assesse during operation
15
TYPES OF CORROSION
How to avoid (or control) L ocalised Corrosion? • Pitting corrosion Mechanism

Pitting/Crevice/deposit: Watch for stagnate water/ electrolyte.
Metal / Alloys Aggressive Ions
 Use gaskets
 Use good welding practices Iron/carbon Cl-, Br-, l-, ClO4_,
 Material Selection steels So4=containing feCl3
 Material with high tendency to pit is not selected Stainless steel Cl-,br-, SCN-
 pH Control
 Inhibitor Injection Aluminium Cl-, Br-, NO3-, ClO4-,
 Cathodic protection SCN-
Intergranular – watch grain size, environ, temp, etc.. Careful with Stainless Steels and AL.
Consider cathodic protection:
 such as zinc (or galvanized) plating on steel
 Mg sacrificial anode on steel boat hull
 Impressed current, etc..
Inspection
 VT, pit guage and UT are techniques
16
TYPES OF CORROSION
Galvanic Corrosion (also called “dissimilar metal  2 dissimilar metals or alloys anode & cathode
corrosion”) in contact with an electrolyte.
 Dissimilar metals connected together in a  Reaction Kinetics: The farther the alloys apart
suitable electrolyte in the table, the higher the driving force for
 In a bimetallic couple, the less noble material is corrosion.
the anode and tends to corrode at accelerated  Geometry: The exposed surface area ratio
rate. between anodic & cathodic.
 Which Materials are Affected?  Corrosion rates of the anode is higher if
 All metals with the exception of most noble small anode to cathode ratio;
metals  conversely the rates of anode will be less if
 What are the Critical Factors of Galvanic there is large anode to cathode ratio.
Corrosion?
 Bulk of Solution Properties: Presence of an
electrolyte,
17
TYPES OF CORROSION
Fig. 3. The red colour corresponds with active material comparative to the green colour (noble)
18
TYPES OF CORROSION
Galvanic Corrosion
19
TYPES OF CORROSION
 Galvanic Corrosion Control
 Inspection & Monitoring
 The following are very effective
 Material Selection: methods for detecting galvanic
corrosion
 Visual inspection , & UT
 Unfavorable area effect: Alloys should not be in contact thickness gauging.
Surface area ratio is favorable.
 Note: The damage may
 Prevent ion movement: Coatings but the more noble sometimes be hidden
material should be coated. underneath a bolt or rivet head.
 Isolation: for piping, insulating bolt sleeves & gaskets can
eliminate the electrical connection
 Install a third metal that is anodic to both metals in the
galvanic contact
 Add corrosion Inhibitor to decrease the aggressiveness of
the environment
20
TYPES OF CORROSION
 Crevice Corrosion
 Narrow crevice filled with ionized solution & Oxygen-rich on the outside,
oxygen-poor on the inside
• Corrosion in crevice is due to deficiency of O2, Acidity changes
 The solution takes longer time to dry out.
 What are the Critical Factors of Crevice Corrosion?
 Depletion of oxygen in the crevice solution.
 Critical crevice solution breakdown passivity
 No O2, low pH, High Cl-
 Increase in acidity and chloride content of the crevice solution
 Permanent breakdown on the passive film
 Which materials are Affected?
 Most metals are susceptible
 CS, SS, Most Nickel based alloys,
21
TYPES OF CORROSION
 Crevice Corrosion  Under Deposit Corrosion
Crevice Corrosion Control  A form of localised corrosion caused by
 Design is the best method, avoid revits and use butt
welded joints  the localised concentration of dissolved
chemicals
 Close crevices in existing lap joints by continuous
welding  (e.g. CO2, Hydrochloric acids and
 Design vessels for complete drainage, avoid Sulphuric acids),
stagnant areas  Scales and sand deposits
 Inspect equipment and remove deposit frequently  Narrow crevice filled with ionized solution
 Remove solids in suspension early in the process if  Oxygen-rich on the outside, oxygen-poor on the
possible inside
 Weld instead of rolling in tube sheets
• Corrosion in crevice is due to deficiency of
 Inspection
O2, Acidity changes
 Similar to galvanic
• Similar to crevice corrosion
22
TYPES OF CORROSION
 Atmospheric Corrosion
 A form of corrosion that occurs from moisture
 It is associated with atmospheric conditions.
 most severe Marine environments and moist polluted industrial environments.
 Dry rural environments cause very little corrosion.
 What are the Critical Factors of Atmospheric Corrosion?
 The physical location (industrial, marine, rural);
 Moisture (humidity), designs that trap moisture
 Cooling tower mist; temperature; presence of salts, sulfur compounds and dirt.
 Marine environments corrosion 0.5 mm/yr (20 mpy)
 Industrial environments corrosion rate 0.1-0.25mm/yr (5-10 mpy) – acids or sulfur compounds
 Inland locations exposed to a moderate amount of precipitation or humidity are considered moderately
corrosive environments (~1-3 mpy).
23
TYPES OF CORROSION
 Atmospheric Corrosion
 What are the Critical Factors of Atmospheric Corrosion?
 Dry environments have very low corrosion rates (<1 mpy).
 Designs that trap water or moisture in crevices are more prone to attack.
 Corrosion rates increase with temperature up to about 250°F (121°C).
 Chlorides, H2S, fly ash and other airborne contaminates from:
 Cooling tower drift, furnace stacks and other equipment accelerate corrosion.
 Most metals are susceptible, CS, low alloy steels and copper alloyed
aluminum,
 Atmospheric Corrosion Control
 Surface preparation
 Followed by proper coating application.
 Inspection – VT and UT are techniques
24
TYPES OF CORROSION
 Cooling Water Corrosion (CWC)

 General or localized corrosion of carbon steels and other metals
 What are the Critical Factors of CWC?
 CWC & fouling are closely related,
 Mineral deposits (hardness), silt, suspended organic materials, corrosion products, marine & microbiological growth
 Fluid temperature & type of water (fresh, brackish, salt water)
 Type of cooling system – Once-through, open circulating, closed circulating),
 Water characteristic & velocities are critical factors.
 If the process side temperature is above 60°C, a scaling potential exists with fresh water as cooling water inlet
temperatures rise.
 300 Series SS can suffer pitting corrosion, crevice corrosion and SCC in fresh, brackish and salt water systems.
 Copper/zinc alloys can suffer dezincification in fresh, brackish and salt water systems.
 The copper/zinc alloys can suffer SCC if any ammonia or ammonium compounds are present in the water or on the process
side.
25
TYPES OF CORROSION
 Cooling water Corrosion

 Most metals are susceptible
 CS, All grades of SS, Copper, Aluminum, Titanium & Nickel base alloys.,
 Cooling water Corrosion Control
 Proper design, operation and chemical treatment of cooling water systems.
 Design for process side inlet temperatures below 140°F (60°C).
 Minimum and maximum water velocities must maintained, particularly in salt water
systems.
 The metallurgy of heat exchanger may need to be upgraded for improved
resistance,
 especially in waters with high chloride content, low velocity, high process
temperatures, and/or poorly maintained water chemistry.
 Periodic mechanical cleaning of tube ID’s and OD’s should be performed in order to
maintain clean heat transfer surfaces.
 With few exceptions, cooling water should be on the tube side to minimize stagnant
areas.
26
TYPES OF CORROSION
 Cooling water Corrosion Control

 Inspection & Monitoring
 Cooling water should be monitored for variables that affect corrosion and fouling
including,
 pH, oxygen content, cycles of concentration, biocide residual, biological activity,
 cooling water outlet temperatures, hydrocarbon contamination and process
leaks.
 Periodic calculation of U-factors (heat exchanger performance measurement) will
provide information on scaling and fouling.
 Ultrasonic flow meters can be used to check the velocity of water in the tubes.
 EC or IRIS inspection of tubes.
 Splitting representative tubes.
27
TYPES OF CORROSION
 Microbial Induced Corrosion (MIC)

 A form of localised corrosion – living organisms such as bacteria, algae or fungi.
 What are the Critical Factors of Microbial Induced Corrosion?
 They are found in aqueous environments or where water is present,
 Stagnant or low-flow conditions allow and/or promote the growth of microorganisms.
 There are several types, – Aerobic & Anerobic
 Light or dark, high salinity, pH range of 0 to 12
 Temperatures from 0°F to 235°F (–17°C to 113°C).
 Different organisms thrive on different nutrients – inorganic substances (e.g., sulfur, ammonia,
H2S) & organic substances (e.g., hydrocarbons, organic acids).
28
TYPES OF CORROSION
 Microbial Induced Corrosion (MIC) Control
 Effective mitigation – requires complete removal of deposits & organisms
 A combination of pigging, blasting, chemical cleaning and biocide treatment.
 Add biocides to water phase in storage tanks.
 Maintain coatings on the interior of storage tanks.
 Inspection and Monitoring

 In cooling water systems, effectiveness of treatment is monitored by measuring biocide residual, microbial counts
and visual appearance.
 Special probes have been designed to monitor for evidence of fouling which may precede or coincide with MIC
damage.
 An increase in the loss of duty of a heat exchanger may be indicative of fouling and potential MIC damage.
 Foul smelling water may be a sign of trouble.
29
TYPES OF CORROSION
 Corrosion Under Insulation

 CUI is the external corrosion Material
 occurs underneath externally clad /
jacketed insulation due to entrapment of
water or moisture under the insulation.
 CUI tends to remain undetected until the
insulation and cladding / jacketing is Contaminants Electrolyte
removed
 Even the best insulation system can be
penetrated by an electrolyte
CUI
 CUI has been responsible for a significant
number of HSE incidents and lost production
time
 Large Maintenance Budgets are required to Coating /
Insulation
Temperature
mitigate the CUI problem
30
TYPES OF CORROSION
CUI Damage  Corrosion rates increase

with increasing metal
temperature up to the point
Material Type Temperature Range (Degrees C) where the water evaporates
 Corrosion is severe at
NACE metal temperatures
API 571
RP0198 100°C to 121°C
Carbon Manganese
Steels & Low -12 to 175 -4 to 150
Alloys
Austenitic
Stainless Steels
60 to 205 60 to 150
Duplex SS 60 to 205 100 to 150
Super Duplex &

High Mol Steels
60 to 205 110 to 150
31
TYPES OF CORROSION
CORROSION UNDER INSULATION
32
TYPES OF CORROSION
The following Inspections are carried out to ensure plant quality:

 Visual Inspection Irrespective of the assigned criticality
 inspect the condition of insulation during the course of normal plant operation e.g. during Inspection walk-through or plant routine
maintenance activities
Insulation Removal
 Removal of insulation - Complete visual inspection for corrosion and condition of coating
 Stainless steel equipment check for CSCC
 Re-evaluate risk level and set next inspection date
Advance NDT Screening Tools – Suitable NDT techniques can be used for CUI
 Long Range (Guided Waves) Ultrasonic Testing (LRUT)
 Creeping Head-wave Inspection Method (CHIME)
 Pipe Support Tool (PST)
 The Sentinel Imaging System
 Lixi Profiler
 Pulsed Eddy Current Systems (PEC Systems)
33
TYPES OF CORROSION
34
TYPES OF CORROSION
 Stress Corrosion Cracking Control  Inspection and Monitoring

 Material selections  Visual Inspection can detect some cracks.
 Use low chloride content water during When hydro  PT or phase analysis EC techniques.
testing,  Eddy current inspection methods on condenser
 dry out thoroughly and quickly. tubes as well as piping and pressure vessels.
 Properly applied coatings under insulation.  Extremely fine cracks may be difficult to find
 Avoid designs that allow stagnant regions with PT.
 where chlorides can concentrate or deposit.  UT shear Wave.
 A high temperature stress relief of 300 Series SS after  RT but often not sufficiently sensitive to detect
fabrication may reduce residual stresses. cracks except in advanced stages where a
significant network of cracks has developed..
 increasing susceptibility to polythionic SCC,
 Possible distortion problems & potential reheat
cracking.
 Sensitization
35
TYPES OF CORROSION
 Erosion Corrosion
 when subjected to high - velocity liquids, undergo a pitting type of corrosion called impingement attack , or erosion corrosion .
 What are the Critical Factors of erosion Corrosion?
 Corrosion plays significant role to erosion
 Pure erosion to as abrasive wear.
 Metal loss rates depends on :
 The velocity and concentration of impacting medium (i.e., particles, liquids, droplets, slurries, two-phase flow),
 The size & hardness of impacting particles,
 The hardness and corrosion resistance of material subject to erosion,
 The angle of impact.
 Softer materials such as copper and aluminum alloys
 Are subject to severe metal loss under high velocity conditions.
 There is a threshold velocity above which impacting objects may produce metal loss.
 This is dependent on the type of material
 This may increase the susceptibility to metal loss.
 Metal may be removed from the surface as dissolved ions, .
36
TYPES OF CORROSION
 Erosion Corrosion Control  Erosion Corrosion Control
 Change in design; shape, geometry and materials selection.  Inspection and Monitoring
 Eg. increasing the pipe diameter to decrease velocity;  Visual examination of
 Streamlining bends to reduce impingement; suspected or troublesome
areas,
 Increasing the wall thickness;
 Follow up with UT checks
 Using replaceable impingement baffles. or RT to detect the extent
 Increasing substrate hardness of metal loss.
 using harder alloys, hardfacing or surface-hardening treatments.  Use of erosion corrosion
 Erosion resistant refractories in cyclones and slide valves. coupons
 Use of corrosion-resistant alloys and/or altering the process environment  Use on-line erosion corrosion
to reduce corrosivity, monitoring electrical
resistance probes
 Example, deaeration, condensate injection or the addition of inhibitors.  IR thermography scans
 Note resistance is generally not improved through increasing  To detect refractory loss
substrate hardness alone. on stream.
37
TYPES OF CORROSION
Erosion-Corrosion
38
CORROSION CONTROL & MITIGATION
39
How to avoid (or control) Corrosion?

 Eliminate any one of the 4 requirements for corrosion!
All Present
Metallic Path Metallic Path Remove Metallic
Corrosion Occurs
Path by isolation /
separation,
Cathode
corrosion minimal
Anode
Cathode
Anode
Electrolyte
Electrolyte
Remove
Metallic Path Remove anodic
Electrolyte by
coating, Metallic Path areas by applying
corrosion CP, corrosion
Cathode
Anode
minimal Inhibitors, Material
Cathode
selection, minimal
Anode
Electrolyte Electrolyte
40
MATERIAL SELECTION
(selection of proper material for a particular corrosive service)
Metallic :
 Treatment of Metallurgy –
 Lining, Coating,
 Use of Corrosion Resistance Alloys (CRAs)
 Avoid combining Dissimilar Metals
Nonmetallic :
 Rubbers (natural and synthetic),
 Plastics,
 Ceramics,
 Carbon and graphite,
 Wood
41

MATERIAL SELECTION
(selection of proper material for a particular corrosive service)
42

METALS AND ALLOYS
No Environment Proper material No Environment Proper
material
1 Nitric acid Stainless steels
2 Hot Caustic Nickel and nickel 6 Nonstaining Aluminium
atmospheric exposure
alloys
3 Hydrofluoric Monel (Ni-Cu) 7 Distilled water Tin
acid 8 Hot strong oxidizing Titanium
4 Hot Hastelloy solution
hydrochloric (Ni-Cr-Mo) 9 Ultimate resistance Tantalum
acid
5 Dilute Lead 10 Concentrated sulfuric Carbon Steel
sulfuric acid acid
43
DESIGN OF STRUCTURES
Design Do’s & Don’ts
 Select the right Material to match fluid corrosivity
 Add Corrosion Allowance
 Avoid sharp corners
 Avoid excessive mechanical stress
 Complete draining of vessels
 Avoid sudden changes in section
 Avoid galvanic contact
 Weld rather than rivet
 Easy replacement of vulnerable parts
 Avoid sharp bends in piping systems
 when high velocities and/or solid in suspension are involved
 Erosion corrosion.
44
 Coatings are used as the first line of defence against corrosion

 Cathodic protection is a backup for coating defects.
 Corrosion is inevitable, but it can be minimised
 Good surface preparation & coating application improves corrosion
resistance.
 Cathodic Protection supplements coatings & should provide protection
where coatings deteriorate, or are damaged
 Steel is coated with zinc and if the zinc coating is scratched and steel
exposed, the surrounding areas of zinc coating form a galvanic cell with
the exposed steel and protects in from corroding.
 The zinc coating acts as a sacrificial anode.
 Titanium Oxide coating also used for coating against corrosion
45
 Process Control is next in corrosion control after design:

 Lower temperature and velocity
 Remove oxygen/oxidizers
 Change concentration
 Control pH
 Add Inhibitors
 Lowering temperature
 but there are cases where increasing T decreases attack.
 E.g hot, fresh or salt water is raised to boiling T and result in decreasing O2 solubility with T.
 Decreasing velocity
 Exception ; Metals & alloys that passivate (e.g stainless steel)
 Have better resistance to flowing mediums than stagnant.
 Avoid very high velocity because of erosion-corrosion effects.
46
47
 Inhibitors  Why use corrosion Inhibitors?

 Inhibitors are materials that may  Fluids more corrosive than expected
be injected into the process
stream.  Mechanical options not viable
 They plate out on the surface and  Extend equipment life
inhibit the formation of corrosion  Assurance -Where there is limited
cells. opportunity for inspection or
 Polarization monitoring.
 This is an effect which reduces the  Cost Effective - Can be sensitive to
actual chemical potential driving of how the economics are run but
the cell. generally the most CAPEX efficient
 If the thermodynamic force option.
driving the ion into solution is
reduced,
48
 Cathodic protection (CP):  Types of CP:

 A technique control the corrosion by  The anode pushes the potential of the steel structure
more negative
 Make metal as a cathode of an electrochemical cell.
 The anode continues to corrode until it requires
 Sacrificing a weaker metal to act as the anode of replacement,
the electrochemical cell.  Applications of this method include underground
 CP systems are most commonly used to protect steel: cables, water tanks etc.
by:
 Use of sacrificial anodes
 Impressed currents
 Sacrificial protection:
 sacrificial anodes (zinc, magnesium or aluminum):
 Metal to be protected is connected to a more anodic
metal.
 The more active metal losses electrons and gets
corroded slowly – Protect the parent cathodic metal.
49
 Impressed Voltage
By imposing a voltage which causes electrons to flow towards the
object to be protected, we make it less anodic and protect it from
corrosion damage.
50
CORROSION ASSESSMENTS (LOOPS
& CIRCUITS)
51
CORROSION ASSESSMENTS (LOOPS & CIRCUITS)

At PFD level, consider a process stream with respect to
Start
damage mechanism
Corrosion Loop Development Which affect corrosion, e.g process

chemistry, i.e. acids, moisture, etc
Is there a change in
Process?
No
Yes
material? Yes
Start new loop
Is there a change in damage

mechanism? Yes
No Maintain loop End
52
WET BENZENE
BENZENE EFFLUENT
ALKYLATOR
BENZENE FEED TO 26C51

BENZENE
EFFLUENT
ALKYLATOR
•26V50
•26C50
53
At P&ID level, consider loop boundary from major equipment (e.g. Columns,
Start
exchangers, vessels) for main circuit boundary
Injection points, mixing

streams, contaminants.
Is there a change in Is there a change in

operating condition? No Process?
Yes Yes
Change in
temperature
pressure, etc.
No
material? Yes
No
Start new circuit

external condition? Yes
Coating / painting
No Maintain circuit End
54

Corrosion loop (32CRL2-08 Chlorine (Gas) (CS))
Identify CML locations
All interconnected
piping in circuit
Piping circuit number
Accurate line class
55
THANK YOU

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A SABIC Affiliate

• Corrosion, Its Effects & Key factors

• Corrosion Control & Mitigation

• Corrosion Assessments (Loops & Circuits)

Objectives: the objective of this lecture is to provide:

• Understanding of Material Degradation due to corrosion

• Understand key factors in failures due to Corrosion

• Corrosion & Mitigation

CORROSION, ITS EFFECTS & KEY FACTORS

• The huge annual loss due to corrosion is enormous (5% of

 Proper Materials Selection

 Operating within IOWs

CORROSION, ITS EFFECTS & KEY FACTORS

 Escape of fluids & product Contamination

 Lost surface properties

CORROSION, ITS EFFECTS & KEY FACTORS

CORROSION, ITS EFFECTS & KEY FACTORS

order how much energy will be Aluminum Alloy -1.10

needed to extract metals from their Zinc

Or how much energy will be Cast Iron -0.50

released during the corrosion Stainless Steel

CORROSION, ITS EFFECTS & KEY FACTORS

 Anodic Reactions produce;

CORROSION, ITS EFFECTS & KEY FACTORS

Cathode Material control.

CORROSION, ITS EFFECTS & KEY FACTORS

Acceleration of Corrosion Acceleration of Corrosion

 Relative uniform corrosion rates used in design

Rate mpy mm/yr µm/yr Nm/h Pm/s

Good 5-20 0.1-0.5 100-500 10-50 5-20

Fair 20-50 0.5-1 500- 50-150 20-50

How to avoid (or control) L ocalised Corrosion? • Pitting corrosion Mechanism

 Cooling Water Corrosion (CWC)

 Cooling water Corrosion

 Cooling water Corrosion Control

 Microbial Induced Corrosion (MIC)

 Inspection and Monitoring

 Corrosion Under Insulation

CUI Damage  Corrosion rates increase

Duplex SS 60 to 205 100 to 150

Super Duplex &

CORROSION UNDER INSULATION

The following Inspections are carried out to ensure plant quality:

 Stress Corrosion Cracking Control  Inspection and Monitoring

CORROSION CONTROL & MITIGATION

How to avoid (or control) Corrosion?

minimal Inhibitors, Material

CORROSION CONTROL & MITIGATION

CORROSION CONTROL & MITIGATION

CORROSION CONTROL & MITIGATION

CORROSION CONTROL & MITIGATION

CORROSION CONTROL & MITIGATION

 Coatings are used as the first line of defence against corrosion

CORROSION CONTROL & MITIGATION

 Process Control is next in corrosion control after design:

CORROSION CONTROL & MITIGATION

CORROSION CONTROL & MITIGATION

 Inhibitors  Why use corrosion Inhibitors?

CORROSION CONTROL & MITIGATION

 Cathodic protection (CP):  Types of CP:

CORROSION CONTROL & MITIGATION

CORROSION ASSESSMENTS (LOOPS & CIRCUITS)

Corrosion Loop Development Which affect corrosion, e.g process