Corrosion; Forms, Mitigation and

Surface Protection Technologies

Course

Eng. Amr Saleh

OGS
OIL & GAS SKILLS
 Welcome to Fundamentals of
Corrosion & Corrosion Control Course
 Course Overview
Course duration

Tuesday (Day One) – Thursday (Day 3)

09:00 a.m. to 02:00 p.m.
 Course schedule

❑ Tuesday (Day One)

Chapter 1 : Introduction to Basic Corrosion
Chapter 2 : Basics of Corrosion Electrochemistry
❑ Wednesday (Day Two)

Chapter 3 : Corrosive Environments

Chapter 4 : Materials
Chapter 5 : Forms of Corrosion
❑ Thursday (Day Five)

Chapter 6 : Corrosion Control Methods (material selection, coating, cathodic

protection)
 Classroom Policies

To provide the best environment for training, please observe and

follow these requirements:

• No smoking or other tobacco products.

• Class starts at designated times.
• Participants are responsible for their own learning a timekeeping.
• Turn off mobile phone ring tones, and do not make or answer
calls, text messages, or tweets while in the classroom.
• Observe designated times for lunch breaks, coffee breaks, and
smoke breaks.
• Note location(s) of restrooms and smoking facilities.
 Chapter 1:

Introduction to Basic
Corrosion
Definition of Corrosion:
Corrosion is the deterioration of a material,
usually a metal, or its properties because of a
reaction with its environment.
Example of corrosion of structural steel in
the splash and atmospheric zones of an
offshore platform
 Importance of Corrosion
Cost of Corrosion
✔ Maintenance /Repair/Replacement/Inspection
✔ Lost production/Downtime
✔ Warranty Claims
✔ Fuel and Energy
✔ Loss of production
✔ Environmental Cleanup-Fines
✔ Capital Investment
✔ Loss of Efficiency
Cost of Corrosion
 Importance of Corrosion
Cost of Corrosion
Maintenance/Repair/Replacement/Inspection
● The maintenance cost is more expensive than the cost to
avoid corrosion at the design stage.

● Preparation during the design stage includes the

substitution of more corrosion-resistant materials, changing
the operating conditions of the system, or applying other
corrosion control measures.
 Importance of Corrosion
Cost of Corrosion
Lost Production and Downtime
● When corrosion damage creates the need for
maintenance or repair, it usually interrupts production.

● These interruptions result in reduced income for the plant

creating an economic impact.
 Importance of Corrosion
Cost of Corrosion
Product Contamination
● In many industries, contamination of a product caused by
corroded material entering the product stream can be
harmful.

● This is particularly true for the food processing and

pharmaceutical industries, but it also impacts other
systems.
 Importance of Corrosion
Cost of Corrosion
Loss of Product
● Losing a product due to leaks can have significant direct
and indirect costs.

● The direct costs include the value of the product itself, the
cost of repairs, the associated costs of downtime, including
shutdown and startup, and the disposal costs of the
contaminated products.
 Importance of Corrosion
Cost of Corrosion
Loss of Efficiency: Oversizing and Excess Energy Costs
● In many cases, when designers expect substantial corrosion,
they may enlarge the system to accommodate the corrosion.

● In addition to the direct cost of excess material, oversizing

can have other direct economic effects.
Importance of Corrosion
 Importance of Corrosion
Cost of Corrosion
Loss of Efficiency: Oversizing and Excess Energy Costs

Corrosion Allowance on an
Offshore Platform Leg in
Splash Zone
 Importance of Corrosion
Cost of Corrosion
Accidents
● Corrosion can and has caused severe accidents, resulting
in personal injury or loss of life.
Direct cost Indirect cost
medical bills, employee or For example, if a plant has a bad
plant downtime, investigations, and safety record because of corrosion,
lawsuits the cost of insurance will be higher
than if they had maintained a good
safety record.
 Importance of Corrosion
Cost of Corrosion
Increased Capital Costs
● The addition of extra material to a system for corrosion
control can increase the capital cost for construction and
maintenance.
● Capital costs include the initial costs of other corrosion
control measures, such as :
protective coatings, cathodic protection systems, and
equipment for the injection of corrosion inhibitors.
 Importance of Corrosion
Cost of Corrosion
Fines
● The cost of environmental cleanup for product spills has
increased greatly due to intensified awareness of the
potential short- and long-term effects these spills can have
on the environment.
● Laws now require the cleanup of most spills.
● Recent spill fines have exceeded $1,000,000
 Importance of Corrosion
Indirect Consequences of Corrosion
Safety Risks

● Corrosion can and has caused many accidents.

● Most accidents could have been avoided by the proper

application of corrosion control measures .
 Importance of Corrosion
Indirect Consequences of Corrosion
Structural Collapse
● Although complete structural collapse due to corrosion
occurs infrequently, it does occur.

● Corrosion can also reduce the resistance of structures to

natural forces, such as earthquakes
 Importance of Corrosion
Indirect Consequences of Corrosion
Structural Collapse

Fatal Highway Bridge Collapse Parking Garage Collapse Due to

into the Ohio River Accelerated Corrosion of
Reinforcing Steel
 Importance of Corrosion
Indirect Consequences of Corrosion
Leaks
● Leaks in systems carrying flammable or toxic materials are
an obvious safety hazard which can lead to Fire and
explosions from corrosion leaks.

● Although, in many cases, third-party damage, not corrosion,

causes the leaks that result in fire and explosion.
 Importance of Corrosion
Indirect Consequences of Corrosion
Consumer Confidence
● Corrosion can impact the marketability of a product.

● Recent improvements in the corrosion resistance of

automobiles, particularly with long-term guarantees against
rust-through, are now a major selling feature.
 Importance of Corrosion
Indirect Consequences of Corrosion
Loss of Redundancy
● When an organization requires continuous processing,
redundant systems ensure continuous operation.
● These systems either operate in parallel or use one system
as a spare.
● The worst-case scenario is failure of the backup system
before the first can be repaired and placed back in service.
 Importance of Corrosion
Indirect Consequences of Corrosion
Appearance
● Corrosion, particularly the all-too-familiar red rust from
corroding iron and steel, is unsightly even if it does not
interfere with system operation.

● Industry spends a significant effort trying to eliminate such

unsightly corrosion simply for the aesthetic benefits
 Importance of Corrosion
Indirect Consequences of Corrosion
Appearance

Unsightly Corrosion on a Ship

 Importance of Corrosion
Indirect Consequences of Corrosion
Increased Regulation
● Many aspects of corrosion control are now regulated.
● For example, legislation regulates the corrosion-related
aspects for safe operation of pipelines carrying hazardous
liquids or flammable gases.
● Due to recent failures, the Pipeline Hazardous Material
Safety Administration (PHMSA), has instituted new and
more stringent regulations for all regulated pipeline systems.
 Importance of Corrosion
Indirect Consequences of Corrosion
Increased Regulation

1965 Pipeline Explosion in Natchitoches, Louisiana

 Importance of Corrosion

Environment
● Environmental pollution is an increasing concern worldwide.

● During the 1990s the United States and Canada required

the replacement of all underground storage tanks (USTs) at
filling stations and similar operations USTs due to repeated
problems with ground water contamination from corroded
leaking USTs.
 Importance of Corrosion
Environment
Oil Containment Boom and Oil-Absorbing Papers on the Surface of a
River to Minimize the Spread of Crude Oil from a Corroded Pipeline
 Importance of Corrosion
Changes in Engineering Practice
● Sometimes corrosion changes engineering practices.
● Modern electronics are exposed
to a wide variety of environments and
are made from increasingly complex
microelectronic components and
circuit boards.
● The most common approach to
limiting corrosion is to coat the circuits.
 Importance of Corrosion
Changes in Engineering Practice

Ruptured Pipeline Resulting in Internal Surface of Corroded

12 Fatalities Pipeline
 Importance of Corrosion
Changes in Engineering Practice

The internal corrosion shown in last Figures led to industrial

efforts to control internal corrosion including the
development of Internal Corrosion Direct Assessment
(ICDA) efforts.
 Forms of Corrosion
Corrosion is commonly classified in the following
categories:
• General Corrosion
• Localized Corrosion
– Pitting
– Crevice
– Filiform
 Forms of Corrosion
• Galvanic Corrosion
• Environmental Cracking
• Flow-Assisted Corrosion
• Intergranular Corrosion
• Dealloying
• Fretting Corrosion
• High-Temperature Oxidation/Corrosion
 List of Organizations Involved in
Corrosion
• NACE International
• American National Standards Institute
• American Petroleum Institute
• American Society of Mechanical Engineers
• American Society for Testing and Materials
• ASM International
• Materials Technology Institute
• SSPC-The Society for Protective Coatings
Thanks for your Attention