Module 06-Designing For Corrosion

Steels
in Service Course 600-‐852

MODULE 6: Designing for Corrosion
Content -‐ Module 6
•  Designing for Corrosion -‐ Part 1

•  FabricaCon and Pickling of Stainless Steel -‐
Part 2
Metallurgy of Iron and Steel CerBficate Program Steels in Service Course 600-‐852 – MODULE 6
Designing for Corrosion
MODULE 6
Part 1
Designing for Corrosion
•  Mistakes in design cause 58% of corrosion failures in

chemical process industries.
•  Careful design may overcome many material shortcomings.
•  Manufacturers used to regard corrosion as a process to
guarantee future business.
Principles for Designing for Corrosion
A. Allow for uniform aPack
B. Minimize aPack Cme
C. Restrict galvanic cells
D. Protect against
environmental cells
E. Avoid corrosive-‐
mechanical interacCon
F. Design for inspecCon and

maintenance
A. Allow for Uniform AJack
Corrosion at a reasonable rate can be

A. Allow for uniform aJack
designed for and can be tolerated
unless:
B. Minimize aPack Cme
Corrosion products create problems
•  Contaminate product or environment-‐e.g.
C. Restrict galvanic cells drinking water
•  Plug pipes
D. Protect against
environmental cells

maintenance
B. Minimize AJack Time
•  Avoid structural shapes that collect

dirt and/or moisture
•  Issues
B. Minimize aJack Bme •  Drainage problems
•  SuscepCble metals
C. Restrict galvanic cells •  ConcentraCng liquids
•  Vapor problems
D. Protect against
environmental cells

maintenance
Drainage -‐ Example 1
Poor Good Other structural shapes that can

collect dirt and moisture
Bad Good Best Bad Good Bad Good
Bad Good Bad Good
SuscepBble Metals
Avoid galvanic cells

•  Containers can retain small amounts of liquid that can corrode the
boPom so locate any welds above the boPom.
•  Join dissimilar metals so that liquid runs off juncCon
SuscepBble Metals
ConcentraBng Liquids -‐ Example 1
Spills, sprays, splashes leave a thin film of liquid that may become corrosive with Cme.
ConcentraBng Liquids -‐ Example 2
In Figure a) a splashing soluCon will concentrate on a hot heaCng coil and corrode the
coil, in contrast to the coil in b) which is completely submerged (good design)
Temperature Differences
•  Local heaCng can increase corrosion rates

•  Heat metal uniformly
•  Cold surfaces can cause problems also. Insulate as shown in
following sketch:
Vapour Problems
•  Vapour can be more corrosive than liquid, e.g., sidewalls of tanks.
•  Design should include venCng.
•  Proper design must prevent gaps in sheathing around thermal
insulaCon on piping – moisture laden air can iniCate corrosion or SCC.
•  Corrosive vapours in outside air can be combated by strategic
locaCon of structures.
C. Restrict Galvanic Cells
•  Not always possible to avoid

dissimilar metals together
•  Proper design can miCgate problems
B. Minimize aPack Cme •  Use metals close to each other in
galvanic series
C. Restrict galvanic cells •  Be aware of corrosion products that
may change nobility of one of the
metals
D. Protect against
environmental cells •  Issues
•  The electrodes
E. Avoid corrosive-‐ •  The electrolyte

maintenance
The Electrodes -‐ InsulaBng Dissimilar Metals
Top -‐ Methods for insulaCng metals a) Two plates insulated from each other and from
fastener b) Cadmium-‐plated ring prevented from touching Magnesium plate. However
insulaCng washers and the like, cannot be used at extremely high stresses or
temperatures, or in corrosives that will aPack the insulaCng material.
Restrict Galvanic Cells
•  Decrease the cathode/anode raCo
•  With welds, specify the filler metal to be more noble than the base
metal
•  Require weld to be oriented so that the least surface area is
oriented to the corrosive environment
Figure -‐ Weld to expose minimum amount of weld metal to a corrosive
environment a) poor, b) good. For welds specify filler metal the same or slightly
more noble than the base metal
The Electrolyte
Galvanic corrosion can also be controlled by managing the electrolyte,
that is
•  Take advantage of the distance effect
•  Use connector of intermediate corrodibility between the two other
secCons – this also takes advantage of the distance effect
•  If different metals must be used but cannot be insulated, keep the
environment from contacCng one of them.
HeaBng Coil
In Figure a) Galvanic corrosion occurs

as a result of a copper heater in steel
tank and b) this corrosion can be
reduced by the distance effect. That
is, take advantage of the distance
effect by placing the anode and
cathode as far apart as possible,
especially in low-‐conducCvity
soluCons. The heater in Figure should
be put in the centre of the tank to get
it as far from tank wall as possible, if
the two metals cannot be insulated
from each other.
InsulaBng Dissimilar Metals
Figure shows an exchangeable connector for joining dissimilar metals. The distance
effect can reduce corrosion if the middle secCon is made of a metal that is intermediate
in corrodibility between the other tow secCons.
This technique separates the highly noble metal that serves as the principal cathode
from the reacCve metal that is doing most of the corroding. Or, the intermediate secCon
can be the most corrodible if the wall thickness is made heavy (see in figure).
PotenBal Corrosion Cell
Figure a) Galvanic corrosion and b) prevented by isolaCng one metal from the
environment. Liquid should never be allowed to flow over a noble metal then on to
a very reacCve metal, even water dripping from copper onto aluminium severely
corrodes aluminum. Copper ions carried by the water will plate out on the
aluminum and setup a galvanic cell.
D. Protect Against Environmental Cells
•  Issues
•  Crevices
•  Porous materials
B. Minimize aPack Cme •  Temperature differences
D. Protect against
environmental cells

maintenance
Protect Against Environmental Cells-‐Crevices
Crevices
•  Avoid deposits with designs that do not have ledges, pockets,
flanges or obstrucCons that have places entrained solids can sePle
•  If crevices in carbon steel cannot be filled they must be protected
•  Galvanize both nuts and bolts
•  Paint metals with zinc-‐rich primer
•  PainCng may not seal crevice but it reduces the cathode area
around crevice.
PotenBal Corrosion Cell -‐ Example 1
Figure shows crevices created by welding and ways to seal them a) skipped
weld b) replaced by conCnuous weld.
PotenBal Corrosion Cell -‐ Example 2
Figure c) shows a space between tube and plate and d) sealed with masCc.
Porous Materials
•  Absorbent nonmetallic materials contacCng metal can set up

potenCal crevice corrosion condiCons
•  Gaskets, fiberglass blankets, sponge rubber, adhesives, etc.
Corrosion under insulaCon (CUI)
Porous Materials -‐ Example 1
a) SupporCng post with boPom plate fastened above floor level b) support tanks above floor
level. Metals sieng on concrete pose a special problem because the concrete is porous and
hold moisture. The metal should sit off the floor so that spills and cleaning water contact the
metal only a brief Cme. Concrete should slope away from the metal for rapid drainage.
Thin-‐wall tanks b) should be supported so that they do not contact concrete at all.
Figure a) Support pad protects horizontal tank from concrete saddle
b) bePer design metal saddle with support pad
Details of a tank installaCon a) Leak in roof will wet side wall insulaCon and b)
improved design. This is a pracCcal design for thermal insulaCon on an outside storage
tank. The designer assumed that somewhere the roof would leak, to prevent water
from running down the tank walls, drainage was provided for the roof insulaCon with
a steel reinforcement separaCng the roof from the walls.
E. Avoid Corrosive-‐mechanical InteracBon
•  Problems
•  Erosion-‐corrosion and cavitaCon, or
•  Stresses with corrosion (3 main types)
B. Minimize aPack Cme 1.  SCC (Stress corrosion cracking)
2.  CFC (Corrosion faCgue cracking)
3.  HIC (Hydrogen induced cracking)
D. Protect against Dangers of SCC and

environmental cells CFC always present
but careful design
E. Avoid corrosive-‐ can keep stresses
mechanical interacBon low.
maintenance
Avoid Corrosive-‐Mechanical InteracBon
Erosion-‐corrosion
•  Use design to reduce
velocity, turbulence, and
impingement
Figure – Showing reacCon

vessel with removable
drainpipe Good design to
reduce turbulence and
potenCal erosion-‐corrosion by
allowing drainage in two
stages to reduce velocity in the
second stage
Minimize Impingement
a) Impingement of flow, b) prevenCng impingement by streamlined

connecCons c) impingement on tank wall d) direcCng flow away from wall
and e) deflector plate. Suspended material should be filtered from liquids, if
possible and water droplets should be removed from high-‐velocity steam.
Ways to Avoid Corrosive-‐Mechanical InteracBon
Causing Stress and Corrosion
•  Avoid cold work

•  Avoid welds combined with high stresses
•  Avoid corrosion situaCons and high stresses
•  Avoid sharp radii and corners in design
Stresses with corrosion
•  Residual stresses from cold work cause problems
Explain why (b) in following sketches is bePer than (a)
Stresses and corrosion
•  When welds are combined with high stress, a dangerous situaCon can be set-‐up.
Figure -‐ High stress should not be put on welds in a corrosive environment a) bad b) bePer c)
best. Move stresses away from welds and minimize the number of welds
Use of generous fillets reduces stresses
F. Design for InspecBon and Maintenance
•  A design must provide ready accessibility to

A. Allow for uniform aPack criCcal areas for repairs, replacement of
parts and cleaning.
B. Minimize aPack Cme •  The design should include provision for
monitoring corrosion especially in criCcal
locaCons.
D. Protect against
environmental cells
F. Design for inspecBon and

maintenance
Design for InspecBon and Maintenance
Design MUST allow for monitoring of corrosion -‐ don’t let failure be the first
sign of trouble -‐ See sketches below
Figures -‐ Profiles a) and c) cannot be painted as spacing between surfaces must
be at least 1/3 of the height and not less than 45mm does not leave enough
space between surfaces for a painter to get in a brush or spray from a paint gun.
Designs b) and d) are acceptable designs.
FabricaBon and Pickling of Stainless Steel
MODULE 6
Part 2
Surface contaminants
The corrosion resistance of corrosion resistant alloys may be impaired
by the presence of surface contaminants.
Iron contaminaBon and weld spaJer
Weld Spatter
44
Iron contaminaBon
45
Importance of removal of heat Bnt
Effect of heat tint removal methods on CPT (oC),

of 2205, in 3%NaCl
Pickling Acid
Avesta BlueOne Avesta Pickling Bath

Pickling Paste Concentrate 302
Nitric Acid 15 – 20% 40 – 50%
Hydrofluoric Acid 2 – 6% 10 – 15%
Sulphuric Acid 10 – 15%
ComposiCon of Pickling Bath is dependent on the type of stainless steel being pickled
304L & 316L mix 1 part 302 with 3 parts water
2205 and 904L mix 1 part 302 with 2 parts water
Super-‐austeniCc and super-‐duplex stainless steel mix 1 part 302 with 1 part water
Pickling
DetecBng Iron contaminaBon
•  Surface wetting Test

•  Copper Sulphate Test
•  Ferroxyl Test
•  ASTM A380 and A967

and Avesta Handbook on
Cleaning and Pickling
are good guides in
detecting and removing
iron contamination

Module 06-Designing For Corrosion

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Steels

in Service Course 600-­‐852

• Designing for Corrosion -­‐ Part 1

• Mistakes in design cause 58% of corrosion failures in

A. Allow for uniform aPack

B. Minimize aPack Cme

C. Restrict galvanic cells

F. Design for inspecCon and

Corrosion at a reasonable rate can be

F. Design for inspecCon and

• Avoid structural shapes that collect

F. Design for inspecCon and

Poor Good Other structural shapes that can

Bad Good Best Bad Good Bad Good

Bad Good Bad Good

Avoid galvanic cells

• Local heaCng can increase corrosion rates

• Not always possible to avoid

F. Design for inspecCon and

In Figure a) Galvanic corrosion occurs

C. Restrict galvanic cells

F. Design for inspecCon and

• Absorbent nonmetallic materials contacCng metal can set up

Corrosion under insulaCon (CUI)

D. Protect against Dangers of SCC and

Figure – Showing reacCon

a) Impingement of ﬂow, b) prevenCng impingement by streamlined

• Avoid cold work

• A design must provide ready accessibility to

F. Design for inspecBon and

Effect of heat tint removal methods on CPT (oC),

Avesta BlueOne Avesta Pickling Bath

• Surface wetting Test

• ASTM A380 and A967

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in Service Course 600-‐852

•  Designing for Corrosion -‐ Part 1

•  Mistakes in design cause 58% of corrosion failures in

•  Avoid structural shapes that collect

•  Local heaCng can increase corrosion rates

•  Not always possible to avoid

•  Absorbent nonmetallic materials contacCng metal can set up

•  Avoid cold work

•  A design must provide ready accessibility to

•  Surface wetting Test

•  ASTM A380 and A967