Corrosion Control Lectrures

Corrosion and its Control Management System in industry
1
Eng.Abdellatif Radwan
INTRODUCTION TO CORROSION COURSE
Power Station
Corrosion Field in Industries
Petroleum refinery
Petrochemical industries
Petroleum production
Chemical industries
Eng.Abdellatif Radwan 2
Corrosion
Corrosion and
and Its its Control
Control Management
Management System System in industry
In Petroleum Industry
-Corrosion Field (Science ,Manpower and Engineers)
Metallurgical
Mechanical Eng
Eng.
Science
Inspection div.
chemical chemical Operation/process div.
Eng. Thermo Maintenance div.
Fluid Work shop
Electrical physics Projects
Eng. design div.
Corrosion control
management system
Corrosion science content 3

Corrosion problems and its control PROCESS
process management system
MAINTENANCE
DESIGNE
CORROSION/INSPECTION
MATERIAL
WORKSHOP
Corrosion Engineer Working Field & Requirements
-Processing knowledge
Inside Plant production - Material Selection
& Refinery Co./power - Corrosion Monitoring
plants/ chemicals -Painting & Coating
industries -Cathodic Protection
-NDT
Corrosion & Inspection Pipeline and -Cathodic Protection

Engineer Transportation Co. -Painting & Coating
& Storage Tanks - Codes and Standards
- NDT certificates
-API certificates
Quality Control &
-welding knowledge
Inspection
-References & standards
painting knowledge
Painting Co. -NACE certification
-codes and standard for
painting
CORROSION CERTIFIED COURSES
NACE CERTIFIED AND RECOMMENDATION
CATHODIC PROTECTION
CP1 - Cathodic Protection Tester Certification

CP2 - Cathodic Protection Technician Certification
CP3 - Cathodic Protection Technologist Certification
COATING INSPECTION
CIP LEVEL 1 COURSE / BASIC COATINGS INSPECTOR CERTIFICATION

CIP LEVEL 2 COURSE / CERTIFIED COATINGS INSPECTOR CERTIFICATION
INSPECTION CERTIFIED COURSES
NDT CERTIFIED AND RECOMMENDATION
-ASNT SNT-TC-1 2, A PERSONNEL QUALIFICATION AND CERTIFICATION IN NONDESTRUCTIVE TESTING

-ASNT NDT Level II Certification Program
-ASNT NDT Level III Certification Program
API CERTIFIED AND RECOMMENDATION

API 510 - Pressure Vessel Inspector
API 570 - Piping Inspector
API 653 - Above Ground Storage Tank Inspector
API 571 - Corrosion and Materials Professional
API 577 - Welding Inspection and Metallurgy Professional
API 580 - Risk Based Inspection Professional
CWI : CERTIFIED WELDING INSPECTOR
INSPECTION IN SERVICE REFRENCES AND CODES
INSPECTION IN SERVICE OF PRESSURE VESSELS

-API PUBLICATION 510, PRESSURE VESSEL INSPECTION CODE: MAINTENANCE INSPECTION,
RATING, REPAIR, AND ALTERATION
INSPECTION IN SERVICE OF PIPING AND PIPELINES

- API PUBLICATION 570
- Recommended Practice 574, Inspection Practices for Piping System Components
- MTI 129 4, A Practical Guide to Field Inspection of FRP Equipment and Piping
- ASME PCC-2, Repair of Pressure Equipment and Piping
CORROSION AND DAMAGE MECHANISM

- API Recommended Practice 571, Damage Mechanisms Affecting Fixed Equipment in the Refining
Industry API
- NACE RP 0170, Protection of Austenitic Stainless Steels and Other Austenitic Alloys from
Polythionic Acid Stress Corrosion Cracking During Shutdown of Refinery Equipment
- NACE Pub 34101, Refinery Injection and Process Mixing Points
FABRICATION INSPECTION REFRENCES AND CODES
DESIGNE AND INSPECTION OF NEW PIPING INSIDE PLANT

- ASME B31.3, Process Piping
DESIGNE AND INSPECTION OF NEW PIPIELINE

-ASME B31.4, Pipeline Transportation Systems for Liquids and Slurries
-ASME B31.8, Gas Transmission and Distribution Piping Systems
DESIGNE OF NEW PRESSURE VESSELS

-ASME Boiler and Pressure Vessel Code (BPVC), Section V, Nondestructive Examination
-ASME BPVC, Section VIII, Divisions 1 and 2
-ASME BPVC, Section IX, Welding and Brazing Qualifications
- API Recommended Practice 578, Material Verification Program for New and Existing
Piping Systems
TARGET OF CORROSION CONTROL MANAGEMENT SYSTEM COURSE
-How to identify and predict corrosion
-How to handle and manage the corrosion problems

according your condition in plant
-How to identify the suitable corrosion control

methods according to your condition
-Codes And References Of Corrosion And How To Apply
-Sharing Experiences And Knowledge
-Get Knowledge, improvement For Internationally

Corrosion and Inspection Certified
2- Course Main Topics:
I- Introduction To Corrosion Basics:

- Definition Of Corrosion
- Corrosion Losses
II - Corrosion Types In Oil Field And Refinery.
III - Factors Affecting Corrosion Process.
IV- Corrosion Monitoring System In Petroleum Industry
V - Corrosion Control Methods:
- Design
- Material Selection
- Cathodic Protection
- Protective Coating
- Chemical Injection System
VI - Factors Affecting Selection Of Corrosion Control.
VII – Case Studies In Oil Field And Refinery.
VIII- References And Standards.
11
DATE SUBJECT
- INTRODUCTION TO CORROSION BASICS

- DEFINTION OF CORROSION
DAY 1
- CORROSION LOSSES
- TYPES OF CORROSION
- FOLLOW TYPES OFCORROSION

DAY 2 - FACTORS AFFECT IN CORROSION
- CORROSION MONITORING SYSTEM
-PRACTICAL CASE OF CORROSION MONITORING

- CORROSION CONTROL
DAY 3 -DESIGINE
- MATERIAL SELECTION
- CATHODIC PROTECTION
FOLLOW CORROSION CONTROL

DAY 4 -CHEMICAL INJECTION SYSTEM
-PROTECTIVE COATING
- PRACTICAL CASE OF CORROSION CONTROL
DY 5 -REFRENCE & STANDARDS RELATED CORROSION
- GENERAL REVIEW
I-Introduction Corrosion Basics.
Definition of corrosion:
Deterioration of metal due to chemical or electrochemical
reactions between metal and its environment.
Definition of corrosion:
Deterioration of metal due to chemical or electrochemical reactions
between metal and its environment.
corrosion circuit: (oxidation)

Fe Fe++ + 2e- Anode
- anode
- cathode O2 + 2H2O + 4e 4OH- cathode
- electrolyte
- metallic connection in neutral and alkaline solution
between cathode and anode
2H+ + 2e H2 in ACID SOLUTION
Corrosionand
Corrosion andIts
its Control
Control Management
Managementsystem
SystemIn petroleum industry
In Petroleum Industry
CHEMICAL
PAINTING &
TREATMENT
COATING
CORROSION CONTROL
ENVIORNMENT
MATERIAL
SELECTION ELECTROLYTE
CATHODIC
PROTECTIONNG
METAL
DESIGNE
corrosion circuit: (oxidation)

Fe Fe++ + 2e- Anode
- anode
- cathode O2 + 2H2O + 4e 4OH- cathode
- electrolyte
Why metal corrode:
ENERGY)
METAL
METAL OCCURE IN
NATURE AS
UNSTABLE
ORES CONDITION
(STABLE
CONDITION)
METAL CRRODES AND RETURN TO

ORIGINAL CONDITION
16
-Cost of Corrosion
Cost of Corrosion
Cost of Corrosion
The global cost of corrosion is estimated to be US$2.5 trillion, which
is equivalent to 3.4% of the global GDP (2013).
By using available corrosion control practices, it is estimated that

savings of between 15 and 35% of the cost of corrosion could be
realized; i.e., between US$375 and $875 billion annually on a global
basis.
Ref. : NACE IMPACT REPORT(3/2016)

-Corrosion Losses.
I- Direct losses
-cost of replacement corroded equipment.
II- indirect losses

-High cost preventive maintenance
-Loss of efficiency.
-Loss of production due to corroded portion
-Safety requirements measures from fire hazard
or explosion from leaked hazard product
-Pollution of environment and health problems
due to corrosion.
-Corrosion Losses.
Corrosion
Losses
Direct Indirect
losses losses
cost of High cost Loss of pollution of

Safety requirements
replacement production due
Loss of
preventive measures from fire environment
corroded to corroded leaked hazard product efficiency
maintenance and health
equipment's portion
problems
II. COMMON CORROSION TYPES IN INDUSTRIES
PITTING
CORROSION
UNIFORM
CORROSION
GALVANIC
CORROSIO
N
II. Common
Corrosion
Types In
INDUSTRIES
EROSION/
CORROSION
CREVICE/
CORROSION STRESS
CORROSION CAVITATION
CRACKING CORROSION
22
II. Common Corrosion Types In Petroleum
Can Be Classified according to :
1-The Shape and type Of Corrosion.
2-The Location Of Corrosion In Equipment (Ext. Or Int.).
3- The Environment And Medium Of Corrosion.
23
1-Acc. The shape of corrosion
PITTING CORROSION
UNIFORM
CORROSION
GALVANIC
CORROSION
II. Common Corrosion
Types In
Petroleum
EROSION/
CORROSION
CREVICE/ STRESS
CORROSION CORROSIONCRAC CAVITATION
KING CORROSION
24
25
II. Common corrosion types in petroleum
Uniform Corrosion
corrosion rate at the same on the entire surface of equipment.
II. COMMON CORROSION TYPES IN PETROLEUM
1-ACC. THE SHAPE OF CORROSION

Uniform Corrosion
corrosion rate at the same on the entire surface of equipment
1-Acc. The shape Of Corrosion
Pitting Corrosion
CORROSION IS DEEP IN SOME AREAS THAN OTHER AREAS ALONG THE METAL SURFACE
PITTING CORROSION
Pitting is a localized form of corrosive attack. Pitting corrosion is typified by the formation of holes
or pits on the metal surface. Pitting can cause failure, yet the total corrosion, as measured by weight
loss, may be minimal.
MICOBIOLOGICAL INDUCED
CORROSION ( MIC CORROSION)
PITTING CORROSION
ACID CORROSION ( Hcl, CO2,H2S AND DISSOLVED GAS)

Dissolved Carbon Dioxide (CO2).When CO2 dissolves in water, it forms
carbonic acid, decreases the pH of the water, and increases its
corrosiveness results in pitting.
Corrosion primarily caused by dissolved CO2 often is referred to as

“sweet” corrosion, as opposed to corrosion caused by H2S, commonly
called“sour” corrosion. Co2 corrosion
CO2 CORROSION
-GAS PIPING
- PRODUCTION OIL ACCOICATED WITH GAS
the partial pressure of CO2 can be used as a yardstick to predict corrosion problems in gas condensate wells.
The partial pressure of CO2 can be determined by the formula:
Partial pressure = total pressure x mole fraction of CO2 in the gas
•A partial pressure above 30 psi (0.2 MPa) statistically indicates CO2 corrosion w
•At a partial pressure between 3 and 30 psi (0.02 and 0.2 MPa), CO2 corrosion may cause
A partial pressure below 3 psi (0.02 MPa) statistically indicates COC corrosion will not be a problem
REF. Corrosion Control in Petroleum Production TPC Publication 5 Second Edition Harry G. Byars
NACE• TH E CORROS IO N SOCI ETY 1999 Houston, Texas P.29-30
II-Common Corrosion Types In Petroleum
1-Acc.The Shape Of Corrosion
Galvanic Corrosion
galvanic corrosion occurs when two dissimilar metals are

immersed in a conductive solution and are electrically connected.
1-Acc. The Shape Of Corrosion
Galvanic Corrosion
Factors affecting in in Galvanic corrosion :

- Potential difference .between two difference metals
- Area Ratio between anode and cathode
- Eff. Of insulation between two difference metals.
Galvanic Corrosion
Refrence:
Galvanic Corrosion
 Dissimilar metals are physically joined in the presence
of an electrolyte.
• The more anodic metal corrodes.
Practicle Ex. Of Galvanic Corrosion
St.St bolt
Cs bolt
CS
St.St
II-COMMON CORROSION TYPES IN PETROLEUM for harsh environments, such as outdoors, high humidity, and salt environments fall
into this category. Typically there should be not more than 0.15 V difference in the
"Anodic Index". For example; gold silver would have a difference of 0.15V being
Galvanic Corrosion acceptable.
For normal environments, such as storage in warehouses or non-temperature and
humidity controlled environments. Typically there should not be more than 0.25 V
difference in the "Anodic Index".
For controlled environments, such that are temperature and humidity controlled, 0.50
V can be tolerated. Caution should be maintained when deciding for this application
as humidity and temperature do vary from regions
METALLURGICAL CATEGORY ANODIC
INDEX (V)
Gold, solid and plated, Gold-platinum alloy 0.00
Rhodium plated on silver-plated copper 0.05
Silver, solid or plated; monel metal. High nickel-copper alloys 0.15
Nickel, solid or plated, titanium an s alloys, Monel 0.30
Copper, solid or plated; low brasses or bronzes; silver solder; German 0.35
silvery high copper-nickel alloys; nickel-chromium alloys
Brass and bronzes 0.40
High brasses and bronzes 0.45
18% chromium type corrosion-resistant steels 0.50
Chromium plated; tin plated; 12% chromium type corrosion-resistant 0.60
steels
Tin-plate; tin-lead solder 0.65
Lead, solid or plated; high lead alloys 0.70
Aluminum, wrought alloys of the 2000 Series 0.75
Iron, wrought, gray or malleable, plain carbon and low alloy steels 0.85
Aluminum, wrought alloys other than 2000 Series aluminum, cast 0.90
alloys of the silicon type
Aluminum, cast alloys other than silicon type, cadmium, plated and 0.95
chromate
Hot-dip-zinc plate; galvanized steel 1.20
Zinc, wrought; zinc-base die-casting alloys; zinc plated 1.25
Eng.Abdellatif Magnesium & magnesium-base alloys, cast or wrought
Radwan 36
1.75
Beryllium 1.85
Erosion/Corrosion
degradation of material surface due to mechanical action, often by impinging liquid, abrasion by a slurry, particles
suspended in fast flowing liquid or gas, bubbles or droplets, cavitation, etc.
1-acc. The Shape Of Corrosion
erosion/ corrosion
degradation of material surface due to mechanical action, often by impinging liquid, abrasion by a slurry, particles
suspended in fast flowing liquid or gas, bubbles or droplets, cavitation, etc.
INSPECTION AND CORROSION CONTROL OF PIPELINE AND PIPING SYSTEM IN PETROLEUM INDUSTRY
INTERNAL CORROSION CORROSION TYPES AND MECHANISM IN PIPING
EROSION /CORROSION
4 fps
1 fps (immersed in 27 fps
Material (tidal current) seawater flume) (rotating disk)
Carbon steel 6 13 47
Cast iron 9 — 54
Silicon bronze 0.2 0.3 57

Admiralty brass 0.3 3 29
Hydraulic bronze 1 0.2 55

G bronze 1 0.3 46
Al bronze 1 — 44
Aluminum brass 0.4 — 19
90-10 Cu-Ni 1 — 16
70-30 Cu-Ni (0.05 %Fe) 0.3 — 32
70-30 Cu-Ni (0.5 % Fe) <0.2 <0.2 6
Alloy 400 <0.2 <0.2 1
316 SS 0.2 0 <0.2
Alloy C-276 <0.2 — 0.05
Titanium 0 — 0
39
Crevice Corrosion
is a sort of localized corrosion that occurs as a result of the presence of a crevice. Crevice corrosion occurs in
closed areas where fluid flow is limited, such as below sealing in the valves and below gaskets in valves
and flanges
40
Crevice Corrosion
Crevice Corrosion
42
Crevice Corrosion TITANIUM

MEDIUM:SEA WATER
REF:NACE PAPER NO.594 CORROSION/98
FAILURE OF CRUDE OIL COOLERS AT RAMADAN FIELD/GULF OF SUEZ
cavitation corrosion
cavitation corrosion is a specific type of erosion which results from gas
bubbles' implosion on metal surfaces
Stress Corrosion Cracking (SCC) :
Cracking Induced From the combined influence of tensile stress and a corrosive environment.
the required tensile stresses may be in the form of directly applied stresses or in the form of
residual stresses. the problem itself can be quite complex.
- chloride stress corrosion cracking

- sulfide stress corrosion cracking
- REFF: NACE NR0175-2000
- NACE MATERIAL SELECTION
45
STRESS CORROSION CRAKING
STRESS CORROSION CRACKING (SCC) IS CAUSED BY THE

“SYNERGISTIC” ACTION OF CORROSION AND APPLIED TENSILE
STRESS; THAT IS, THE COMBINED EFFECT OF THE TWO IS GREATER
THAN THE SUM OF THE SINGLE EFFECTS.
IN THE ABSENCE OF STRESS, THE PARTICULAR METAL WOULD NOT

CORRODE (IN SUCH A CRACKING MANNER), AND IN ABSENCE OF
CORROSION, THE METAL EASILY SUPPORTS THE STRESS.
THE RESULT OF THE COMBINED EFFECT IS A BRITTLE FAILURE OF A
NORMALLY DUCTILE METAL. THE STRESS LEADING TO SCC IS
ALWAYS A TENSILE STRESS.
IT CAN BE EITHER APPLIED OR RESIDUAL. FREQUENTLY, RESIDUAL

STRESSES ARE MORE DANGEROUS BECAUSE THEY MAY NOT BE
CONSIDERED IN EVALU- ATING THE OVERALL STRESSES
REF. Corrosion Control in Petroleum Production TPC Publication 5 Second Edition Harry G. Byars NACE•
TH E CORROS IO N SOCI ETY 1999 Houston, Texas P.64
Sulfide Stress corrosion cracking (SCC) :
HAZ (Heat Affected Zone)

Sulfide Stress Corrosion Cracking Stress corrosion cracking (SCC)
STRESS CORROSION CRAKING

TYPES OF ENVIRONMENTAL CRACKING
THE FOLLOWING TYPES OF ENVIRONMENTAL CRACKING WILL BE DESCRIBED:
- STRESS CORROSION CRACKING (SCC)
- HYDROGEN INDUCED CRACKING (HIC)
- LIQUID METAL EMBRITTLEMENT (LME)
- CORROSION FATIGUE
(REF.NACE CORROSION MANUAL CHAP.5.5.4)
THE MOST COMMON CORROSIVES CAUSING SCC OF MILD

STEELS ARE:
SODIUM HYDROXIDE (NaOH) AND NITRATE SOLUTIONS.
CRACKING IN NaOH, KNOWN AS CAUSTIC EMBRITTLEMENT,
WAS ONCE A VERY SERIOUS PROBLEM.
CRACKING BY AMMONIUM, CALCIUM, AND SODIUM NITRATES
ARE MINIMIZED BY PREVENTIVE MEASURES
-CHLORIDE STRESS CORROSION CRACKING

-SULFIDE STRSS CORROSION CRACKING
-HYDROGEN EMBRITTLMENT
ANSI/API RECOMMENDED PRACTICE 571 THIRD EDITION, MARCH 2020

Damage Mechanisms Affecting Fixed Equipment in the Refining Industry FM P.72
TO P.80 Eng.Abdellatif Radwan 48
- CORROSION FATIGUE
•FATIGUE CRACKING IS A MECHANICAL FORM OF DEGRADATION THAT
OCCURS WHEN A COMPONENT IS EXPOSED TO CYCLICAL STRESSES
FOR AN EXTENDED PERIOD, E.G. FROM DYNAMIC LOADING DUE TO
VIBRATION, WATER HAMMER, OR UNSTABLE FLUID FLOW, OFTEN
RESULTING IN SUDDEN, UNEXPECTED THRU-WALL CRACKING.
•THESE STRESSES CAN ARISE FROM EITHER MECHANICAL

LOADING OR THERMAL CYCLING AND ARE TYPICALLY WELL
BELOW THE YIELD STRENGTH OF THE MATERIAL. THIS
SECTION FOCUSES ON MECHANICAL LOADING, WHILE THE
EFFECTS OF THERMAL CYCLING ARE COVERED IN N THERMAL
FATIGUE.
ANSI/API RECOMMENDED PRACTICE 571 THIRD EDITION, MARCH 2020

Damage Mechanisms Affecting Fixed Equipment in the Refining Industry P.225
INTERGRANULAR CORROSION
IS PREFERENTIAL ATTACK OF A METAL'S GRAIN BOUND- ARIES. (INTERGRANULAR
CORROSION OFTEN IS CONFUSED WITH STRESS CORROSION CRACKING.
HOWEVER, INTER- GRANULAR CORROSION CAN OCCUR IN THE ABSENCE OF STRESS;

STRESS CORROSION CRACKING OCCURS ONLY WHILE THE METAL IS UNDER STRESS.)
INTERGRANULAR CORROSION HAS OCCURRED IN MANY ALLOYS INCLUDING AUSTENITIC

STAINLESS STEELS, COPPER ALLOYS, ALUMINUM ALLOYS, AND NICKEL ALLOYS.
(REF. Corrosion Control in Petroleum Production TPC Publication 5 Second Edition Harry
G. Byars 6NACE• TH E COR ROS IO N SOCI ETY 1999 Houston, Texas P.56)
EXAMPLE : WELD DECAY

WELD DECAY OCCURS IN THE HEAT AFFECTED ZONE ABOUT 6 MM (0.24 IN) FROM
THE ACTUAL WELD AND PARALLEL TO IT. WELD DECAY IS THE SAME AS
SENSITIZATION, EXCEPT IT OCCURS LOCALLY FROM WELDING EFFECTS RATHER
THAN OVER THE ENTIRE SUBSTRATE.
WELD DECAY RESULTS IN UNIFORM THINNING ADJACENT TO THE WELD, WHERE

GRAINS OF METAL HAVE BEEN REMOVED BECAUSE OF INTERGRANULAR ATTACK.
(REF. NACE BASIC CORROSION MANUAL CHAP.5-39)
II. COMMON CORROSION TYPES IN PETROLEUM
2-ACCORDING TO THE LOCATION OF CORROSION IN EQUIPMENT (EXT. OR INT.).
External corrosion Internal corrosion
51
3- ACCORDING TO THE ENVIRONMENT AND MEDIUM OF CORROSION.
Buried Immersion -High temperature

Atmospheric (underground) and submerged corrosion
52
Corrosion and
Damage Mechanism
(API RP 571)
Damage Related
Damage Related Damage Related
Damage Related High Associated
Metallurgical and Uniform or localized
Material Effect metal Loss Temp. Effect Enviornmented
Cracking
Graphitization Galvanic Corrosion

Softening Atmospheric Corrosion
(Spheroidization) Corrosion Under Insulation (CUI) .
Temper Embrittlement Cooling Water Corrosion
Strain Aging Boiler Water Condensate Corrosion
Embrittlement . CO2 Corrosion .....
Creep and Stress Flue-Gas Dew-Point Corrosion …
Rupture Microbiologically Induced Corrosion (MIC)
Thermal Fatigue . Soil Corrosion
III. FACTORS AFFECTING CORROSION PROCESS:
III. Factors Affecting Corrosion Process:
- Factors Related to Environment.

- Factors Related to Operating Condition.
- Factors Related to Material Selection.
Factors Related to Environment
-Dissolved Gases : I.e O2, CO2, H2S
CO2 : Sweet Corrosion H2S : Sour Corrosion O2 : water flow lines
Ex. CO2 &H2S Downhole Corrosion Problems
56
Factors Related to Environment
Impurities and deposits

Under Deposit Corrosion
Factors Related to Operating Condition

- Temp, Press. High Flow Rate
Erosion/Corrosion
- Factors Related to Material Selection
IV- CORROSION MONITORING SYSTEM IN PETROLEUM INDUSTRY
IV- Corrosion Monitoring System In Petroleum Industry:
- Definition and important of corrosion monitoring
- Types of corrosion monitoring system (CMS):
- Weight loss coupons.
- Electrical resistance probes.
- Linear polarization probes.
- NDT ( UT thickness measurements).
- Chemical methods
- Failure analysis
- evaluation of corrosion monitoring system
- practical case of CMS in oil field production
61
OIL PRODUCTION
OFSHORE AREA ONSHORE AREA

STORAGE TANKS
GAS LIFT MODULES
HEATER
HEMIS
H.E
TO GAS PLANT
OIL/GAS SEP.
DESALTER
OIL WELL
WATER INJ.
PROCESS AREA
GAS LIFT INJ.
CORR.MONIRORING SYSTEM
DOWNHOLE CMS
63
Iv- Corrosion Monitoring System In Petroleum Industry
Definition of corrosion monitoring system
Is a process that evaluates and monitors equipment

components, structures, process units, and facilities for
signs of corrosion
Important Of Corrosion Monitoring:
• Identify the critical areas of equipment before failure.

- Help us preparing the maintenance program.
- Evaluate the corrosion control methods.
Corrosion Rate Measurement Units :

MPY Mils Per Year (1inch =1000 Mils)
IPY Inch Per Year 64
CRUDE DISTILLATION UNIT

CONTROL OF CORROSION
CRUDE 40 FL-1
40 D-1
DESALTER
HEX R HEX
E -1 E- NaOH
Inj.
E -2 HEX HEX
4 - -2
- E-
INHIBITORS
HEX HEX
AIR COOLER
40 W5
WATER A B C
CP
DIST.COLUMN
V -2
LP
KER. G.O F.O NAPH.
-
STAB.
-
CMS
OIL PRODUCTION
OFSHORE AREA ONSHORE AREA

STORAGE TANKS
GAS LIFT MODULES
HEATER
HEMIS
H.E
TO GAS PLANT
OIL/GAS SEP.
DESALTER
OIL WELL
WATER INJ.
PROCESS AREA
GAS LIFT INJ.
DOWNHOLE CMS
66
IV- corrosion monitoring system in petroleum industry
Types Of Corrosion Monitoring System (CMS)
Weight Loss Coupons

Is the simplest form of corrosion monitoring that can
be applied to all environments and matches the
material of equipment to be monitored
67
Types Of Corrosion Monitoring System (CMS)
Weight Loss Coupons
-Corr.Rate Weight Loss Coupon CR=

(2.227 * 10 E4 *W) / (A * T * D)
Where CR Average Corr.Rate mpy (Mils per year )
(1 Inch = 1000 Mils)
W Weight Loss of Coupon gm
A Initial Exposed Surface Area ( inch square)
T Exposure Time Days
D Density Of Coupon Metal gm/cm3
(7.8 gm/cm3 For Steel )
Ref : NACE RP0775-91 Coupon Analysis
IV- CORROSION MONITORING SYSTEM IN INDUSTRY
Types of corrosion monitoring system (CMS)
Electrical Resistance Probes

measure the change in electrical resistance of a
component and provide information about metal loss
Principles of Operation
the electrical resistance of a metal or alloy element is given by:
r= (ρ * l ) / a
where:
l = element length
a = cross sectional area
ρ = specific resistance
reduction (metal loss) in the element's cross section due to corrosion

will be increase in the element's electrical resistance.
types of corrosion monitoring system (CMS)
Evaluation Of Electrical Resistance Probes
ER Measure Metal Loss During Certain Period And Used In All Envirnment
CR = (Probe Constant * Diff. Metal Loss *365) / Diff In Days
Ex : in graph metal loss @ 21/6 2.1 mils
metal loss @ 18/5 1 mils
CR = ((2.1 -1 ) * 365) / 3 = 11.8 mpy
-types of corrosion monitoring system (CMS)
Linear polarization resistance probes

Is an electrochemical technique that works by applying current to an
electrode and instantaneously measuring the corrosion rate.
It used in conductive electrolyte medium like water
IV corrosion monitoring system in petroleum industry
NDT : ultrasonic thickness monitoring
is a very common NDT method that measures the wall thickness of

a component over time.
evaluation and corrosion rate by ultrasonic thickness monitoring
CR (corr.rate)= (original thickness mm –measured

thickness mm ) * 365 / diff days
-Types Of Corrosion Monitoring System (CMS)

NDT : Ultrasonic Thickness Monitoring
Practical Case Of Critical Measured Location By UT
Bottom areas & Elbows
NDT : Ultrasonic Thickness Monitoring
calculate Corr.Rate By Ultrasonic Thickness

Monitoring
CR (Corr.Rate)= (Original Thickness mm –measured

thickness mm ) * 365 / Diff Days
Ex.: 8”sch40 8.18 mm

min.meas.thick. 6 mm
time period 400 days
Corr.rate = ( 8.18 - 6)* 365/ 400 = 1.99 mm/year
calculate Corr.Rate By Ultrasonic Thickness Monitoring FOLLOW
Standard limits of Corr.Rate Acc to Nace:

LOW < 1 mpy
moderate1-4.9 mpy
high 5-10 mpy
Severe >10 mpy
Refernces:
NACE STANDARD 0-775-99 STANDARD RECOMMENDED PRACTICE PREPARATION,INSTALLATION , ANALYSIS, AND
INTERPRETAION OF WEIGH LOSS COUPON IN OIL FIELD
-Detect type of corrosion by UT inspection
Uniform corrosion
Pitting corrosion
Detect pipe schedule by UT inspection
data analysis And Corr.Rate By Ultrasonic Thickness Monitoring
data analysis And Corr.Rate By Ultrasonic Thickness Monitoring follow
Data required for ut thickness evaluation:

- isometric drawing (as built drawing)
- pipe schedule
- service
- material type and chemical and
mechanical properties
- data analysis
- identify corr.rate and critical spot
- type of corr.
- FFS calculations
-remaining service life
- remidial action and repair
Detect safe operating pressure by UT inspection
Ut Evaluation consideration
Enviornment of Position of
corrosion equipment Flow regime
mechanism condition
IV- Corrosion monitoring system in petroleum industry
-Types of corrosion monitoring system (CMS)
Biological monitoring probes
Measures The Presence Of Bacteria That Consume Sulphate And

Generate Sulpheric Acid (H2SO4).
82
iv corrosion monitoring system in petroleum industry
-types of corrosion monitoring system (cms)
Chemical Methods
samples taken from corrosive media to detect
corr. rate of system
ppm iron count for flow lines
ib fe /day = 0.00035 ppm fe * bwpd (barrels water per day)

corr.rate mpy =( ib fe per day )/(0.0000287 *l*d
where l: length of tube , d : inside diameter
co2 corr.rate prediction for gas lines:
log (corr.rate mmpy) = 5.8 – (1710/t)+0.67 (log p.p co2)

(deward williams equation) where t temp.absolutr p.p partial press. of co2 in
gas
p.p of co2 < 3 non corrosive
3-30 psi may be corrosive
> 30 psi corrosive
REF :NACE publication tcp5 corrosion control in petroleum production
Failure Analysis
Investigation Performed On The Corroded

Area To Identify The Reasons And Detect The Suitable
Corrosion Control failure Analysis.
Failure Analysis Requirements:
-Destructive test
-Evaluate Monitoring System Types
-Analysis Of Test Performed And Monitoring
-Recommendation For Suitable Selection
Corrosion Control.
IV- Corrosion
Monitoring System In Petroleum Industry
- Evaluation of Corrosion Monitoring System

LOW < 1 mpy
moderate1-4.9 mpy
high 5-10 mpy
Severe >10 mpy
Refernces:
NACE STANDARD 0-775-99 STANDARD RECOMMENDED PRACTICE PREPARATION,INSTALLATION , ANALYSIS, AND
INTERPRETAION OF WEIGH LOSS COUPON IN OIL FIELD
Practical Case Of CMS In Oil Field Production STORAGE TANKS ONSHORE AREA
OFSHORE AREA
TO GAS PLANT H.E

GAS LIFT MODULES
HEATER
HEMIS
OIL/GAS SEP.
DESALTER
OIL WELL
WATER INJ.
PROCESS AREA
GAS LIFT INJ.
DOWNHOLE CMS
86
V - CORROSION CONTROL METHODS
V - Corrosion Control Methods
-PROTECTIVE COATING
-CATHODIC PROTECTION
-CORROSION INHIBITOR
-MATERIAL SELECTION
-DESIGNE
-METHODS DEPEND ON THE CONTROL OF

-OPERAATING CONDITION
- Fe Fe++ + 2e
METHODS DEPEND ON THE MATERIAL
ENVIORNMENT
-SUITABLE MATERIAL SELECTION

CORROSION CIRCUIT
-SUUITABLE DESIGN
corrosion circuit:
- anode Fe Fe++ + 2e- Anode (oxida ion)
t
- cathode
- electrolyte O2 + 2H2O + 4e 4OH- cathode

METHODS ISOLATE METAL FM CORRODED ENVIORNMENT

CORROSION CONTROL BY PROTECTIVE COATING
corrosion control definition:

process through a certain method to make
the corrosion rate in acceptable limits.
Chemical injection system
Protective coating
material selection
CORROSION CONTROL Cathodic protection

METHOD
Operating
condition
design
CORROSION CONTROL BY DESIGNE
CORROSION ALLOWANCE CA:
AN EXTRA MEASUREMENT ADDED TO THE THICKNESS OF THE WALL. ... BY KNOWING THE EXPECTED
RATE OF CORROSION AND THE EXPECTED SERVICE LIFE OF A PLANT OR PARTS.
ASME B31.3 Provides formula and guidelines for calculation of THICKNESS pipe under
pressure..304.1.2 (a) equation :
Seamless Pipes : Design Thickness t = (PD)/2(SE+PY)
Welded Pipes : Design Thickness tm = (PD)/2(SEW+PY)
Where :
P : Internal Design Gauge Pressure
D : Outside diameter of pipe
S : Allowable Stress value for material from Table A-1E
E : Longitudinal Weld Joint Quality factor as per ASME B31.T
W : Weld Joint Strength Reduction Factor
Y : Coefficient from Table 304.1.1,
CORROSION CONTROL BY DESIGNE AND

DURING FABRICATION
CORROSION CONTROL BY MATERIAL SELECTION
ex. main distillation refinery
upper part
carbon steel lined by monel
to avoid chlorides salt
middle and lower part

carbon steel lined by st.st410
to avoid sulfur compound at high temp.
92
Ex. Tube Boundele And Tube sheet Of Sea Water Cooler And Condenser
Tube Sheet
Tube Boundle
TUBE SHEET AND TUBE BOUNDLE GENERALLY FABRICATED FROM

EX. COPPER BASE ALLOY DUE TO GOOD RESISTANCE TO SEAWATER
-PRINCIPLES
-TYPES
SACRIFICIAL ANODES
IMPRESSED CURRENT
-DESIGN CONSIDERATION
- EVALUATION
Cathodic Protection
Impressed Current
transformer/rectifier
- +
STORAGE
TANK
BURIED PORTION
auxiliary anode
96
V - corrosion control methods
CATHODIC PROTECTION
- DESIGN CONSIDERATION
REFRENCE : NACE REFRENCE BOOK
CATHODIC PROTECTION EVALUATION POTENTIAL SURVEY
Buried pipeline Subsea pipeline

Min. potential -850 mv Vs Cu/CuSO4 Min.Potential -800 mv Vs Ag/Agcl Electrode
Electrode
Control of corrosion through operating condition
-Remove stagnation areas -Periodic flushing
99
PROTECTIVE COATING
COATING DEFINITION
IS A LAYER OF MATERIAL DEPOSITED INTO A SUBSTRATE TO ENHANCE THE

SURFACE PROPERTIES FOR CORROSION AND WEAR PROTECTION
Factors Affecting The Choice Of A Coating

-Service Environment
-Life Expectancy,
-Substrate Material Compatibility
-cost.
100
PROTECTIVE COATING
Types Of Coating Classification :
I- According To Environment :
Splash zone & submerged

Atmospheric

Protective Coating
-Inorganic Coating:
Ex. In Organic zinc Silicate Which Is Common Used In Petroleum
Industry It Used In Atmospheric And High Temp. Surface.
-Mastic Coating:
use in locations which is difficult to perform sand blasting
and we can apply on surface prepared by mechanical power
tools.

Protective Coating
Surface preparation degree

Protective Coating
Painting System Component Application

Corrosion Control By Protective Coating
Application Of Coating Procedures
SANDBLASTING AIRLESS SPRAY ROLEER
APPLY PAINTING

Comment Coating Defects
. (a) Blistering (b) Bubbling
.. (c) Sagging
. (d) Solvent lifting
Detachment
Peeling (e) Solvent popping

Evaluation Of Coating Application
- Lab test for paint according To data sheet

Evaluation Of Coating During And After Application
Measure wet film thickness Measure dry film thickness

Holiday detector of painting pinhole

V - Corrosion Control Methods PAINTING REPAIR
Corrosion Control By Protective Coating ASTM D610

Ex. : Painting System
External surface
Epoxy mastic 200 mic ( 2 coat)

Poly urethane 50 mic.
External surface high temp.
Inorganic zinc silicate 50 mic.

Silicon binder 55 mic. ( 2 coats)

Splash zone
High solid epoxy 100 % 0.25 inch

V - Corrosion Control Methods Hot Dip Galvanized
REF.: ASTM A153 VOL 1.06

V -Corrosion Control Methods
Corrosion Control By Chemical Injection System:
Is A Substance Which When Added To An Environment Decrease The

Corrosion Attack On A Metal Surface.
Examples Of Types Chemical Injection
-Inject Chemicals to Isolate Corroded

Environment from metal
i.e. corrosion inhibitor in petroleum
production and refinery
-Add Chemicals To Scavenge Corrosive Element

From Environment
I.E. O2 Scavenger In Water System And Water
Treatment For Boilers
-Add Chemicals to Neutralizing Acid constituents

i.e NAOH in refinery

Corrosion Control By Chemical Injection System
-TYPES OF CORROSION INHIBITORS IN OIL FIELD
-CLASSIFIED AS CHEMICAL BASE
-CLASSIFIED AS
MECHANISM OF
PROTECTION
113
CLASSIFIED AS CHEMICAL BASE:
Inorganic inhibitors: are used mainly in boilers, cooling

towers, and fractionation units.
Organic inhibitors: are used mainly used in oil field systems
Fe Fe++ + 2e- ANODE (OXIDATION
CATHODE
O2 + 2H2O + 4e 4OH-
IN NEUTRAL AND ALKALINE SOLUTION
2H+ + 2e H2 IN ACID SOLUTION
CLASSIFIED AS MECHANISM OF PROTECTION:

Cathodic inhibitors: chemical compounds which inhibit the cathodic reaction of the corrosion cell.
EX:
a-Compounds such as ZnSO4, MgSO4 and Ca(HCO3)2, these compounds inhibit the cathodic reaction by forming
insoluble Zn(OH)2 film or Mg(OH)2 film or CaCO3 film with the cathodically formed ions (in neutral solutions)
the insoluble film isolates the cathodic regions of the corrosion cells from the corrosive medium and stops
corrosion.
b.Oxygen scavengers, these are compounds which react with dissolved oxygen and remove it from the neutral
or alkaline corrosive environment such as sodium sulphite or hydrazine (used to inhibit boiler corrosion and
are called high temperature oxygen scavengers)
Ref:Nace Corrosion Control In Petrolieum Production Chap.7

114
Fe Fe++ + 2e- ANODE (OXIDATION
O2 + 2H2O + 4e 4OH- CATHODE
IN NEUTRAL AND ALKALINE SOLUTION
2H+ + 2e H2 IN ACID SOLUTION
2. Anodic Inhibitors: Are Chemical Compounds Which Inhibit The Anodic Reaction Of The Corrosive Cells.
Exs A. Compounds Such As Na2sio3, Na2co3 And Na3po4, These Compounds Form
With The Anodically Formed Fe++ An Insoluble Film Of Iron Silicate Or Iron Carbonate Or
Iron Phosphate Which Isolates The Anodic Sites Of The Corrosion Cells From The Corrosive
Solution.
b. Passivators: These Are Oxidizing Agents Such As Chromate Inhibitors (Na2cr2o7) Or Nitrite
Inhibitors (Nano2) Which React With The Anodically Formed Fe++ To Form A Passive
Oxide Film On The Anodic Sites Of The Corrosion Cells.

Adsorption Inhibitors:
(organic inhibitors)
These Are Organic Compounds Which Contain A Polar Group Such As NH2 (Amino Group),
These Compounds (RNH2) Adsorb On The Metallic Surface And Isolate It From The Corrosive
Solution

Corrosion inhibitor solubility and impact on performance

The Chemistry Of The Inhibitor Also Determines If It Is Classified As Water Soluble Or Oil Soluble.
Whether A Product Is Water Or Oil Soluble Is A Major Factor On Its Effectiveness In Certain Situations,
And In How The Inhibitor Is Applied.
Water Soluble
Water Soluble Inhibitors Will Dissolve Completely In The Water Phase Of The Fluid Stream. They Remain
In Solution Until Reaching The Tubing Wall. At That Point, They Attach Themselves To The Surface And
Form The Protective Barrier Between The Water And The Metal. Because These Products Are Water
Soluble, They Will Not Completely Dissolve In Oil And They Are Not As Durable As Their Oil-based
Counterparts And Are Easily Stripped Off The Tubing By Moving Fluids.
Oil Soluble
Oil-soluble, Non-water Dispersible Inhibitors Dissolve In The Oil Phase Of The Production Stream. When
One Of These Products Is Mixed With Water It Will Separate Immediately.
Oil-soluble, Water-dispersible Inhibitors Dissolve Into Oil But Also Will Stay Suspended In Water
Temporarily. How Long It Will Stay Dispersed In Water Determines The Product’s Dispersibility. Generally,
It’s More Difficult To Disperse An Oil Soluble Corrosion Inhibitor In Heavy Brines Than In Fresh Water. Oil-
soluble Products Tend To Be More “Sticky” Than Water-base Products. This Allows Them To Better
Adhere To The Tubing Wall.
Vapour Phase Corrosion Inhibitor : Used In Gas System Phase
117
CORROSION CONTROL BY CHEMICAL INJECTION SYSTEM
FACTORS AFFECTING INHIBITOR SELECTION
-Environmental Safety
- (Toxicity, Pollution,…)
- Cost
-Achieving Corrosion Protection In

Acceptable Limit After Accomplished
The Lab Test And Field Test

Evaluation Methods Of Corrosion Inhibitor
lab. test :to achieve efficiency acc. data sheet
Field Test : Install Corrosion Monitoring System
119
Corrosion Control By Chemical Injection System:
Practice Field Test Evaluation And Efficiency Of CI
EFFICIENCY OF CI =
( Corr.Rate Before Inj. - Corr.Rate After Inj.) / (Corr.Rate Befoe Inj ) * 100
Calculations DOSE OF CHEMICAL :

-Dose ppm = ( gpd * 10E6 )/ (Q* 42)
where ppm part per milions
gpd Gallons Per Day
Q Fluid Flow Rate Barrels Per Day

- Corr.Rate Weight Loss Couon CR=

(W*365 *1000) / (A * T * D * 2.54 E3 )
Where CR Average Corr.Rate mpy (mils per year)
W weight loss of coupon gm
A Intial Exposed Surface Area Iinch square
T Exposure Time Days
D Denisity Of Coupon Metal gm/cm3

LOW < 1 mpy
moderate1-4.9 mpy
high 5-10 mpy
Severe >10 mpy
References:
NACE STANDARD 0-775-99 STANDARD RECOMMENDED PRACTICE PREPARATION,INSTALLATION , ANALYSIS, AND INTERPRETAION
OF WEIGH LOSS COUPON IN OIL FIELD

Factors Affecting In Chemical Injection Efficiency (C.I):
periodic pig cleaning of piping
correct location of corr. monitoring system correct

location
use injection tube for. corr inh in liquid phase and atomizer in gas
phase

Corrosion control by chemical injection system
periodic pig cleaning of piping

VI-FACTORS AFFECTING IN SELECTION OF CORROSION CONTROL METHOD

VI-FACTORS AFFECTING IN SELECTION OF CORROSION CONTROL METHOD
-Economical consideration
-Feasibility performed
-Safety considerations

V- Case Studies For Corrosion Control In Oil Fields And Refinery

127
Corrosion Control By Material Selection practical case
10” Hydrocarbon Transfer Line Case Study Refinery Plant
128
Reduction in thickness about
MATERIAL : CARBON STEEL ASTM 335 P11- (1%CR)

SYSTEM : 10 “ SCH 40 TRANSFERE LINE AT VACUUM DISTILLATION UNIT (ASPHALT)
SERVICE LIFE ( YEARS) : 4.5 YEARS

PRACTICAL CASE (INTERNAL CORROSION -HIGH TEMP.CORROSION)
10” Hydrocarbon Transfer Line Case Study Refinery Plant
MATERIAL : CARBON STEEL ASTM 335 P11- (1%CR)

SYSTEM : 10 “ SCH 40 TRANSFERE LINE AT VACUUM
DISTILLATION UNIT (ASPHALT)
SERVICE LIFE ( YEARS) : 4.5 YEARS
Causes :
Hydrocarbons And Sulfur Compounds ( 3% S & Temp. 370 °C ) Cause
Sulfur Corrosion To The Low Alloy Carbon Steel Pipe Due To High
Temp.Corrosion
Remedial Action` : Change Material To A335 P9-9% Cr Steel Sch 80

(12.7mm )
Evaluation Of Corrosion Control :

A UT And Visual Inspection Performed In Periodic
Maintenance And Found Corr.Rate In Acceptable Limit
Acc. Nace Standard (3.4 mpy Low To Moderate Corr.Rate)
Ref. Stand.` : Nace Material In Petrolioum Refinery

130
Reduction in thickness about

ONSHORE AREA
CORROSION CONTROL IN OIL FIELD PRODUCTION
STORAGE TANKS
OFSHORE AREA C.I INJECTION
H.E
GAS LIFT MODULES
PROCESS AREA
HEATER
HEMIS
OIL/GAS SEP.
DESALTER
OIL WELL
WATER INJ.
GAS LIFT INJ.
DOWNHOLE CMS
131
PRACTICE CASE STUDY OF CORROSION CONTROL IN PETROLEUM PRODUCTION:
gas lift modules
oil/gas sep.
oil well
inspection findings
pitting fm 3 to 9 oclock
corrosion control:
gas lift inj.

downhole cms
cathodic protection:
apply suitable coating:
references:
API 510
API RP 579

WATER COOLER CHANNEL CASE STUDY

MATERIAL : CARBON STEEL A516 GR 70

SYSTEM : SEA WATER COOLING SYSTEM
PHENOMENON :INTERNAL CORROSION ON THE SURFACE OF CHANNEL HEAD
LOCATION ::CHANNEL OF SEA WATER CONDENSERS.
APPEARANCE :
PITTING AND UNIFORM CORROSION ON THE INTERNAL SURFACE OF CHANNEL HEAD.
SERVICE LIFE ( MONTHS) : 11 MONTHS

ENVIRONOMENT & OPERATING CONDITION :
MEDIUM : SEA WATER
INLET TEMP. : 20-25 °C
INLET PRESS. : 3 KG/CM2
OUTLET TEMP. : 40 °C OUTLET PRESS. : 1 KG/CM2
CAUSES :
THE CORROSION OCCURRED DUE TO ABOVE ENVIORNMENT ( SEA WATER )
REMEDIAL ACTION
1- APPLY THE SUITABLE COATING SYSTEM
( i.e. POLYAMIDE CURED EPOXY WITH RIENFORCED GLASS FLAKE ).
2- INSTALL SACRIFICIAL ANODES( ZINC ).
3- STUDY AND APPLYING CORROSION CONTROL BY MATERIAL SELECTION (MONEL /CARBON STEEL CLADDING MONEL)
EVALUATION
AND AS A RESULT OF APPLYING REMEDIAL ACTION THE CHANNEL IS IN SERVICE SINCE 4 YEARS AND FOUND IN GOOD
CONDITION.
IV- REFRENCES AND CODES

IV- REFRENCES AND CODES
- NACE : National Accusation For Corrosion Engineer
- API :AMARICAN PETROLIOUM INSTITUTE
- SSPC: THE SOCIETY OF PROTECTIVE COATING

- ASTM:AMERICAN STANDARD FOR TESTING MATERIAL
- ASME :AMERICAN SOCIETY FOR MECHANICA ENGINEER
- ASM:AMERICAN SOCIETY FOR METALS

CORROSION CERTIFIED COURSES
NACE CERTIFIED AND RECOMMENDATION
CATHODIC PROTECTION
CP1 - Cathodic Protection Tester Certification

CP2 - Cathodic Protection Technician Certification
CP3 - Cathodic Protection Technologist Certification
COATING INSPECTION
CIP LEVEL 1 COURSE / BASIC COATINGS INSPECTOR CERTIFICATION

CIP LEVEL 2 COURSE / CERTIFIED COATINGS INSPECTOR CERTIFICATION

INSPECTION CERTIFIED COURSES
NDT CERTIFIED AND RECOMMENDATION
-ASNT SNT-TC-1 2, A PERSONNEL QUALIFICATION AND CERTIFICATION IN NONDESTRUCTIVE TESTING

-ASNT NDT Level II Certification Program
-ASNT NDT Level III Certification Program
API CERTIFIED AND RECOMMENDATION

API 510 - Pressure Vessel Inspector
API 570 - Piping Inspector
API 653 - Above Ground Storage Tank Inspector
API 571 - Corrosion and Materials Professional
API 577 - Welding Inspection and Metallurgy Professional
API 580 - Risk Based Inspection Professional
CWI : CERTIFIED WELDING INSPECTOR

INSPECTION IN SERVICE REFRENCES AND CODES
INSPECTION IN SERVICE OF PRESSURE VESSELS

-API PUBLICATION 510, PRESSURE VESSEL INSPECTION CODE: MAINTENANCE INSPECTION,
RATING, REPAIR, AND ALTERATION
INSPECTION IN SERVICE OF PIPING AND PIPELINES

- API PUBLICATION 570
- Recommended Practice 574, Inspection Practices for Piping System Components
- MTI 129 4, A Practical Guide to Field Inspection of FRP Equipment and Piping
- ASME PCC-2, Repair of Pressure Equipment and Piping
CORROSION AND DAMAGE MECHANISM

- API Recommended Practice 571, Damage Mechanisms Affecting Fixed Equipment in the Refining
Industry API
- NACE RP 0170, Protection of Austenitic Stainless Steels and Other Austenitic Alloys from
Polythionic Acid Stress Corrosion Cracking During Shutdown of Refinery Equipment
- NACE Pub 34101, Refinery Injection and Process Mixing Points
FABRICATION INSPECTION REFRENCES AND CODES
DESIGNE AND INSPECTION OF NEW PIPING INSIDE PLANT

- ASME B31.3, Process Piping
DESIGNE AND INSPECTION OF NEW PIPIELINE

-ASME B31.4, Pipeline Transportation Systems for Liquids and Slurries
-ASME B31.8, Gas Transmission and Distribution Piping Systems
DESIGNE OF NEW PRESSURE VESSELS

-ASME Boiler and Pressure Vessel Code (BPVC), Section V, Nondestructive Examination
-ASME BPVC, Section VIII, Divisions 1 and 2
-ASME BPVC, Section IX, Welding and Brazing Qualifications
- API Recommended Practice 578, Material Verification Program for New and Existing
Piping Systems


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Corrosion and its Control Management System in industry

Corrosion science content 3

Corrosion & Inspection Pipeline and -Cathodic Protection

CP1 - Cathodic Protection Tester Certification

CIP LEVEL 1 COURSE / BASIC COATINGS INSPECTOR CERTIFICATION

-ASNT SNT-TC-1 2, A PERSONNEL QUALIFICATION AND CERTIFICATION IN NONDESTRUCTIVE TESTING

API CERTIFIED AND RECOMMENDATION

CWI : CERTIFIED WELDING INSPECTOR

INSPECTION IN SERVICE OF PRESSURE VESSELS

INSPECTION IN SERVICE OF PIPING AND PIPELINES

CORROSION AND DAMAGE MECHANISM

DESIGNE AND INSPECTION OF NEW PIPING INSIDE PLANT

DESIGNE AND INSPECTION OF NEW PIPIELINE

DESIGNE OF NEW PRESSURE VESSELS

-How to identify and predict corrosion

-How to handle and manage the corrosion problems

-How to identify the suitable corrosion control

-Codes And References Of Corrosion And How To Apply

-Sharing Experiences And Knowledge

-Get Knowledge, improvement For Internationally

I- Introduction To Corrosion Basics:

- INTRODUCTION TO CORROSION BASICS

- FOLLOW TYPES OFCORROSION

-PRACTICAL CASE OF CORROSION MONITORING

FOLLOW CORROSION CONTROL

corrosion circuit: (oxidation)

corrosion circuit: (oxidation)

METAL CRRODES AND RETURN TO

By using available corrosion control practices, it is estimated that

Ref. : NACE IMPACT REPORT(3/2016)

I-Introduction Corrosion Basics.

II- indirect losses

cost of High cost Loss of pollution of

II. COMMON CORROSION TYPES IN INDUSTRIES

1-The Shape and type Of Corrosion.

2-The Location Of Corrosion In Equipment (Ext. Or Int.).

3- The Environment And Medium Of Corrosion.

corrosion rate at the same on the entire surface of equipment.

1-ACC. THE SHAPE OF CORROSION

corrosion rate at the same on the entire surface of equipment

ACID CORROSION ( Hcl, CO2,H2S AND DISSOLVED GAS)

Corrosion primarily caused by dissolved CO2 often is referred to as

galvanic corrosion occurs when two dissimilar metals are

Factors affecting in in Galvanic corrosion :

Silicon bronze 0.2 0.3 57

Hydraulic bronze 1 0.2 55

Aluminum brass 0.4 — 19

Alloy 400 <0.2 <0.2 1

316 SS 0.2 0 <0.2

Alloy C-276 <0.2 — 0.05

Crevice Corrosion TITANIUM

- chloride stress corrosion cracking

STRESS CORROSION CRAKING

STRESS CORROSION CRACKING (SCC) IS CAUSED BY THE

IN THE ABSENCE OF STRESS, THE PARTICULAR METAL WOULD NOT

IT CAN BE EITHER APPLIED OR RESIDUAL. FREQUENTLY, RESIDUAL

HAZ (Heat Affected Zone)

STRESS CORROSION CRAKING

THE MOST COMMON CORROSIVES CAUSING SCC OF MILD

-CHLORIDE STRESS CORROSION CRACKING

ANSI/API RECOMMENDED PRACTICE 571 THIRD EDITION, MARCH 2020

•THESE STRESSES CAN ARISE FROM EITHER MECHANICAL

ANSI/API RECOMMENDED PRACTICE 571 THIRD EDITION, MARCH 2020

HOWEVER, INTER- GRANULAR CORROSION CAN OCCUR IN THE ABSENCE OF STRESS;