Corrosion Control - Lec3

Corrosion and its Control Management System in industry
II. Common corrosion types in petroleum

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.
Eng.Abdellatif Radwan 1
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
3
Eng.Abdellatif Radwan
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
4
1-Acc. The shape Of Corrosion
Crevice Corrosion
Crevice Corrosion
6
Crevice Corrosion TITANIUM

MEDIUM:SEA WATER
REF:NACE PAPER NO.594 CORROSION/98
FAILURE OF CRUDE OIL COOLERS AT RAMADAN FIELD/GULF OF SUEZ
1-Acc. The shape Of Corrosion
cavitation corrosion
cavitation corrosion is a specific type of erosion which results from gas
bubbles' implosion on metal surfaces
1-Acc. The shape of corrosion
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
9
1-Acc. The shape of corrosion
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
1-ACC. THE SHAPE OF CORROSION
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 12
- 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
15
II. Common Corrosion Types In Petroleum
3- ACCORDING TO THE ENVIRONMENT AND MEDIUM OF CORROSION.
Buried Immersion -High temperature

Atmospheric (underground) and submerged corrosion
16
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
20
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
25
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
27
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 28
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.
CORR.MONIRORING SYSTEM
DOWNHOLE CMS
30
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
31
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
-types of corrosion monitoring system (CMS)
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
IV- Corrosion Monitoring System In Petroleum Industry
-Types Of Corrosion Monitoring System (CMS)

NDT : Ultrasonic Thickness Monitoring
Practical Case Of Critical Measured Location By UT
Bottom areas & Elbows
IV- Corrosion Monitoring System In Petroleum Industry
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

Corrosion Control - Lec3

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Corrosion Control - Lec3

Uploaded by

Copyright:

Available Formats

Corrosion and its Control Management System in industry

II. Common corrosion types in petroleum

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;

INTERGRANULAR CORROSION HAS OCCURRED IN MANY ALLOYS INCLUDING AUSTENITIC

EXAMPLE : WELD DECAY

WELD DECAY RESULTS IN UNIFORM THINNING ADJACENT TO THE WELD, WHERE

(REF. NACE BASIC CORROSION MANUAL CHAP.5-39)

External corrosion Internal corrosion

Buried Immersion -High temperature

Graphitization Galvanic Corrosion

III. FACTORS AFFECTING CORROSION PROCESS:

III. Factors Affecting Corrosion Process:

- 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

Factors Related to Environment

Impurities and deposits

Factors Related to Operating Condition

- Factors Related to Material Selection

IV- CORROSION MONITORING SYSTEM IN PETROLEUM INDUSTRY

OFSHORE AREA ONSHORE AREA

GAS LIFT MODULES

Is a process that evaluates and monitors equipment

Important Of Corrosion Monitoring:

• Identify the critical areas of equipment before failure.

Corrosion Rate Measurement Units :

CRUDE DISTILLATION UNIT

OFSHORE AREA ONSHORE AREA

GAS LIFT MODULES

Weight Loss Coupons

Weight Loss Coupons

-Corr.Rate Weight Loss Coupon CR=

Ref : NACE RP0775-91 Coupon Analysis

Electrical Resistance Probes

reduction (metal loss) in the element's cross section due to corrosion

Linear polarization resistance probes

NDT : ultrasonic thickness monitoring

is a very common NDT method that measures the wall thickness of

evaluation and corrosion rate by ultrasonic thickness monitoring

CR (corr.rate)= (original thickness mm –measured

-Types Of Corrosion Monitoring System (CMS)

Bottom areas & Elbows