Corrosion Control - Lec5

Corrosion and its Control Management System in industry
V -Corrosion Control Methods

Corrosion Control By Chemical Injection System
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

1
Eng.Abdellatif Radwan
Fe Fe++ + 2e- ANODE (OXIDATION
CATHODE
O2 + 2H2O + 4e 4OH-
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.
Eng.Abdellatif Radwan 2
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
4
V - CORROSION CONTROL METHODS
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
V - Corrosion Control Methods
Evaluation Methods Of Corrosion Inhibitor
lab. test :to achieve efficiency acc. data sheet
Field Test : Install Corrosion Monitoring System
6
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
Standard limits of Corr.Rate Acc to Nace:

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
14
Corrosion Control By Material Selection practical case
10” Hydrocarbon Transfer Line Case Study Refinery Plant
15
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
CORROSION CONTROL BY MATERIAL SELECTION
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

17
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.
CORR.MONIRORING SYSTEM
GAS LIFT INJ.
DOWNHOLE CMS
18
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

V -Corrosion Control Methods

CLASSIFIED AS CHEMICAL BASE:

Inorganic inhibitors: are used mainly in boilers, cooling

2H+ + 2e H2 IN ACID SOLUTION

CLASSIFIED AS MECHANISM OF PROTECTION:

Ref:Nace Corrosion Control In Petrolieum Production Chap.7

Fe Fe++ + 2e- ANODE (OXIDATION

2H+ + 2e H2 IN ACID SOLUTION

Corrosion inhibitor solubility and impact on performance

Vapour Phase Corrosion Inhibitor : Used In Gas System Phase

CORROSION CONTROL BY CHEMICAL INJECTION SYSTEM

FACTORS AFFECTING INHIBITOR SELECTION

-Achieving Corrosion Protection In

Evaluation Methods Of Corrosion Inhibitor

lab. test :to achieve efficiency acc. data sheet

Field Test : Install Corrosion Monitoring System

Practice Field Test Evaluation And Efficiency Of CI

Calculations DOSE OF CHEMICAL :

- Corr.Rate Weight Loss Couon CR=

Standard limits of Corr.Rate Acc to Nace:

Factors Affecting In Chemical Injection Efficiency (C.I):

periodic pig cleaning of piping

correct location of corr. monitoring system correct

Corrosion control by chemical injection system

periodic pig cleaning of piping

VI-FACTORS AFFECTING IN SELECTION OF CORROSION CONTROL METHOD

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

10” Hydrocarbon Transfer Line Case Study Refinery Plant

Reduction in thickness about

MATERIAL : CARBON STEEL ASTM 335 P11- (1%CR)

10” Hydrocarbon Transfer Line Case Study Refinery Plant

MATERIAL : CARBON STEEL ASTM 335 P11- (1%CR)

Remedial Action` : Change Material To A335 P9-9% Cr Steel Sch 80

Evaluation Of Corrosion Control :

Ref. Stand.` : Nace Material In Petrolioum Refinery

Reduction in thickness about

OFSHORE AREA C.I INJECTION

gas lift modules

gas lift inj.

WATER COOLER CHANNEL CASE STUDY

WATER COOLER CHANNEL CASE STUDY

MATERIAL : CARBON STEEL A516 GR 70

SERVICE LIFE ( MONTHS) : 11 MONTHS

WATER COOLER CHANNEL CASE STUDY

IV- REFRENCES AND CODES

IV- REFRENCES AND CODES

- NACE : National Accusation For Corrosion Engineer

- API :AMARICAN PETROLIOUM INSTITUTE

- SSPC: THE SOCIETY OF PROTECTIVE COATING

- ASM:AMERICAN SOCIETY FOR METALS

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

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