CORROSION

Introduction to Practical
Corrosion
In aqueous environment
for PIPELINES

CORROSION 1
Introduction to corrosion

Corrosion definition

 Corrosion is a degradation of the

material due to its interaction with
the environment
 For metal, the reaction called
electrochemical reaction

CORROSION 2
Introduction to corrosion

EXTRACTION
AND
WORKING

ORE
FINISH PRODUCT

DAMAGE AND
CORROSION
CORROSION 3
Introduction to corrosion

DAMAGE FORM DUE TO CORROSION

1. Thinning

2. Cracking and Pitting formation

3. Appearance modification

4. Decrease of structure strength

5. Embrittlement

CORROSION 4
Introduction to corrosion

Inconveniences due to corrosion

 Damage
 Appareance degradation
 The increase of maintenance cost
 Plant shutdown
 Product contamination
 Decrease of safety

CORROSION 5
Introduction to corrosion

GALVANIC CELL
(wet corrosion)

V
i
Conductor
Anode Cathode
e--
e e-
H2 e-
e-- Mn+
e- H2 e-
ee- Mn+ H2 e-
H2
ee-- Mn+ H+
H+ H+ H+ e-- H+
Mn+ H+ H+ e

Electrolite
CORROSION 6
Introduction to corrosion

ELECTROCHEMICAL REACTION
OXIDATION
Ag Ag+ + e-
Zn Zn 2+ + 2e-
Al Al 3+ + 3e -
General: M Mn+ + ne -
Reduction
2H+ + 2e- H2 (hydrogen evolution)
O2 + 4H+ + 4e- H2O (oxygen reduction /acid
solution)
O2 + 2H2O + 4e- OH - (oxygen reduction – netral
/basic solution)
Mn+ + ne - M (metal ion reduction)
CORROSION 7
Environmental effect

Reduction reaction:
O2 + 2H2O + 4e- OH -
O2
O2

Fe2+ O2
O2
OH- Fe2O3 Fe2O3 OH-

e- e-

e- e-

Cathode Anode Cathode

CORROSION 8
Environmental effect

Reduction reaction:
O2 + 2H2O + 4e- OH -
O2
O2 O2
O2 e-
e- Mn+
e- Mn+
Mn+
H2 O
H2 O

CORROSION 9
Classification of Corrosion
Mechanisms
1. Uniform corrosion/General corrosion
2. Pitting corrosion
3. Crevice corrosion
4. Stress corrosion

A. Aquaeous Corrosion 5. Fatigue corrosion

6. Intergranular corrosion
B. Atmospheric 7. Erosion corrosion
Corrosion 8. Hydrogen embrittlement
9. Cavitation
C. High Temperature 10. Selective leaching
Corrosion 11. Exfoliation
12. Biological corrosion
13. Etc.
CORROSION 10
Classification of corrosion

UNIFORM
CORROSION CORROSION 11
 Local Corrosion: Galvanic Effects
Sn Sn

active noble
STEEL

Zn Zn

STEEL

CORROSION 12
Classification of corrosion

PITTING
CORROSION CORROSION 13
Classification of corrosion

CREVICE
CORROSION
CORROSION 14
Classification of corrosion

STRESS
CORROSION
CRACKING /
SCC
CORROSION 15
Classification of corrosion

INTER-
GRANULAR
CORROSION

CORROSION 16
Classification of corrosion

INTER-
GRANULAR
CORROSION CORROSION 17
Classification of corrosion

HYDROGEN
EMBRITTLEMENT
CORROSION 18
Classification of corrosion

EROSION
CORROSION
CORROSION 19
Classification of corrosion

Dealloying
CORROSION
CORROSION 20
Classification of corrosion

BIOLOGICAL
CORROSION CORROSION 21
General Wall Thinning
 Thinning: mpy (mils/year) or mdd
(mg/dm2/day)

 Related to weight gain or weight loss

CORROSION 22
General wall thinning

Corrosion rate

 Thinning:
 mm/year
 mpy (mils/year)
W = weight loss (mg)

 534
mpy= ---------W D = density (g/cm3)
A = Area (in2)
DAT T = time (hour)

 Weight loss
 mdd (mg/dm2/day)
 mg/mm2/year
CORROSION 23
General wall thinning

Interpretation & data evaluation

The depth of damage = (to - tm)/2

Thinning (metal loss) (mm):
= DW/(A)(d)

CORROSION 24
Metallurgical aspect

CORROSION 25
Environmental Effects

 Type of media
 Chemical composition of the
environment
 pH
 Oxygen concentration

CORROSION 26
 Hydrogen and H2S Effects
 H2S decrease pH to 4
 Anion sulfide play a role as “poison” which trap H ion at the metal
surface and facilitate hydrogen penetration into metal lattice.
 Hydrogen induced cracking, hydrogen blistering, hydrogen attack
and formation of hydride at the sensitive alloy, will be formed with
the presence of H2S.
 Corrosion product are the soluble Sulfide and sulfide deposit.
 At High strength steel, hydrogen stress cracking and sulfide stress
cracking could occur.

CORROSION 27
Microbiological Influenced
Corrosion (MIC)
 MIC has some corrosion form as:
 Crevice corrosion
 Underdeposit corrosion
 Survey at Nova Gas Transmission Ltd
(Calgary), state that MIC occupy 27% from
the whole pipeline corrosion
 At outer surface, MIC create a disbonded
coating.

CORROSION 28
Microbiological Influenced Corrosion

 MIC condition
 Individual bacteria dimension is 0.2 – 3 mm. It is easy to
penetrate through the gap, and growing to the
macroscopic scale.
 Bacteria has a resistance to the difficult and easy
environment
 Bacteria can absorb chemical and concentrate it to
certain area and create a high concentration in the metal
surface
 Microorganism has a resistance to the temperature –10
to 99oC oxygen concentration 0-100% atm.
 Bacteria growth to a colony

CORROSION 29
Microbiological Influenced Corrosion

 MIC condition
 The reproduction of bacteria is rapid
 Transferable by air, water, wind, animal etc.
 Survive in any nutrition. Pseudomonas fluorescents can
use 100 type of nutrition, carbon and energy sources, as
sugar, alcohol, phenol, organic acid etc.
 Same bacteria form layer/slime which was used to avoid
a contact with poison, and trap a nutritious. Some poison
can be change in concentration.
 Some bacteria form spore which resist to temperature,
disinfectant and dry condition.

CORROSION 30
Microbiological Influenced Corrosion

Example:

CORROSION 31
Microbiological Influenced Corrosion

MIC Mechanism
 Type of bacteria
 Metal oxidizing bacteria
 Sulfate reducing bacteria
 Acid producing bacteria
 Metal reducing bacteria
 Corrosion forms:
 Pitting corrosion
 Crevice corrosion
 Under deposit corrosion
 Dealloying
 Galvanic corrosion
 Erosion corrosion
 Once localize corrosion was initiated, microbial reaction can
maintain low oxygen condition for continued pit/crevice growth
CORROSION 32
Microbiological Influenced Corrosion

MIC Mechanism (cont’d)

 Sulfate reduction (for steel)
 SRB is an anaerobe bacteria
 Metal/biofilm interface infuenced by respiration rate and
oxygen content. If the oxygen diffusion is low, the
interface will be anaerobic and SRB develop
 SRB growth at soil, water and salt solution at anaerobic
condition. SRB oxidize organic solution to be organic
acid and carbon dioxide, and reduce the inorganic
sulfate to sulfide
 Absence of oxygen make a sulfide concentration at the
surface increase, and form an iron sulfide as a
temporary protective scale.
 Corrosion rate of mild steel containing SRB, is 1.45
md/dm2/day
 Corrosion rate at air exposure increase the corrosion
rate to 129 mg/dm2/day
CORROSION 33
Microbiological Influenced Corrosion

MIC Mechanism (cont’d)

 Acid Production (for steel)
 Produced by bacteria and fungi
 Asetic acid will be very aggressive if present below
a colony or under deposit
 Cl accelerate corrosion
 Cl rich corrosion products was flaked easily
 Other bacteria species, form H2SO4. Another
bacteria create a high concentaration of CO2, and
with air form a carbonate acid which can form
general, pitting dan SCC.

CORROSION 34
Microbiological Influenced Corrosion

MIC Mechanism(cont’d)
 Metal deposition (at steel)
 Caused by formation of the differential aeration cell related to
the colony. The microorganism create a deposition of Iron
and manganese oxide
 Mn was reduced to Mn+ (soluble and Mn2O3, MnOOH,
Mn3O4) and MnO2 (insoluble). It occur with water containing
Mn 10-20 ppb. Mn2O3 function as cathode.
 Iron reducing bacteria form tubercles iron oxyde and
hydroxides, and with other bacteria maintain low oxygen
condition
 With oxygenated environment anodic site became smaller,
create a higher cathode – anode ratio and accelerate pitting
corrosion. Cl accelerate the growth.
 Pit initiation forme pit propagation, and influenced by
metallurgical condition

CORROSION 35
Microbiological Influenced Corrosion

Mekanisme MIC (cont’d)

 Metal reduction (Pada baja)

 Ion Fe 3+ dan Mn4+ merupakan ion yang mudh
menerima elektron, dan bila berada dalam bentuk
oksida akan tereduksi oleh MRB akan menjadi ion
terlartt Fe2+ dan Mn3+

CORROSION 36
Microbiological Influenced Corrosion

Penanganan MIC pada pipelines

 Lingkungan
 Potensial MIC pada burried pipelines tergantung pada
kandungan nutrient, air dan electron acceptor seperti
oksigen.
 Kesemuanya berpengaruh terhadap pertumbuhan
koloni bakteri
 Kebanyakan kasus pada burried pipelines adalah kasus
SRB dan APB
 Proteksi dari korosi eksternal dilakukan dengan coating
polyolefin tapes, fusion bonded epoxies dan proteksi
katodik
 Antisipasi yang tidak sesuai masih memungkinkan
terjadinya MIC
CORROSION 37
Microbiological Influenced Corrosion

Penanganan MIC pada pipelines (cont’d)

 Coating
 Akibat soil stress dan irregular welding, dapat
mengakibatkan terbentuknya gap antara pipeline dan
coating yang dapat diisi oleh air yang mengandung bakteri.
 Temperatur tinggi juga dapat mengakibatkan disbonding
 Combine material seperti dengan Coal Tar dan asphalt,
dapat memperbaiki kinerja coating
 Tetapi dengan waktu, coating tersebut dapat terdegradasi,
oleh microorganism dan sebab lainnya.
 Pemakaian jenis tape sangat tergantung pada adhesive
yang digunakan.
 Urutan ketahanan dari disbonding adalah FBE (Fusion
Bonded Epoxy), PE (Polyethylene) dan PE tape.
 Penyebab coating damage adalah water leaching dan
permeation
 Pembentukan Iron sulfides dan baja , menimbulkan efek
galvanik. Makin banyak Iron sulfide akan semakin korosif.
CORROSION 38
Microbiological Influenced Corrosion

Penanganan MIC pada pipelines (cont’d)

 Proteksi katodik
 Proteksi katodik dapat mempercepat pertumbuhan
SRB pada saat terhenti. (Dapat lebih cepat
dibandingkan tidak ada CP)
 Aplikasi CP yang tidak merata akan mempercepat
pertumbuhan koloni
 Keberadaan bakteri membutuhkan penurunan
potensial pipa hingga –950mV dan bukan –850mV
sehingga membutuhkan arus proteksi yang lebih
besar
 Penetrasi air dalam sistim CP akan merusak.
CORROSION 39
Microbiological Influenced Corrosion

Penanganan MIC pada pipelines (cont’d)

 Mendeteksi
 Keberadaan beberapa jenis bakteri tidak selalu
menyebabkan korosi mikrobiologi, perlu identifikasi
dari baakteri yang ada
 Aktivitas SRB dapat menyebabkan potensial
logam menjadi negatif.
 Lokasinya dapat ditandai dengan ciri
 daerah aktivitas MIC yang besar
 CP dalam keadaan off
 Coating
CORROSION 40
Cathodic Protection Overview

SACRIFICIAL ANODE IMPRESSED CURRENT

CATHODIC PROTECTION

CORROSION 41
Cathodic protection

Data for cathodic protection design

 Corrosivity of the environment

 Soil structure and resistance
 Coating condition
 Coating quality and alectrical resistance
 Pipeline material
 Pipeline dimension and the availability of CP current
transfer
 The presence of other structure.
 Possibility of stray current presence

CORROSION 42
Cathodic protection

 Protected structure, became cathode

 Current flow through cathode from
electrolyte
 At anode, current flow away from anodic
area
 For protection, every area has to collect
current from the environment
 Direct current shift pipeline potential to
active condition an decrease corrosion
rate
 Every current has to be handled against
current flow from anodic area, and change
the potential to cathodic condition.
 Driving voltage CP has to be higher than
driving voltage corrosion cell

CORROSION 43
Cathodic protection

CORROSION 44
Cathodic protection

Coating effect on CP system

Influenced factors:
 Coating conductivity

 Exposure area

CORROSION 45
Cathodic protection

CORROSION 46
Cathodic protection

Take care about:

 Over voltage cause disbonding of coating

 Absorb water and ion to the metal surface
and increase pH
 Create an hydrogen evolution
 To avoid coating degradation, quality and
application of coating and soil condition has
to be attended.

CORROSION 47
Cathodic protection

Effectiveness of CP in stopping leaks

CORROSION 48
Cathodic protection

Influence of crossing structure

CORROSION 49
- CO2
- Coating
- Material selection
- Inhibitors

CORROSION 51