CORROSION AND ITS CONTROL

CONTENTS

• Fundamentals of corrosion.
• Classification of corrosion.
• Types of corrosion.
• Corrosion Monitoring.
• Corrosion in petroleum and petrochemical industries.
FUNDAMENTALS OF CORROSION

 Corrosion is the destruction or deterioration of material (metal /non

metal) because of its interaction with the environment.
 Deterioration –by Chemical / Electro chemical reactions.
 Destruction –by mechanical wear/ abrasion.
CLASSIFICATION OF CORROSION

Based on :
• Corrosion Process
• Nature of corrosion
• Corrosion deterioration
• Mechanical factors
 Reason for corrosion to occur:
Corrosion occurs in metals because most metals are not in their natural state until they return to
their ore form.
Corrosion in Plastic:
Corrosion occurs in plastic because different environments can effect the bonds between the
organic molecules, making up the plastic.
SOME IMPORTANT TYPES OF CORROSION

Uniform corrosion:
• Surface phenomenon
• Characterised by chemical/ electrochemical reactions.
• Prevention: by using inhibitors.
Galvanic corrosion:
• Occurs when two dissimilar metals are brought into contact.
• Prevention: by insulation.
UNIFORM CORROSION
GALVANIC CORROSION
Pitting corrosion :
• One of the most destructive corrosion.
• Characterized by surface cavities.
• Prevention: by addition of inhibitors.
Stress corrosion :
• Caused by simultaneous presence of tensile stress.
• Prevention: adding inhibitors, applying cathodic protection.
PITTING CORROSION
Caustic embrittlement:
• Occurs in metals in contact with caustic soda
• Crack results in combined action of tensile stress and corrosion.
Microbiological corrosion:
• It is deterioration of metal by corrosion that occurs directly or indirectly as the result
of living organism.
• Prevention: by using biocides.
CORROSION MONITORING

It involves the direct application of corrosion measurement techniques to industrial plants.

Methods of corrosion monitoring:
• Coupon method
• Electric resistance method
• Potential measurements
• Polarization
• Resistance method
• Impedance method
• Hydrogen permeation method
Non destructive methods:
• Ultrasonic technique
• Eddy current technique
• Radiography
CORROSION IN PETROLEUM AND
PETROCHEMICAL INDUSTRIES
• Corrosion in pipelines, storage vessels, pumps, valves, heat exchangers and condensers
are a cause of great concern in the petrochemical industries.
• It is absolutely undesirable.
• Occurs due to the presence of chlorides, organic and inorganic sulphur compounds,
naphthenic acids and moisture, high pressures and temperatures.
• Stress corrosion is a common phenomenon in petroleum and petrochemical complexes.
• Chloride corrosion is caused by hydrogen chloride, which is formed from hydrolysis of
chloride salts present in the crude itself.
• Majority of chloride salts are: Mg, Ca,Na salts.
• Organic sulphur compounds such as mercaptans, poluysulphides and thiophenes can
cause heavy corrosion even at lower temperatures.
• Hot and wet sulphide corrrosions are common in petrochemical complexes.
ROLE OF WATER IN CORROSION

• The petroleum and petrochemical complexes uses a large amounts of water and steam at
various amounts of operation.
• The two major causes of corrosion in steam and condensate line- oxygen which results in
pitting and low pH.
• Low pH condensate is formed by carbonic acid which is formed by the reaction of CO2
with condensate steam.
• Crude refining operation in the coastal areas forces an additional problem of seawater
corrosion.
CORROSION IN PIPELINES:

• Internal pipeline corrosion

• External pipeline corrosion

• Corrosion under insulation

CORROSION PREVENTION AND CONTROL

• Selecting corrosion resistant material of construction

• Corrosion Inhibitors
• Design consideration
• Isolation of material from the corrosive atmosphere
• Coating
• Corrosion monitoring