METALLURGY

&
CORROSION
What is Carbon Steel?

Carbon steel is an iron based alloy where carbon is the

main strength giving element.

In case of pressure components (plates, pipe, tubes, castings

etc.) and structural components the carbon content may
vary from 0.1 to 0.3%

What is alloy steel?

An iron based alloy wherein the total alloying element is

less than 10%.
What is stainless steel?
An iron based alloy where chromium percent is minimum
11%. There are three types.,
Ferritic Stainless steel - Corrosion resistance
Austenitic stainless steel - High temp. Corrosion resistance
& high temp. strength e.g., all 304, 316
Martensitic stainless steel - Corrosion resistance + strength
e.g., SS410
Non ferrous alloys where high corrosion resistance is
required.

Aluminum
Monel
Inconel & Incoloy
Titanium
Cupro Nickel
Brass
Alloy grades / designations

CS - Carbon steel
KCS - Killed Carbon steel
P11 - 1.25% Chromium and 0.5 Molybdenum
P22 - 2.25% Chromium and 1.0 Molybdenum
P5 - 5%Chromium and 1.0 Molybdenum
P9 - 9% Chromium and 1.0 Molybdenum
SS410 - 11% - 13% Chromium
SS304 - 0.08% C, 18% Cr and 8% Ni.
SS316 - 0.08% C, 16% Cr 10% Ni and 2% Mo.
SS321 - SS304 with Titanium stabilization
SS347 - SS304 with Columbium stabilization

All alloy designation should be preceded by relevant ASTM/

BS / IS standard number
How to select the material of construction for a given service?

Pressure
Temperature
Operating fluid (Corrosion characteristics)
Expected Minimum life (especially furnace tubes)
Fabricability
Availability
Economics
Carbon steel Why?

Very good mechanical properties, Very Good

fabricability, weldability, Low Cost, easy
availability.

SS

AS

CS
Strength

Temperature
How to select material for corrosion resistance?

ACCEPT CORROSION

Definite life - Replace periodically

Increased corrosion allowance

Disadvantage - Maintenance and Inspection intensive

PREVENT CORROSION

Monitor operating parameters

Add corrosion inhibitors

Disadvantage - Recurring cost in case of option II

How to select material for corrosion resistance?

ELIMINATE CORROSION

Remove corrosive component or Upgrade metallurgy

Disadvantage - Capital intensive

BEWARE

Material change without design review can be disastrous. Be

very cautious when changing metallurgy in

Hydrogen service
Aqueous Hydrogen sulfide service
Services containing chlorides with 300 series stainless steel
Hydrogen fluoride
Caustic

Above fluids are few that can cause catastrophic failures

without any warning called stress corrosion cracking.
CORROSION

Corrosion is defined as the destruction or deterioration of

material because of a chemical reaction with its
environment.
Different types of Corrosion

General Chemical corrosion

Under deposit Corrosion
Pitting Corrosion
Galvanic corrosion
Erosion corrosion
Crevice corrosion
Stress corrosion cracking
Cavitation corrosion
Fretting corrosion
What is corrosion resistance?
Corrosion is a surface phenomenon. Corrosion
resistance depends upon the chemistry of the
surface scale.

CS

SS304
General Corrosion is where the rate of corrosion is
uniform and the thickness reduction can be predicted
very precisely.

Direct Chemical attack. For e.g., dilute inorganic acids

flowing inside a carbon steel pipeline.

Atmospheric Corrosion

Single largest type of corrosion.

Remedial action ………….

Under deposit corrosion

Normal flow regime no corrosion.

Dead zones is a problem where foulant and deposits accumulate.

Pitting corrosion

If depth of pitting more than 3 times the width then it is

called a pit. Pitting can cause a hole while the corrosion
rate in terms of metal loss is minimal.
Pitting is generally under deposit.
Galvanic Corrosion - Noble metal and reactive metal.

Steel Zinc
Galvanic Corrosion - Noble metal and reactive metal.

Steel Copper

Corroding metal is always anode.

Protected metal is cathode
Galvanic series in aerated sea water
Carbon (graphite
Platinum
Titanium
Hastealloys
316 Stainless steel (Passive)
Monel
304 stainless steel (Passive)
Silver
Nickel
CuproNickel
Lead
Bronze
Brass
Copper
Tin
316 Active
304 Active
Steel
Cadmium
Aluminum
Zinc
Magnesium
Erosion Corrosion

Solids - Catalyst transfer lines

High velocity/turbulence of fluids.

STRESS CORROSION CRACKING

Three basic needs

Stress - fabrication stress, testing stress, thermal stress etc.

Corrodant
Susceptible material

Failure is sudden.
INTERGRANULAR CORROSION SPECIFIC TO
AUSTENITIC STAINLESS STEEL

SS304 - 0.08% C, 18% Cr and 8% Ni.

SS304L - 0.03% C, 18% Cr and 8% Ni.
SS321 - SS304 with Titanium stabilization
SS347 - SS304 with Columbium stabilization
SS316 - 0.08% C, 16% Cr 10% Ni and 2% Mo.
SS316L- 0.03% C, 16% Cr 10% Ni and 2% Mo.
SS316Ti - SS316 with Titanium stabilization
 SS304 - 0.08% C, 18% Cr and 8% Ni.

C Cr CrC3

Liquid weld metal

1500 - 2000 C Heat affected Zone
400 - 900 C
How to avoid sensitization?

Reduce carbon less than 0.03% to get “L” grades

Add micro alloying elements like Titanium or Columbium.

Ti C TiC

Cb C CbC

Welding consumables should match the base material

Carbon steel
(Ferritic)
Cracked Cracked
blister blister

Cracked and uncracked

blisters
To avoid blistering use killed carbon steel.
A106 Gr B is a Killed carbon steel
A53 Gr B is a non-killed carbon steel
Avoid lamination type defect in the plate / pipe.

Hydrogen embrittlement

Above 250 C the following reaction occur in steel

C + 2H2 - CH4
Pure Carbon steel
hydrocarbons
Impure Carbon steel  Higher MoC
Hydrocarbons Alloy steels  based on
Stainless Steel temperature
Hydrogen sulfide Carbon steel  With
as impurity Alloy steels  hardness
Stainless Steel control.
NACE.
Hydrogen Carbon steel  Higher MoC
Alloy steels  based on
Stainless Steel Pressure and
Temperature.
API941.
Steam Carbon steel  Higher MoC
Alloy steels based on
temperature.
No Aus. SS
Air, Nitrogen Carbon steel
Water Carbon steel
Non-ferrous for
heat exchangers
Demineralised SS304 upto 150
water C and then
carbon steel or
rubber lined
Sea Water  Carbon steel
epoxy coated
 FRP
 CS with
refractory
lined
Acetic acid SS316 or SS317
Hydroflouric Carbon steel or
acid Monel
Caustic Carbon steel Carbon steel
upto 104 C and welds to be
then Monel stress
relieved after
72 C.
Catalyst (Solid) Carbon steel or Generally
alloy steel stand by
facility is
available.
 CATHODIC
PROTECTION
SYSTEM
Galvanic Corrosion - Noble metal and reactive metal.

Steel Zinc
 SACRIFICIAL ANODE SYSTEM

Soil Zinc or Magnesium or Aluminium

Pipe
 SACRIFICIAL ANODE SYSTEM

Coating

Soil Zinc or Magnesium or Aluminium

Pipe
 IMPRESSED CURRENT CATHODIC PROTECTIONSYSTEM

Coating

Soil
Pipe
Rectifier
+ ve - ve
To have an efficient cathodic Protection system

1. Ensure good quality primary protection

2. Ensure back fill on the under ground systems is proper
3. Ensure installation of the CP system is as per design
4. Monitor potential

All storage tanks have ICCP on the tank bottoms at Jamnagar

All under ground piping have been provided with sacrificial

anode CP systems
END