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Corrosion
Presented By
Asim Hayat


To create awareness on corrosion to better understand the
consequence of it


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Training Outcome:
Knowledge about corrosion & corrosion types

How corrosion is damaging our assets

How to fight corrosion

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Course Outline:
Corrosion

Types of Corrosion

Corrosion related to Refinery

Control of Corrosion

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Personal Qualification
Certified Piping Inspector
Certified ASNT UT Level-II
Certified ASNT PT Level-II
Certified ASNT MT Level-II
Certified ASNT RT Level-II
Around 04 years of experience in inspection
section and exposure to corrosion related
activities.


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WHAT IS CORROSION?

It is the destruction or deterioration of metal because
of its reaction with the environment

But How It Happen?

Environments are corrosive
Some examples are
Air & moisture, brine, steam and other gases such as
chlorine, ammonia, hydrogen sulfide.
CORROSION ESSENTIALS
Anode
Cathode
Electrolyte
Conductive
Path
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Cost Of Corrosion

Why control of corrosion is important?

The Cost of corrosion to U.S industries and American
public is currently estimated at $170 billion (ASM).

Corrosion to refineries can damage in the form of:
Safety Risk
Unplanned Shutdown
Product Loss
Profit Loss
Equipment cost Loss



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EIGHT FORMS OF CORROSION
1. Uniform or general attack
2. Galvanic or two metal corrosion
3. Crevice corrosion
4. Pitting Corrosion
5. Intergranular Corrosion
6. Selective Leaching or Parting
7. Erosion Corrosion
8. Stress Corrosion

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1. UNIFORM ATTACK
Electrochemical reaction
Complete Area
Material becomes thinner
and eventually fails.
Highest Contributor
towards corrosion.
Examples, Steel lying in
open yard
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2. Galvanic or two-metal corrosion
Two dissimilar metals
Contact
Corrosive environment
Galvanic Series
More Negative or active
Noble or passive
Severity can be low or
high
Distance Effect
Area effect

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3. Crevice Corrosion
Intensive Localized
Small volumes of
stagnant solution
Holes, gasket surface,
lap joints, surface
deposits and crevice
under bolt and rivet
heads.
Slow corrosion


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4. Pitting Corrosion
Localized form of corrosion

Pits or holes are produced

Most dangerous form

Difficult to detect, predict and
design against.

Narrow pit can lead to the failure
of an entire engineering system.
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4. Pitting Corrosion (Continued)
Velocity decreases
effect

Generally Gravity
oriented

Examples
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Pits Morphologies
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5. Intergranular Corrosion
Localized attack at grain boundaries
Chromium depletion in SS
Corrosion occurs by preferential attack on the grain-boundary
phase
The attack usually progresses along a narrow path along the
grain boundary .
Example SS- Sensitized, carbon content higher, Chromium
carbide, depleted chromium at boundaries.
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Intergranular corrosion of a failed
aircraft component
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6. Selective Leaching
One constituent of a metal is selectively
corroded out of a material.
Brass (Zinc & Copper)
Mechanical properties of the metal are
impaired and some metal will begin to crack.



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7. Erosion Corrosion
Accelerated corrosion
attack
Relative motion of a
corrosive fluid and a metal
surface.
Corrosion and erosion
effects are combined.
Grooves, valleys
Passivity weakens
Impingement.
Turbulence


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8. Stress-corrosion cracking - SCC
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 tensile stress is usually the result
of expansions and contractions that
are caused by violent temperature
changes or thermal cycles.
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Corrosion in Refineries
Softening
Erosion corrosion
Galvanic corrosion
CUI
Soil Corrosion
Sulfidation (high temperature)
General Corrosion
HCl Corrosion
Corrosion at storage tanks (Internal, External)
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Crude Unit Damage Mechanisms
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Control of Corrosion
Material Selection
Coating
Inhibitors
Cathodic Protection
Insulate dissimilar metals
Welded butt joints instead of riveted joints
Complete penetration

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Monitoring of Corrosion
Thickness Gauging
Corrosion Rates
TMLs or CMLs
Visual Inspection
Weighing of coupons

Equipments
Tanks
UT
VT
MFL
Piping
VT
UT
LRUT

Equipments
Pressure Vessels
UT
VT
Chime
PT
MT
Boilers
RT
UT
VT

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Corrosion Benefits
Chemical Milling
Corrosion Coupons
Cathodic Protection
Trim Coolers
Cross Country Lines
Batteries
Passivation

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Its over
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CORROSION MECHANICS
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Practical Galvanic Series
- Commercially pure Magnesium -1.75 Volts
- Magnesium alloy (6% Al 3%Zn 0.15Mn) -1.6
- Zinc -1.1
- Aluminium Alloy (5% Zn) -1.05
- Pur Alluminium -0.8
- Mild Steel (clean & shiny) 0.5-0.8
- Mild Steel Rusted -0.2-0.5
- Cast Iron (not graphitized) -0.5
- Lead -0.5
- Mild Steel in Concrete -0.2
- Copper Brass Boronze -0.2
- High Silicon -0.2
- Mill Scale on Steel -0.2
- Carbon, graphite, coke +0.3

Reference
Control Of Pipeline Corrosion By A.W Peabody
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Theory Of Crevice
Acidic & Basic Solution
In general, corrosion is the result of water with a low pH. Acidic waters
have lots of H+ ions in the water to react with the electrons at the
cathode, so corrosion is enhanced.
In contrast, water with a higher pH (basic water) lowers the solubility of
calcium carbonate so that the calcium carbonate is more likely to
precipitate out as scale.
Scaling tends to be the result of water with a high hardness. Hard
water typically contains a lot of calcium compounds which can
precipitate out as calcium carbonate.
Water with a high alkalinity is more likely to be scale-forming even at a
relatively low pH.
Oxygen/CO
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effect
The most common of these are oxygen, carbon dioxide, and dissolved solids.

Oxygen reacts with hydrogen gas at the cathode, causing depolarization and
speeding up the corrosion. As a result, water with a high D.O. (dissolved
oxygen) will tend to be corrosive.

Other oxidizing agents can perform the same function, although they are less
common. Nitrates and chlorine are two other oxidizing agents found in water.

Carbon dioxide in water also tends to cause corrosion. The carbon dioxide gas
can combine with water to form carbonic acid, which lowers the pH of the
water. As mentioned in the last section, a low pH promotes corrosion.

Dissolved solids are typically present in water as ions. These ions increase the
electrical conductivity of the water, making the electrolyte more effective. Thus,
they will increase the rate of corrosion.


Velocity & Temperature
The most important of these physical characteristics are temperature and velocity of flow.

Temperature speeds up the rate of corrosion just as it does most other reactions.

Pits and tubercles tend to form in cold water while hot water promotes uniform corrosion.

Moderate flow rates are the most beneficial since they promote the formation of scale without breaking loose
tubercles.

At low flow velocities, corrosion is increased and tends to be in the form of tuberculation due to the prevalence of
oxygen concentration cell corrosion.

At very high flow velocities, abrasion of the water against the pipe tends to wear the pipe away in a very different
form of corrosion. High flow velocities also remove protective scale and tubercles and increase the contact of the
pipe with oxygen, all of which will increase the rate of corrosion.