Professional Documents
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(Enppi) Corrosion & Cathodic Protection in Petroleum Industry Course (Yasser Tawfik)
(Enppi) Corrosion & Cathodic Protection in Petroleum Industry Course (Yasser Tawfik)
(Enppi) Corrosion & Cathodic Protection in Petroleum Industry Course (Yasser Tawfik)
BASICS OF CORROSION
Corrosion of Metals
All interactions between a metal ( or alloy )
with its environment.
BASICS OF CORROSION
Corrosion of Metals
Wet
Occurs in wet
environments
Dry
Occurs in dry
environments
high or elevated temp.
BASICS OF CORROSION
BASICS OF CORROSION
BASICS OF CORROSION
Why Metals Corrode?
Metals tend to corrode in order to retain their natural
form (ore).
Metals are usually extracted and purified from their
ores via high-energy input processes.
For example :
Thermal energy (high furnace for Fe)
Electric energy (electrolytic paths for Al & Cu)
BASICS OF CORROSION
Blast Furnace
of reducing iron
ore to iron
In
Ore +
Limestone +
Coke
Waste gases
Out
Hot air
In
Slag
Molten Iron
Out
Out
The extracted free metal has a high energy content. i.e. active state
BASICS OF CORROSION
Electrolytic production of Cu
The extracted free metal has a high energy content. i.e. active state9
BASICS OF CORROSION
Active free metals tend to react easily to produce
compounds, such as salts and oxides.
Metals in the compounded forms have less energy
content, i.e. stable state.
10
BASICS OF CORROSION
Corrosion
Thermodynamic Cycle
Oxides, Ore thermodynamically stable
Corrosion
Mining & Extraction
Pipe Mill
Equipment fabrication,
thermodynamically unstable
11
BASICS OF CORROSION
12
BASICS OF CORROSION
Exceptions
There are some exceptions, such as gold, which can occur natively in their
metallic state.
These metals, sometimes known as Nobel Metals ,have low driving forces
for oxidation and can survive in their metallic state for thousands of years
without reacting with oxygen or other elements to form oxides or other
compounds .
13
BASICS OF CORROSION
Iron oxides
+
Mining &
Extraction
Steel
+
Corrosion
Iron oxides
14
BASICS OF CORROSION
Thermodynamics of Corrosion
In a chemical reaction :
Reactants
Products
G = Gprod Greact
In all corrosion reactions
Gprod < Greact. Therefore,
G is ve
Hence, the corrosion reaction is:
spontaneous
irreversible
15
BASICS OF CORROSION
Occurrence of Corrosion
An old adage in materials science says:
"materials are like people; it is the defects that make them interesting".
The manufacture of a perfect crystal of a material is currently physically
impossible.
Defects in crystalline materials such as:
Non-metallic inclusions,
grain boundaries,
interstitial atoms,
vacancies or
substitutional atoms.
16
BASICS OF CORROSION
Occurrence of Corrosion
Corrosion is initiated at the metal surface defects since they are
the highest energy sites, i.e. the most active sites.
B
A
C
(1)
(2)
(3)
Schematic model of a free metal surface
Atom
Degree of Freedom
C , Terrace (Plane)
1
B , Step (Ledge)
2
A , Kink
3
Activity Order : A > B >C
Dislocation
17
BASICS OF CORROSION
THEORY OF CORROSION
Corrosion Process
Due to the electrochemical nature of corrosion, there shall
be electron transfer
Electron transfer requires presence of anode sites and
cathode sites on the metal surface
Due to potential difference ( V ) between anodes and
cathodes electrons migrate from anodes to cathodes
Electrons liberated at anodes
should be consumed at cathodes
I
e-
19
Ea
Anode
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe++
Fe Fe
Fe
Fe
Fe
Fe
Fe
Fe++
Fe
Fe
Fe
Fe
O
H
Cathode
Fe
Fe
Fe
Fe
Fe
Fe
Fe
H
H
O
H
Fe
Fe
Fe
O
H
Fe
Fe
H
H
Ec
20
When a piece of iron is placed in electrolyte, V is established between anodes and cathodes
THEORY OF CORROSION
Corrosion Process
@ Anode Sites :
Surface defects
More -ve potentials
Metal atoms have high energy, i.e. unstable & active
Thus, metal atoms ionize by losing their electrons, i.e.
oxidation reaction : M0
Mn+ + n eAs a result, metal loss occurs, i.e. metal dissolution
OILRIG
Oxidation Is Loss of electrons
Reduction Is Gain of electrons
21
THEORY OF CORROSION
Corrosion Process
@ Cathode Sites :
Intact ( un-defected ) surface areas
More +ve potentials
Metal atoms have low energy, i.e. stable & un-active
Receive electrons to be consumed, i.e. reduction reaction
As a result, no metal loss occurs, i.e. no corrosion
OILRIG
Oxidation Is Loss of electrons
Reduction Is Gain of electrons
22
THEORY OF CORROSION
23
THEORY OF CORROSION
Corrosion Process
The corrosion process involves two reactions:
Anodic Reaction (metal dissolution / oxidation )
Cathodic Reaction ( reduction )
THEORY OF CORROSION
Corrosion Process
Fe atoms at Defect Site
a.
Anodic Reaction
(metal dissolution)
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
25
THEORY OF CORROSION
Corrosion Process
O
a.
Anodic Reaction
(metal dissolution)
Fe
Fe
Anode
Fe (surface defect)
Fe
Fe
Fe
Fe
Fe
Fe++
Fe
Fe
Fe++
Fe
O
If place in electrolyte - e.g. water - Fe
atoms at the defect sites on the metal
surface ionize (dissolve in the
electrolyte) leaving their valance
electrons behind onto the metal
surface
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
26
THEORY OF CORROSION
Corrosion Process
O
b. Charge Transfer
Fe
>
Icorr
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Cathode
Fe++
Fe
Anode
Fe
Fe
Fe++
A
>
27
THEORY OF CORROSION
Corrosion Process
c. Cathodic Reaction
Once the liberated electrons arrive to the cathode site:
if the electrons accumulate without being consumed, this would cause
cathodic polarization and the corrosion process completely stops.
if the medium contains electron consumer (i.e. Depolarizer), the cathode
will be depolarized and the corrosion process continues.
the most common depolarizers are:
1) Dissolved oxygen
2) Hydrogen ions, H+
28
THEORY OF CORROSION
Corrosion Process
c. Cathodic Reaction
There are 2 main reactions depending on :
Oxygen availability &
pH
29
THEORY OF CORROSION
Corrosion Process
c. Cathodic Reaction
1. Oxygen reduction reaction
O2 + 2H2O + 4e-
4 OH-
Fe(OH)2
30
O2
OH_
Fe
Fe
Fe++
Fe
Anode
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Cathode
Fe
Fe
O2
OH_
Fe++ +
Fe
OH
Fe(OH)2
OH_
Fe
O2
Fe
O2
O2
O
H
H
H
O
H
O2
O2
Fe
O
H
O2
O
H
The surface becomes covered with brown-orange corrosion product (Iron Hydroxide)31
known as RUST. Rust is specific to steel corrosion in water due to oxygen.
THEORY OF CORROSION
c. Cathodic Reaction
2. Hydrogen evolution reaction
2H+ + 2e2H (adsorbed)
H2 (gas)
Predominates in acid solutions pH < 5
P.S.
The corrosion product is H2 gas
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Fe
Cathode
O
H
Fe
H
H
Fe++
H+
Fe
Fe
Fe
H+
H
H+
H+
H+
O
H
H+
Anode
Fe
H+
H+
H
H0
H+
H+
H0
H+
O
H
H+
33
THEORY OF CORROSION
A.
B.
In Conclusion
The corrosion process involves two reactions:
Anodic Reaction
: occurs @ anode sites
M n+solution + neMetal Dissolution
: M 0surface
Oxidation Reaction : involves loss of electrons
Cathodic Reaction : occurs @ cathode sites
Reduction Reaction : involve gain of electrons
Oxygen reduction : gain of electrons by dissolved O2
Hydrogen evolution: gain of electrons by H+ ions
34
THEORY OF CORROSION
O2 + 2H2O + 4e-
(natural water)
Charge Transfer
2H+ + 2e-
H2 (gas)
(acid water)
Fe3+ + e-
Fe2+
(acid water)
Cl2 + 2e-
2Cl-
(SRB)
(chlorinated water)
S2- + 4H2O
(bacterial)
p.s.
more than one cathodic reaction can occur at the same time
Anodic Reaction
Fe (surface defect)
THEORY OF CORROSION
Corrosion of metals requires the following conditions:
An anode, a cathode, an electrical path, and an electrolyte
must all be present .
The anode and cathode must be in contact with the same
electrolyte .
The metal must electrically connect the anode and
cathode for electrons to flow .
The anodic (oxidation) and cathodic (reduction) reactions
must be equivalent and simultaneous .
36
THEORY OF CORROSION
In conclusion:
A piece of metal immersed
in an electrolyte acts as its
own:
Anode
Cathode
Electrical connection
Electrolyte
Anode
2H++2e
Cathode
2H
H2
37
THEORY OF CORROSION
The Corrosion Cell
In a corrosion cell:
Electrons leave the anode
and migrate to cathode
within the metal;
i.e. electronic movement
Corrosion Cell
THEORY OF CORROSION
Where:
Rm = resistance of metallic path between anode and
cathode
Rm
Icorr
Re
Ec
THEORY OF CORROSION
Factors of Corrosion
1- Water
2- Oxygen
3- Acidity
THEORY OF CORROSION
Aerated neutral
saline aqueous
solution
Deaerated
neutral saline
aqueous solution
THEORY OF CORROSION
Testimony
An environment
is considered
corrosive if it
contains Water
with dissolved
Oxygen and / or
Acidity ( H+ ions )
Fe
42
THEORY OF CORROSION
Pourbaix Diagram:
Theoretical
Based on thermodynamic data
Correlates metal potential in
water at different pHs
Metal can exist in 1 of 3 states:
Corrosion- Passivation- Immunity
Gives no information about rate of
corrosion
43
THEORY OF CORROSION
Potential
Fe3+
Fe oxides
stable
Fe2+ stable
Fe metal stable
0
14
44
THEORY OF CORROSION
Potential
Fe oxides
stable
Fe2+ stable
Fe metal stable
0
Yes - there is a
reasonably wide
range of potentials
where hydrogen
can
14 be evolved
and iron dissolved
45
THEORY OF CORROSION
Pourbaix Diagram for Iron
2.0
1.6
1.2
Fe3+
0.8
0.4
Fe oxides
Yes - although iron can
stable
0.0
form an oxide in neutral 2+
Fe stable
solution, it tends-0.4
not to
-0.8
form directly on the
metal,
Fe metal stable
as the potential is-1.2
too low,
therefore it is-1.6
not
0
7
protective.
Potential
14
46
THEORY OF CORROSION
Pourbaix Diagram for Iron
Potential
0.8
0.4
Fe oxides
stable
0.0
-0.4 Fe2+ stable
-0.8forms a solid
No - iron
Feand
metal stable
oxide at-1.2
all potentials,
will
passivate
-1.6
0
7
14
47
THEORY OF CORROSION
mmpy
Or
P.S. :
48
THEORY OF CORROSION
NACE International Ranking for Corrosion Rates
of Steel
Corrosion Rate
(mpy)
Level of Corrosion
<1
Low
1-5
Moderate
5-10
Severe
>10
Intense
COST OF CORROSION
STATISTIC RELEVANCE OF CORROSION FAILURES
50
COST OF CORROSION
Consequences of Corrosion
Corrosion related problems are the MOST costly
and hazardous, since
Corrosion is the primary source of failure in process industry
Corrosion related failures could be Catastrophic leading to
loss of human lives and injuries
Leakages resulting from corrosion failures have negative
impact on the environment and living species
51
COST OF CORROSION
Leakage leading to
environmental pollution
BP Crude P/L Alaska 2006
52
COST OF CORROSION
Catastrophic failures
COST OF CORROSION
54
COST OF CORROSION
55
COST OF CORROSION
56
COST OF CORROSION
Corrosion An Expensive Issue for Industry
Corrosion Co$t :
NACE study in 2005 showed that:
Costs associated with corrosion
losses were estimated as $364
billion dollars, draining about 3.1%
of the GDP from the US economy.
Corrosion
yearly
losses
are
presently comparable to those
associated with Hurricane Katrina !
57
COST OF CORROSION
Annual Est. Corrosion Costs (US$)
$2.8B
$3.4B
$7.4B
Refining
$14B
58
Chemical Processes
Utilities
COST OF CORROSION
The Co$t of Corrosion
Direct Cost:
59
COST OF CORROSION
Corrosion cost :
Indirect cost
corrosion-related inspection
corrosion- related maintenance
repairs due to corrosion
replacement of corroded parts
rehabilitation
loss of productive time
60
COST OF CORROSION
Global Direct Cost of Corrosion:
In 2004, NACE has surveyed the direct cost in only 17 countries.
In this year the Worlds gross output (GWP) was $51.48 Trillion, and
the global cost of corrosion was $990 Billion approx.
I.e. 2% of the GWP
61
COST OF CORROSION
62
COST OF CORROSION
Asset loss risk depends on type of equipment
High
Risk
. Piping
. Reactors
Priority of
Maintenance
. Tanks
. Process
Lower towers
Risk
63
COST OF CORROSION
Severity
People
Consequence
Massive
effect
International
impact
Major
effect
National
impact
Localised
effect
Considerable
impact
4. Severe
D.
Single fatality
or permanent
total disability
3. Critical
C.
Major injury
or health
effects
Local
damage
Minor injury
or health
effects
Minor
damage
Minor
effect
Minor
impact
Slight injury
or health
effects
Slight
damage
Slight
effect
Slight
impact
B.
2. Marginal
A.
1. Negligible
Major
damage
Probability
Likelihood
(Probability)
1A
2B
3C
Improbable
Remote
1 in 10,000
years
1 in 100,000
years
Occasional
1 in 1000
D
4
Probable
1 in 100
5E
Frequent
1 in 10
years
years
years
64
MANAGING CORROSION
65
Overall Predictive
Management Program
DESIGN PHASE
RUNNING PHASE
Process flow
Stream analyses
Service conditions
Codes, standards,
specifications, textbooks,
handbooks, vendors
recommendations
Operation Dept.
Corrosion
Monitoring
Inspection Dept.
Predictive mode
Predictive
Maintenance
- Effective corrosion
control
- Extended service life
Reduced Cost
High Profitability
66
MANAGING CORROSION
Types of Maintenance
Cost
Corrective (Reactive):
Unplanned.
Most costly.
1.00
0.75
0.50
0.25
Preventive:
Planned on a fixed time scale.
Corrective
Preventive
Predictive
MANAGING CORROSION
68
MANAGING CORROSION
Causes of Corrosion Failures
US based leading chemical company investigation outcome
Causes
% Freq
36
B Wrong specification
16
C Bad inspection
10
D Human error
12
E Poor planning
14
F Others
G Unforeseen
F
G
D
E
69
MANAGING CORROSION
92% of corrosion failures are Preventable if the Predictive
Corrosion Management Program is strictly implemented
during Design and Running phases
Only 8% of unforeseen causes to be dealt with
70
MANAGING CORROSION
Consequences of Management on Operation & Production
Proper Management
1 Pro-active
Mismanagement
Reactive
71
FORMS OF CORROSION
Types of Corrosion:
1. Uniform (General) Corrosion
1. Localized Corrosion
Pitting and Crevice Corrosion
Stress Corrosion Cracking
Hydrogen Damage ( Embrittlement / Blistering )
Galvanic Corrosion
72
FORMS OF CORROSION
73
FORMS OF CORROSION
General Corrosion
In general corrosion there is no distinction between the
anode and the cathode sites
i.e. the whole metal surface is acting as anode and cathode
Therefore, the metal loss is equally and uniformly distributed
all over the surface, i.e. corrosion proceeds horizontally
along the metal surface
74
FORMS OF CORROSION
General Corrosion
Rust Layer
Environment (Electrolyte)
O2
H2O
Fe++
Anode
Cathode
O2
H2O
Fe++
Cathode
Anode
Fe++
O2
H2O
Anode
Cathode
Iron
FORMS OF CORROSION
General Corrosion
Environment (Electrolyte)
O2
H2O
Fe++
Cathode
Anode
O2
O2
H2O
Fe++
H2O
Cathode
Anode
Cathode
Fe++
Anode
O2
Iron
FORMS OF CORROSION
General Corrosion
Uniform corrosion of an
internal carbon steel pipe
77
FORMS OF CORROSION
General Corrosion
78
FORMS OF CORROSION
General Corrosion
Atmospheric General Corrosion
79
FORMS OF CORROSION
Localized Corrosion
In localized corrosion there is clear distinction between the
anode and the cathode sites
The anode sites are being very small compared with the
large cathode
Therefore, the metal loss is concentrated in local areas, i.e.
corrosion proceeds downwards perpendicular to the metal
surface ( Penetration )
Penetration
80
FORMS OF CORROSION
Pitting corrosion
Occurs with metals having oxide ( Passive )
film
I.e. the metal is in the zone of Passivity, e.g.
stainless steels, due to film local breakdown
Chloride ions (Cl-) have damaging effect on
oxide film of stainless steels
81
FORMS OF CORROSION
Pitting Corrosion
Oxide Layer
Environment (Electrolyte)
Cl-
Fe++
Anode
ee
O2
H2O
Cathode
Cl-
O2
H2O
Anode
Cathode
Cl-
Cathode
e
Iron
Fe++
Anode
Iron
Cathode
FORMS OF CORROSION
Pitting Corrosion
What is the role of chloride ions in localized corrosion;
pitting ?
Help in breaking down the passive oxide film, specially
at weak point
Allow a very low pH to be achieved inside the pit, due
to the formation of HCl
Metal chlorides are very soluble
83
ClClO2
OH-
ClCl-
Cl-
Cl-
Cl-
Cl-
Cl-
Cl-
Cl
ClCl
Cl
Cl
Cl
Cl
Cl
Cl
Cl- Cl
-
ClCl-
ClCl-
O2
Cl-
OH-
M+
O2 + 2H2O +
M+
4e
->
4(OH )
M+
M+
M+
M+
Pitting
Corrosion
84
Cl-
Cl-
ClO2
Cl-
ClClCl-
Cl-
ClCl-
Cl-
ClCl-
Cl-
Cl-
Cl-
Cl-
Cl-
Cl-
O2
Cl-
Cl-
Cl-
OH-
OH-
M+
ClCl-
e-
M+
M+
Cl-
M+
M+
e-
M+
Cl-
M+
e-
M+
e-
M+
M+
M+
e-
Pitting
Corrosion
85
FORMS OF CORROSION
Pitting Corrosion
86
FORMS OF CORROSION
Pitting Corrosion
Pitting may lead to pipe perforation
87
FORMS OF CORROSION
Crevice Corrosion
88
FORMS OF CORROSION
Examples of avoiding
crevice corrosion by design
89
FORMS OF CORROSION
Examples of avoiding
crevice corrosion by
design
Continuous Weld
Good
Bad
Skip Weld
90
FORMS OF CORROSION
Examples of avoiding
crevice corrosion by
design
Improper Weldments
Proper Weldment
91
Crevice Mechanism
O2
Cl-
Cl- Cl
O2
OH-
Metal (M)
M+
Na+
e-
e-
Cl- Cl- Cl Cl
Cl
+
Cl
+
Cl
M
+
Cl
Cl
M
Na
+ HClH+
Cl- - MCl
Na+ + H2O = MOH
+
Na
ClO
H+
O2
- H+
OH
2
Na+
O2
O2
+
Na H
O2
+ - OH
+
Cl- H
Cl H+
O2
OH- Cl
OH
OH
+
O2
H
2
2
M+
M+
M+ -
O + 2H O + 4e -> 4(OH )
e-
e-
Metal (M)
e-
92
FORMS OF CORROSION
93
FORMS OF CORROSION
Pitting corrosion on
free surface
Crevice corrosion
under washers
94
FORMS OF CORROSION
95
FORMS OF CORROSION
96
FORMS OF CORROSION
Stress Corrosion Cracking (SCC)
Caused by the simultaneous effects of tensile stress and a
specific corrosive environment.
Tensile Stress
Susceptible
Alloy
Corrosive
Environment
97
FORMS OF CORROSION
Stress Corrosion Cracking (SCC)
Stresses may be due to:
applied loads ( static / dynamic )
residual stresses from the
manufacturing process, or
combination of both
98
FORMS OF CORROSION
Stress Corrosion Cracking (SCC)
Atoms of metal at stressed areas
have high energy , i.e. very active
High localized corrosion rates at
such areas
Localized metal loss leading to
cracking, i.e. Pit-to-Crack Transition
99
FORMS OF CORROSION
Stress Corrosion Cracking (SCC)
Cracked weld
Weld
Cracked Pipe
100
FORMS OF CORROSION
101
FORMS OF CORROSION
Hydrogen Damage
H (atomic) can diffuse into the metal causing:
cracking
blistering
embrittlement
Hydrogen evolution reaction
2H+ + 2e-
2H (adsorbed)
H2 (gas)
102
FORMS OF CORROSION
Hydrogen Blistering
Grain Boundaries
103
FORMS OF CORROSION
Hydrogen Blistering :
Surface bulges, resulting from subsurface voids produced
in a metal by hydrogen absorption in (usually) low-strength
alloys.
H+
H+
H2
e-
H2
e-
H2
104
FORMS OF CORROSION
Hydrogen Blistering
Hydrogen blistering of
a carbon steel plate
105
FORMS OF CORROSION
Example of hydrogen
blistering damage in steel
pressure vessel
106
FORMS OF CORROSION
Hydrogen Embrittlement
Hydrogen Embrittlement
caused violent rupture
107
FORMS OF CORROSION
Galvanic Corrosion
Occurs when two dissimilar metals are in
direct electric contact
Dissimilar metals have different reactivities
since they have different positions in the
Electrochemical Series
108
FORMS OF CORROSION
Active (-) ANODIC
GALVANIC SERIES
OF METALS
Nobel (+)
more reactive
Magnesium
Zinc
Aluminium
Steel
Lead
Tin
Brass
Bronze
Copper
Nickel-Copper
Alloys
Stainless Steel
Silver
Gold
Platinum
CATHODIC
less reactive
109
FORMS OF CORROSION
Galvanic Corrosion
Anode from Latin word Anodos = way-up
Cathode from Latin word Kathodos = way-down
110
FORMS OF CORROSION
Galvanic Corrosion
Due to the potential difference
between dissimilar metals :
The less noble metal is more Active
and acts as Anode ; i.e. it dissolves
The more noble metal acts as
Cathode ; i.e. it remains intact.
111
FORMS OF CORROSION
Conventional
current
Electrons
2+ 2+
FeFe
Fe
O2
O2
Cu
Galvanic Corrosion
112
FORMS OF CORROSION
Galvanic Corrosion
Conditions of galvanic corrosion:
1- Presence of two different metals.
2- The two metals are exposed to the
same electrolyte completely or partially.
3- The two metals are in direct contact,
either by:
touching/welding, or
via a metallic conductor
113
FORMS OF CORROSION
Brass fitting
Steel pipe
114
FORMS OF CORROSION
Carbon steel
tube sheet
Galvanic corrosion
Galvanic corrosion is very common in tube and shell heat exchangers. The main
areas of concern are where the tubes enter the tube sheets and where they go
through the baffles.
115
FORMS OF CORROSION
SS
CS
Stainless
Steel Valve
Carbon Steel
116
FORMS OF CORROSION
Carbon Steel
Valve
Stainless Steel
CS
SS
117
FORMS OF CORROSION
Surface area effect in galvanic corrosion
9
Brass rivets on a steel structure
X
Steel rivets on a brass structure
FORMS OF CORROSION
Surface area effect in galvanic corrosion
FORMS OF CORROSION
Surface area effect in galvanic corrosion
Steel rivets on a brass bar
submerged in 3% sodium
chloride solution at the start
of the experiment
FORMS OF CORROSION
Galvanic Corrosion
FORMS OF CORROSION
Galvanic Corrosion
An Example of Small anode - Large cathode combination, which is
NOT Acceptable
122
FORMS OF CORROSION
To prevent galvanic corrosion
Avoid contact between dissimilar metals
by using Flange Isolating Kits @ material break points
Non-metallic Gasket
Non-metallic
Sleeve
Non-metallic Washers
Components of
Flange Isolating Kit
123
FORMS OF CORROSION
To prevent galvanic corrosion
Avoid contact between dissimilar metals
Nobel
Active
124
FORMS OF CORROSION
Modes of Corrosion
The forms of corrosion can be divided into 2 main categories:
Intrinsic modes of corrosion (occur independently of design configuration)
general corrosion
pitting corrosion
stress corrosion cracking
hydrogen damage
Extrinsic modes of corrosion (affected by design)
crevice corrosion
galvanic corrosion
flow assisted corrosion
P.S.: The corrosion process for all modes is basically the same; i.e. it
involves anodic reaction and cathodic reaction.
125
CORROSION CONTROL
Corrosion Control
Corrosion - A Natural But Controllable Process
Corrosion can be best controlled by manipulating Either:
The driving force of the metal to corrode, or
The reaction rate
126
CORROSION CONTROL
CORROSION CONTROL
128
CORROSION CONTROL
Controlling the Reaction Rate
An army of corrosion control techniques is
deployed to fulfill this goal
CORROSION CONTROL
Economics
Safety
Environmental Concerns
130
CORROSION CONTROL
ECONOMICS
The true cost of protecting steelwork from corrosion has to take
into consideration two important elements:
133
134
Sea Water
Fe2+
O2 + 2H2O
4OH-
e- e-
Pipe Wall
Pipe Inside
O2 + 2H2O
4OH-
e- e- e- e- e- e- e- e- e-
Pipe Wall
Pipe Inside
135
Electronic movement in
conductor wire
e-
Electronic movement
Ionic migration
The portion of structure
surface that is included
in the CP electric circuit,
i.e. which sees the
umbrella, is ONLY under
cathodic protection
I
External supply
of electrons
Corrosion
Mitigated
-.5
-.6
-.65
-.6
-.7
-.58
-.58
-.6
-.65
-.6
-.7
-.58
-.6
-.6
-.65
-.6
-.7
-.6
-.65
-.65
-.65
-.65
-.7
-.65
-.7
-.7
-.7
-.7
-.7
-.7
137
Application of CP Systems
On-Shore
138
Off-Shore
Jackets
Piles
Vessels
Subsea Pipelines
139
Types of CP Systems
According to the source of external supply of electrons,
there are two types of CP systems:
1- Sacrificial (Galvanic) anode system
2 - Impressed current system
140
Types of CP Systems
A galvanic cell: is an electrochemical cell in which a spontaneous
reaction occurs to produce electricity.
An electrolytic cell: is an electrochemical cell in which electricity is
used to bring about a chemical reaction that does not occur
spontaneously .
141
Magnesium
ACTIVE
Zinc
Aluminum
Iron
e-
Tin
Nickel (Active)
Brass
Copper
Nickel (Passive)
Zn
410 Stainless
Titanium
304 Stainless
Silver
Fe
Simplified Galvanic
Series
Lead
Gold
Platinum
NOBLE
142
143
Fe Fe/Cu
Fe/Ag Cu/Ag
Without electrolyte
With electrolyte
144
Drain Point
Anode
e-
Fe
145
146
147
Recommended Electrolyte
Magnesium (Mg)
Zinc (Zn)
Aluminum (Al)
Sea waters
149
151
X 1,000,000 ohm.cm
TDS (ppm)
152
Mg
GYPSUM
75%
BENTONITE
20%
SODIUM SULPHATE
5%
Zn
The backfill mixture completely surrounds the anode within a cotton bag.153
5.3 - 6.7%
Zinc
2.5 - 3.5%
Manganese
0.15 - 0.7%
Silicon
0.10% max
Copper
0.20% max
Nickel
0.002% max
Iron
0.003% max
Others
0.30% max
Magnesium
Remainder
156
Element
Aluminum
0.01% max
Manganese
0.50 - 1.3%
Silicon
0.05% max
Copper
0.02% max
Nickel
0.001% max
Iron
0.03% max
Others, each
0.05
157
159
160
Cow horn
cores pipe
bending
161
162
Goal post
Straight pipe
163
2. Flush mounted
164
165
166
Pig Tail
167
168
169
Zn
Mg
170
171
174
Test
Station
175
1.5m min
176
Sacrificial Aluminum Alloy Anode for Pipe Frame of Drilling Platform Offshore
177
178
179
180
181
Segmented Bracelet
Half-Shell Bracelet
183
Tank
CP
Current
185
186
188
189
Sacrificial Anode
190
191
SEC A-A
SEC A-A
EL +7500
SEC B-B
EL +5500
SEC A-A
EL +3500
SEC B-B
EL +1500
LL Level
SEC A-A
SEC B-B
EL +500
192
193
Direct Welding
2. Bolt-On Type
194
Tack weld
Full felet
weld
Bracket
Anode Alloy
Direct Welding
weldment
Anode Insert
Anode Insert
Anode Alloy
195
U-Bolt
Nuts
Anode Alloy
Anode Insert
Steel Bar
Anode Insert
Tank Floor
Bracket
(Bolt-On Type)
Different arrangements for Bolt-On
type anode fixation
197
198
199
200
201
202
Anode Sleds
203
204
205
206
208
210
211
212
Inter coat
213
214
Drain Point
215
Results:
1- The nail at +ve
terminal Corrodes
2- The nail at ve
terminal remains
Uncorroded 216
217
e-
Drain Point
Drain Point:
Location of negative cable connection to the structure to be protected.
It is the ENTRY POINT of electrons, or the Current drain.
218
AC input
Voltage, Single/ three phase, Frequency
DC maximum output
Air Cooled:
Oil Cooled:
Amp, Volt
with Sun-shade
with Thermometer &
Level indicator
219
Explosion-proof
outdoors
Pole-mounted
Wall-mounted
221
223
Rectifier
Transformer
224
Consumable Anodes
Si Fe
Si Cr Fe
Platinized
Magnetite
Graphite
225
Fe
Fe2+ + 2e-
226
Rods
Tubular
227
Fe - Si Anodes
Fe - Si Anodes
229
Fe - Si Anodes
ITEM DESCRIPTION
1 Anode
2 Double insulation electrical cable
3 Steel core
4 Tin-lead solder alloy
5 Epoxy resin
6 Heat shrink cap
230
Fe - Si Anodes
Heat-shrinkable
anode cap
231
New Si Fe Anode, 44 lb
232
Anode
Drop
Height
Anvil
233
2Cl-
2 H2O
O2 + 4H+
+ 4e-
234
2Cl-
Non Consumable
235
236
237
MMO Coating
Rods
238
Tubular 239
Cannistered
240
241
(-)
T/R
(+)
242
243
244
245
Sacrificial CP Systems
Impressed Current CP Systems
246
Definition of Groundbed:
One or more anodes installed below the earth's surface for the purpose of
supplying cathodic protection.
Deep-well GB
Horizontal shallow GB
Distributed Anodes
247
Soil Resistivity
Soil Moisture
Interference with other Structures
Availability of Power Supply
Accessibility
Vandalism or other Damage
Availability of Right of Way
248
Remote Earth:
Part of electrolyte where no voltage difference due to
current flow is recorded between two points.
249
Junction
Box
Sand topping
Carbonaceous backfill
for anodes section
Non-metallic
perforated
vent tube
251
253
Vent Tube
3-5m
255
3-5m
256
257
258
Do 2:
Connect the cable(s) from the anode bed to the rectifier DC positive
terminal(s), and
The cable(s) from the structure to the T/R DC negative terminal(s)
259
Mounting
Post
T/R
Copper
Rod
Conductive
Backfill
260
conductive
cementitious
product
261
262
Connection via
variable resistance
Direct connection
to +ve buss bar
263
Anode Connection :
265
Anode Connection :
Connection via
variable resistance
266
267
268
269
273
274
275
276
277
Ground Bed
278
V vs CSE
Cathodic Protection
GB1
GB2
GB3
Distance
280
2.0
1.6
1.2 Fe
Passivity
0.8
0.4
Anodic Protection
Fe2+
0.0
pH
-0.4 Corrosion
Adjustment
-0.8
Cathodic Protection
-1.2
Immunity
-1.6
0
7
14
pH
Potential
3+
281
Potential vs Cu/CuSO4
Description
mV
-500
Intense Corrosion
-600
Free Corrosion
-700
Some Protection
-800
-900
Some Over-Protection
-1000
Increased Over-Protection
-1100
-1200
Sever Over-Protection
Problems
282
283
V vs. CSE
Time
284
285
-850
-950
Lead
-600
Copper
-500
Aluminum
-950
(2)
286
Criteria
Environment
Copper/copper sulphate
Silver/silver chloride
- 0.85 (V)
- 0.80 (V)
Soil
Sea water
Zinc
- 0.25 (V)
Sea Water
288
= Soil Resistivity
i.e., the value of 850 mV is only for soils with < 10,000 ohm.cm
289
290
. Sea Water
291
person
+20
+15
-15
292
E (volts)
H2/H+
Zn / Zn2+
-0.76
Cu / Cu2+
+0.34
Ag / Ag+
+0.80
293
Portable Type
294
CuSO4 Saturated
Solution
HIGH SO42- IONS
CONTENT
AVO meter
Cu
Cu2+
SO42-
Water
Porous Disc
SO42-
Water molecules
Pipe
296
298
Maintenance of the
Reference Electrode
Copper Sulphate
Crystals & Solution
300
302
Pipe
303
Pipe
304
305
306
Prepackaged CSE
Backfill :
Gypsum +
Bentonite clay +
Sodium sulfate
308
309
Voltmeter
On-Potential
Eon Reading
Eon = Ep + IR error
CSE @ soil
surface
IR error
CP current
Coating
Ep
310
Voltmeter
Voltmeter
Off-Potential
Coating
Ep
311
Off Potential
312
313
314
Flush to Ground
315
Test Post
Pipeline
Permanent
Reference electrode
316
317
Electrical insulation
Vm
Riser pipe + CP
318
319
320
321
No. of Electrodes
Required
5-10
10-23
23-36
45 and above
322
1/8D
1/6D
1/4D
3/8D
2/8D
2/6D
D=23-36m
D=10.5-22.5m
Key :
D=5-10m
Reference Electrode
323
Plug RE
RE
RE
324
Tank
PVC Pipe
Under Tank Soil
Top View
Concrete Ring
Concrete Ring
325
AVO
Tank
CSE
AVO
Concrete / Asphalt
Buried Pipe
Correct method for measuring structure potentials
when surface is covered with concrete or asphalt.
327
328
329
330
Cable to surface
meter
331
332
334
335
Current
Potential
336
337
338
339
340
341
342
343
Anode ribbon
Ti conductor bar
Reference anode
Drain point
welded to
Ti bar
344
Junction box
345
MMO ribbon
346
347
350
351
RE
352
T/R
+
-
to tank shell
353
X
354
356
Oxygen Evolution
2H2O
Water Thermodynamically
Stable
Hydrogen Evolution
2H+ +2eH2
Hydrogen is Stable
357
Compacted
Soil
End Caps
359
Tank
(-)
T/R
(+)
Compacted Soil
Always make sure that the watering slotted tubes are above the ICCP anode grid
361
Horizontal GB
MMO strip
anode
362
363
364
365
366
Distributed Anode
Cathodic Protection
System
367
368
369
370
Shielding effect
No shielding effect
371
Hanging
ICCP
anode
372
373
PVC Support
ICCP anode
Anode Cable extended to
outside along vent tube
374
RE
Side View
T/R
Suspended Horizontal Impressed Current Anode
System
375
T/R
Suspended Vertical Impressed
Current Anode System
376
T/R
378
379
380
381
382
383
Linear Anodes
384
SHIP
Anodes
Icp Current
Power
Supply
(+)
Controller
(-)
Reference Cell
385
Put on your
thinking cap !!!386
388
CP System Design :
Basic information for design considerations
1. Type of electrolyte (environment)
Soil
Fresh/ saline water.
2. Temperature
3. Type of coating
4. Structure size
5. System Lifetime (years)
6. Availability of power supply
7. For pipelines:
Pipeline route
Crossings (foreign pipeline, roads, rivers, etc.)
Presence of high transmission power lines
Presence of foreign metallic structures.
389
CP System Design :
Significance of Design Criteria:
Type of electrolyte
Temperature
Type of coating
Structure size
Current Demand
Current Demand
Type of electrolyte
Structure size
Type of CP system
Current Demand
Type of electrolyte
System Lifetime
Number of Anodes
Type & number of GBs
390
CP System Design :
Significance of Design Criteria:
Availability of power
supply (ICCP)
Use of:
Rectifiers, or
Solar units
Pipeline route
Soil resistivity
Soil represents the electrolyte
Soils with low resistivity have high conductivity; i.e.
corrosive
NACE ranking
Soil resistivity (ohm. m)
Corrosivity
up to 10
Severely corrosive
10-50
Corrosive
50-100
Moderately corrosive
100-200
Slightly corrosive
Non-corrosive
392
393
Distance
Four-Terminals (Wenner)
Measurement of Soil Resistivity.
Cables
Power Unit
Kit
C
P
1
1
C
P2
2
a
C1
Resistance Test
Instrument
P1
a
P2
Depth = a
C2
395
Survey procedure
2- Current is applied to the outer pins by the instrument and a voltage is
measured between the two inner pins.
3- The instrument
displays average
resistance of the
soil.
396
: Resistance (ohm)
: Applied Voltage
: Recorded Amperage
397
Rating of Soil
25,000 - 100,000
not corrosive
10,000 - 25,000
hardly corrosive
5,000 - 10,000
slightly corrosive
impressed current
2,000 - 5,000
moderately
corrosive
1,000 - 2,000
highly corrosive
under 1,000
very highly
corrosive
398
Current Density
mA/m2
Aggressive Soil
10
Normal soil
Sea water
90
Fresh water
30
400
Current Requirement:
Current Drain Test
Whenever possible, a trial and error process using a temporary groundbed and a
portable power supply should be used to determine the current required to protect
the structure .
1) Set up a temporary groundbed with ground rods and a temporary power supply .
2) Energize the system
3) Perform an on-off survey over the structure to be protected .
4) Increase the current and repeat the survey .
5) Repeat Steps 3 and 4 until the structure is protected according to established
criteria .
401
Variable resistor
Pipe
Temporary
groundbed
402
2.0
1.5
1.0
Galvanic
0.5
0
10
20
30
40
50
60
70
80
90
100
403
404
405
Batteries
Basic Requirements:
Long life reliability (25 years or more)
Simple maintenance
Corrosion resistance in harsh atmospheres
Alcad nickel-cadmium battery :
The heart of the cell is a series of steel pockets which are
made from finely perforated steel strip filled with active
materials - nickel in the positive plate and cadmium in the
negative. The plates are immersed in an electrolyte.
406
Sun
Junction Box
Converter
(+)
Structure
(-)
Batteries
Solar Modules
GB
Pipe to be protected
407
Metal protection
Passive protection
A passive protection is offered by paints. Paints form an
insulation layer or barrier on top of the metal. That is why
it is also called a barrier protection.
Active protection
An active protection is also called cathodic protection.
408
413
Coating Resistance
414
Coating Quality:
The structures leakage resistance (RL,S) is the sum of the coatings leakage
resistance (RL,C) and the leakage resistance to remote earth (RL,E).
416
Coating quality
Range of coating
leakage resistance
(RL,C), ohm.m2
Poor
1,000 - 2,500
Fair
5,000 - 10,000
good
25,000 - 50,000
Excellent
100,000 - 500,000
417
% breakdown
Initial
Mean
Final
Thick coating
10
5-10
10-20
Fusion bonded
epoxy
1-2
5-10
5-20
Polypropylene (25
yrs)
0.5
0.5
Electrolyte
(Soil)
Protective
Coating
Protective
Coating
Pipe Wall
A Coating Breakdown
exposing bare steel to
electrolyte
CP Current
418
power
source
pipe shown in
cross-section
coating material
419
420
Lifting
421
Non-metallic
Rolli Cradles
423
424
425
426
Topsoil Backfill:
Coarse
Subsoil Backfill
covering the pipe:
Pipe
Compacted, Fine,
Rock-free
428
Subsoil
Trench
Topsoil
Pipe
Preparation
Subsoil
Topsoil
Prepared
Pipe
Trenching
Subsoil
Lowering In
Topsoil
Backfilling
429
Trench
Prepared
Pipe
Subsoil
430
Asphalt Enamel
-2
-1.5
-1.5
Tape wrap
-1.5
Polyethylene
-1.0
431
432
Pipeline Route
Cross-country P/Ls pass through different types of soils,
i.e. different electrolytes
Presence of high voltage power transmission lines
433
Pipeline Route
434
Pipeline Route
Pipeline in Sandy Soil
Pipeline Submerged
435
438
439
440
441
442
443
Polarization cell
Zn ribbon
Zn ribbon
Pipeline
445
Polarization cells
446
447
449
450
451
452
CP umbrella
453
In
I4
I3
I2
I1
Rn
R4
R3
R2
R1
The current takes all paths the path with the lowest
resistance passes more current
454
Current pickup
Current discharge
455
456
457
458
Equi-potential jumpers
Bonding Box
AUTOBOND
459
Bonding Box
Bonding Box
Foreign Pipe
Protected Pipe
Foreign
Pipe
Protected
Pipe
460
Foreign
Pipe
Protected
Solid Bonding
461
Foreign
Pipe
Protected
462
463
Solid Bonding
464
Variable Resistance
Bonding
465
Before Bonding
After Bonding
Electrolyte
(Soil)
Stray Current
Discharge
Pipeline
469
470
471
INT
ERF
CUR ERAN
REN CE
T
DC Stray-current corrosion
472
Cables Connections
Cable to - cable connection
Cable to - pipe connection
Cable to - structure connection
473
5.Sheath: HMWPE
3.Bedding: PVC
475
477
Araldite is poured
& let to dry 478
479
Cable Connections
Crucible
(Mold)
Spark Flint
480
481
482
Thermite Weldment
Prior to welding :
The coating must be removed at
welding point ( 5x5 cm square )
Metal surface to be polished and
cleaned
485
Primer
Self-adhesive
Handy Cap
486
cable
487
4
488
489
Lug
Pistol / Gun
490
Grinder
491
4 Test connection
3 Pin braze
492
493
494
Cable Connections
Terminal Lugs :
for cable-to-structure ( tank )
connection
495
Cable Connections
Clamps
Brass Ground Clamp with Brass Screws
to connect copper conductors to pipe
and rods
496
No CP
CP
Point of Electrical
Isolation
Cathodically
Protected Tank
CP umbrella
498
Not Acceptable
May Be Accepted
499
500
501
F type
502
503
Sealing Gaskets
504
Before
Tightening
After
Tightening
Greater separation
between pipe
ends minimizes
"bridging"
506
No CP
CP
507
Surge Arrester
508
509
Polarization
cells
510
511
512
Protected
Protected
Polarization Cell
Polarization Cell
Cathodically
Protected Tanks
shall be electrically
earthed separately
or connected to the
earthing network via
Polarization Cell
Copper
Earthing
Rod
Cathodically
Protected Tank
CP umbrella
Polarization Cell
514
515
516
Cathodic Isolator
517
518
519
520
521
522
Reference
Electrode
Vent Pipe
Carrier Pipe
V
+c-
V
p +
Casing
Shorted
Isolated
Casing
0.900 VCSE
0.750 VCSE
Pipe
0.900 VCSE
0.910 VCSE
523
524
Dome Marker
CP Test Station
& Marker
Flat Markers
525
526
Headers include:
Danger - If not avoided will result in death or serious injury
Warning - If not avoided could result in death or serious injury
Caution - If not avoided may result in minor or moderate injury
Notice - Usually used to indicate a statement of company policy
527
non-detectable tape
The non-detectable tape is made from a lowdensity polyethylene plastic formulated for
extended underground use. It is acid and
alkali resistant and exhibits superior tensile
strength.
The detectable tape is manufactured with a
solid aluminum core which is sealed between
durable Mylar.
The underground warning tape is an alert to
excavators, and is typically the last item to be
installed in the trench.
detectable tape
Legend:
Buried Cathodic Protection Line Below
or
Cathodic Protection Cable Buried Below
528
529
CD= S x A x CBDC
CD
: Current Demand (A)
S
: Design Current Density (A/m2)
A
: Surface Area (m2)
CBDF : Coating Break-down Factor
530
W= (CD x C x t) / u
W
C
t
u
531
P.S. the anode net weight & current output are available
in suppliers catalogues
532
CP Circuit Resistance
Rt= Rc + RGB + Rs
533
where:
p = average soil resistivity (ohm-m)
L = length of groundbed (meters)
d = diameter of groundbed (m)
h = depth to center of groundbed (m)
534
where:
RN = groundbed resistance (ohm)
p = average soil resistivity (ohm-m)
N = number of anodes in parallel
L = length of an anode (m)
d = anode diameter (m)
s = spacing of anodes in groundbed (m)
535
Notes:
1) This equation assumes that L >> d
2) L, represents the length of active anode
536
L, active part
of groundbedd
d
537
539
13.0
13.3
541
Ea/Em = Cosh(L)
Ea = Ea - En
Em = Em - En
= (Rs/Rlf)
Rlf = Rf/( * D)
Rs = s/ ( * D * t)
En (v)
Ea (v)
Ea (v)
Em (v)
Em (v)
(m-1)
Rlf (ohm.m)
Rf (ohm.m2)
Rs (ohm/m)
s (ohm.m)
D (m)
t (m)
L (Km)
-0.55
-1.3
15664.8566
20000
1.5665E-05
0.00000019
Pipeline Diameter
Pipeline Wall Thickness
Attenuation Distance
0.4064
0.0095
39.26
542
543
Impressed Current CP
Adjustable Voltage
Fixed Current
Adjustable Current
Low Maintenance
Higher Maintenance
544
545