Corrosion Control - Lec4

Corrosion and its Control Management System in industry
Detect safe operating pressure by UT inspection
Eng.Abdellatif Radwan 1
IV- corrosion monitoring system in petroleum industry
Ut Evaluation consideration
Enviornment of Position of
corrosion equipment Flow regime
mechanism condition
IV- Corrosion monitoring system in petroleum industry
-Types of corrosion monitoring system (CMS)
Biological monitoring probes
Measures The Presence Of Bacteria That Consume Sulphate And

Generate Sulpheric Acid (H2SO4).
3
Eng.Abdellatif Radwan
iv corrosion monitoring system in petroleum industry
-types of corrosion monitoring system (cms)
Chemical Methods
samples taken from corrosive media to detect
corr. rate of system
ppm iron count for flow lines
ib fe /day = 0.00035 ppm fe * bwpd (barrels water per day)

corr.rate mpy =( ib fe per day )/(0.0000287 *l*d
where l: length of tube , d : inside diameter
co2 corr.rate prediction for gas lines:
log (corr.rate mmpy) = 5.8 – (1710/t)+0.67 (log p.p co2)

(deward williams equation) where t temp.absolutr p.p partial press. of co2 in
gas
p.p of co2 < 3 non corrosive
3-30 psi may be corrosive
> 30 psi corrosive
REF :NACE publication tcp5 corrosion control in petroleum production
IV- Corrosion Monitoring System In Petroleum Industry
-types of corrosion monitoring system (CMS)
Failure Analysis
Investigation Performed On The Corroded

Area To Identify The Reasons And Detect The Suitable
Corrosion Control failure Analysis.
Failure Analysis Requirements:
-Destructive test
-Evaluate Monitoring System Types
-Analysis Of Test Performed And Monitoring
-Recommendation For Suitable Selection
Corrosion Control.
IV- Corrosion
Monitoring System In Petroleum Industry
- Evaluation of Corrosion Monitoring System
Standard limits of Corr.Rate Acc to Nace:

LOW < 1 mpy
moderate1-4.9 mpy
high 5-10 mpy
Severe >10 mpy
Refernces:
NACE STANDARD 0-775-99 STANDARD RECOMMENDED PRACTICE PREPARATION,INSTALLATION , ANALYSIS, AND
INTERPRETAION OF WEIGH LOSS COUPON IN OIL FIELD
IV- Corrosion Monitoring System In Petroleum Industry
Practical Case Of CMS In Oil Field Production STORAGE TANKS ONSHORE AREA
OFSHORE AREA
TO GAS PLANT H.E

GAS LIFT MODULES
HEATER
HEMIS
OIL/GAS SEP.
DESALTER
OIL WELL
WATER INJ.
PROCESS AREA
GAS LIFT INJ.
CORR.MONIRORING SYSTEM
DOWNHOLE CMS
7
V - CORROSION CONTROL METHODS
V - Corrosion Control Methods
-PROTECTIVE COATING
-CATHODIC PROTECTION
-CORROSION INHIBITOR
-MATERIAL SELECTION
-DESIGNE
-METHODS DEPEND ON THE CONTROL OF

-OPERAATING CONDITION
- Fe Fe++ + 2e
METHODS DEPEND ON THE MATERIAL
ENVIORNMENT
-SUITABLE MATERIAL SELECTION

CORROSION CIRCUIT
-SUUITABLE DESIGN
corrosion circuit:
- anode Fe Fe++ + 2e- Anode (oxida ion)
t
- cathode
- electrolyte O2 + 2H2O + 4e 4OH- cathode
- metallic connection in neutral and alkaline solution

between cathode and anode
2H+ + 2e H2 in ACID SOLUTION
METHODS ISOLATE METAL FM CORRODED ENVIORNMENT

CORROSION CONTROL BY PROTECTIVE COATING
corrosion control definition:

process through a certain method to make
the corrosion rate in acceptable limits.
Chemical injection system
Protective coating
material selection
CORROSION CONTROL Cathodic protection

METHOD
Operating
condition
design
CORROSION CONTROL BY DESIGNE
CORROSION ALLOWANCE CA:
AN EXTRA MEASUREMENT ADDED TO THE THICKNESS OF THE WALL. ... BY KNOWING THE EXPECTED
RATE OF CORROSION AND THE EXPECTED SERVICE LIFE OF A PLANT OR PARTS.
ASME B31.3 Provides formula and guidelines for calculation of THICKNESS pipe under
pressure..304.1.2 (a) equation :
Seamless Pipes : Design Thickness t = (PD)/2(SE+PY)
Welded Pipes : Design Thickness tm = (PD)/2(SEW+PY)
Where :
P : Internal Design Gauge Pressure
D : Outside diameter of pipe
S : Allowable Stress value for material from Table A-1E
E : Longitudinal Weld Joint Quality factor as per ASME B31.T
W : Weld Joint Strength Reduction Factor
Y : Coefficient from Table 304.1.1,
CORROSION CONTROL BY DESIGNE AND

DURING FABRICATION
CORROSION CONTROL BY MATERIAL SELECTION
ex. main distillation refinery
upper part
carbon steel lined by monel
to avoid chlorides salt
middle and lower part

carbon steel lined by st.st410
to avoid sulfur compound at high temp.
13
Ex. Tube Boundele And Tube sheet Of Sea Water Cooler And Condenser
Tube Sheet
Tube Boundle
TUBE SHEET AND TUBE BOUNDLE GENERALLY FABRICATED FROM

EX. COPPER BASE ALLOY DUE TO GOOD RESISTANCE TO SEAWATER
-PRINCIPLES
-TYPES
SACRIFICIAL ANODES
IMPRESSED CURRENT
-DESIGN CONSIDERATION
- EVALUATION
Cathodic Protection
Impressed Current
transformer/rectifier
- +
STORAGE
TANK
BURIED PORTION
auxiliary anode
17
V - corrosion control methods
CATHODIC PROTECTION
- DESIGN CONSIDERATION
REFRENCE : NACE REFRENCE BOOK
CATHODIC PROTECTION EVALUATION POTENTIAL SURVEY
Buried pipeline Subsea pipeline

Min. potential -850 mv Vs Cu/CuSO4 Min.Potential -800 mv Vs Ag/Agcl Electrode
Electrode
Control of corrosion through operating condition
-Remove stagnation areas -Periodic flushing
20
PROTECTIVE COATING
COATING DEFINITION
IS A LAYER OF MATERIAL DEPOSITED INTO A SUBSTRATE TO ENHANCE THE

SURFACE PROPERTIES FOR CORROSION AND WEAR PROTECTION
Factors Affecting The Choice Of A Coating

-Service Environment
-Life Expectancy,
-Substrate Material Compatibility
-cost.
21
PROTECTIVE COATING
Types Of Coating Classification :
I- According To Environment :
Splash zone & submerged

Atmospheric
Protective Coating
-Inorganic Coating:
Ex. In Organic zinc Silicate Which Is Common Used In Petroleum
Industry It Used In Atmospheric And High Temp. Surface.
-Mastic Coating:
use in locations which is difficult to perform sand blasting
and we can apply on surface prepared by mechanical power
tools.
Protective Coating
Surface preparation degree
Protective Coating
Painting System Component Application
Corrosion Control By Protective Coating
Application Of Coating Procedures
SANDBLASTING AIRLESS SPRAY ROLEER
APPLY PAINTING
Comment Coating Defects
. (a) Blistering (b) Bubbling
.. (c) Sagging
. (d) Solvent lifting
Detachment
Peeling (e) Solvent popping
Evaluation Of Coating Application
- Lab test for paint according To data sheet

Evaluation Of Coating During And After Application
Measure wet film thickness Measure dry film thickness

Holiday detector of painting pinhole
V - Corrosion Control Methods PAINTING REPAIR
Corrosion Control By Protective Coating ASTM D610
Ex. : Painting System
External surface
Epoxy mastic 200 mic ( 2 coat)

Poly urethane 50 mic.
External surface high temp.
Inorganic zinc silicate 50 mic.

Silicon binder 55 mic. ( 2 coats)
Splash zone
High solid epoxy 100 % 0.25 inch
V - Corrosion Control Methods Hot Dip Galvanized
REF.: ASTM A153 VOL 1.06

V -Corrosion Control Methods
Corrosion Control By Chemical Injection System:
Is A Substance Which When Added To An Environment Decrease The

Corrosion Attack On A Metal Surface.
Examples Of Types Chemical Injection
-Inject Chemicals to Isolate Corroded

Environment from metal
i.e. corrosion inhibitor in petroleum
production and refinery
-Add Chemicals To Scavenge Corrosive Element

From Environment
I.E. O2 Scavenger In Water System And Water
Treatment For Boilers
-Add Chemicals to Neutralizing Acid constituents

i.e NAOH in refinery
V -Corrosion Control Methods
Corrosion Control By Chemical Injection System
-TYPES OF CORROSION INHIBITORS IN OIL FIELD
-CLASSIFIED AS CHEMICAL BASE
-CLASSIFIED AS
MECHANISM OF
PROTECTION
34

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Corrosion and its Control Management System in industry

Detect safe operating pressure by UT inspection

Biological monitoring probes

Measures The Presence Of Bacteria That Consume Sulphate And

ppm iron count for flow lines

ib fe /day = 0.00035 ppm fe * bwpd (barrels water per day)

co2 corr.rate prediction for gas lines:

log (corr.rate mmpy) = 5.8 – (1710/t)+0.67 (log p.p co2)

REF :NACE publication tcp5 corrosion control in petroleum production

Investigation Performed On The Corroded

Failure Analysis Requirements:

Standard limits of Corr.Rate Acc to Nace:

TO GAS PLANT H.E

V - CORROSION CONTROL METHODS

-METHODS DEPEND ON THE CONTROL OF

-SUITABLE MATERIAL SELECTION

- metallic connection in neutral and alkaline solution

2H+ + 2e H2 in ACID SOLUTION

METHODS ISOLATE METAL FM CORRODED ENVIORNMENT

corrosion control definition:

CORROSION CONTROL Cathodic protection

CORROSION CONTROL BY DESIGNE AND

CORROSION CONTROL BY MATERIAL SELECTION

ex. main distillation refinery

middle and lower part

CORROSION CONTROL BY MATERIAL SELECTION

TUBE SHEET AND TUBE BOUNDLE GENERALLY FABRICATED FROM

REFRENCE : NACE REFRENCE BOOK

Buried pipeline Subsea pipeline

-Remove stagnation areas -Periodic flushing

IS A LAYER OF MATERIAL DEPOSITED INTO A SUBSTRATE TO ENHANCE THE

Factors Affecting The Choice Of A Coating

Types Of Coating Classification :

Splash zone & submerged

Surface preparation degree

Application Of Coating Procedures

SANDBLASTING AIRLESS SPRAY ROLEER

Comment Coating Defects

. (a) Blistering (b) Bubbling

Evaluation Of Coating Application

- Lab test for paint according To data sheet

Measure wet film thickness Measure dry film thickness

Ex. : Painting System

Epoxy mastic 200 mic ( 2 coat)

External surface high temp.

Inorganic zinc silicate 50 mic.

High solid epoxy 100 % 0.25 inch

REF.: ASTM A153 VOL 1.06

Is A Substance Which When Added To An Environment Decrease The

Examples Of Types Chemical Injection

-Inject Chemicals to Isolate Corroded

-Add Chemicals To Scavenge Corrosive Element

-Add Chemicals to Neutralizing Acid constituents

-TYPES OF CORROSION INHIBITORS IN OIL FIELD

-CLASSIFIED AS CHEMICAL BASE

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