Chapter 2 CORROSION CONTROL

PREPARED BY : Eng. Omar Ezzat

Dec., 2012

CONTENTS
1. 2. 3. 4. 5. 6. 7.
CORROSION ENGINEERING. DEFINITION OF CORROSION. IMPACT OF CORROSION. MECHANISM OF CORROSION. FACTORS AFFECTING CORROSION. FORMS OF CORROSION. CORROSION CONTROL TECHNIQUES. 7.1 Improved Design 7.2 Chemical Treatment

1. CORROSION ENGINEERING

Corrosion engineering is the application of science and art to prevent or control corrosion damage economically and safely.

2. DEFINITION OF CORROSION
Corrosion is defined
as the destruction or deterioration of a material due to its reaction with the surrounded environment.

Oxides, Ore thermodynamically stable

Corrosion of metals
could be considered as extractive metallurgy in reverse.
Mining & Extraction

Corrosion

Equipment fabrication, thermodynamically unstable

2. DEFINITION OF CORROSION (Cont.)

In case of metallic corrosion, corrosion is

related to the law of conservation of energy.
Energy
(Smelting)

ORE

METAL

(Corrosion)

3. Impact of Corrosion
In some countries corrosion damage reaches 5% of

the total yearly GDP. Economic losses are attributed to; loss of production, replacement of equipment, maintenance of equipment, environmental pollution, etc. Recent studies revealed that 2/3 of such corrosion damage could have been avoided if a proper corrosion control technique was applied. Corrosion damage can extend far from economic losses, where it could cause loss of life in some circumstances. Loss of life was reported in many incidents and reason was directly attributed to corrosion.

3. Impact of Corrosion (Cont.)

Catastrophic failure

Corroded rotor leading to equipment failure

Leakage leading to environmental pollution

4. Mechanism of Corrosion
In most cases corrosion is an electrochemical

phenomenon. For corrosion to take place, the following are required: An anode - at which the metal goes into solution (corrodes) A cathode - at which electrons from the anode are consumed An electrical continuity between anode and cathode (the internal conductor) A common continuous electrolyte (the external conductor) across both anode and cathode.

4. Mechanism of Corrosion (Cont.)

e
ANODE

Flow of Electrons
CATHODE

H2O H+ Na+ ClH2O OHNa+

Flow of Electrical Current

ClNa+ H2O H2O H+ Fe++ OHFe++OHH+ Fe++ OHCl-

+
2e-

Fe
2e2e-

Cu

H2O

ClH2O

2e-

Na+ H2O

Reaction at Anode
2Fe 2Fe++ + 4e

Electrolyte

Reaction at Cathode
2H+ + 2e H2 2H2O 4OHO2 + 4H+ + 4e O2 + 2H2O + 4e Fe3+ + e Fe2+

4. Mechanism of Corrosion (Cont.)

The faster that electrons are consumed at the
cathode, the faster will the metal go into solution at the anode (corrode). This keeps the reaction in equilibrium. Overall reaction is 4Fe + 4H2O + 2O2 = 4Fe(OH)2

Un-corroded surface Corroded Surface

Standard EMF Series

Standard EMF series represents a ranking of metals in terms of its natural potential reference to a hydrogen electrode.
Element
Magnesium Aluminum Zinc Mg Mg++ + 2e Al Al+++ + 3e Zn Zn++ + 2e

Potential (Volts)
-2.34 -1.67 -0.76

Readiness to Corrode (Reconvert to Ore)

Iron
Nickel Tin Lead Hydrogen Copper Silver Platinum Gold

Fe Fe++ + 2e
Ni Ni++ + 2e Su Su++ + 2e Pb Pb++ + 2e 2H 2H+ + 2e Cu Cu++ + 2e Ag Ag++ + 2e Pt Pt++ + 2e Au Au+++ + 3e

-0.44
-0.25 -0.14 -0.13 0.00 0.34 0.79 1.20 1.42

Ease of Smelting

Standard Galvanic Series

Standard galvanic series represents a realistic ranking for metals. Ranking is made in seawater reference to a Ag/AgCl electrode.

5. Factors Affecting Corrosion

There are numerous factors that affect the corrosion process these are:

pH of environment Concentration of corrosive species Stream Velocity Oxygen Content Temperature Pressure

6. Forms of Corrosion There are two major forms of corrosion : I. Uniform Corrosion

II.

Localized Corrosion

I.

Uniform Corrosion

Is called general corrosion Is of little engineering importance Can be easily controlled Can be easily monitored Is caused by natural environments and acids

II. Localized Corrosion Takes place on specific locations: Is hard to predict Is hard to monitor Can lead to catastrophic failures Has numerous forms, such as: i. Pitting ii. Crevice iii. Stress Corrosion Cracking iv. Erosion Corrosion v. Galvanic

i. Pitting Corrosion
Pitting is another form of much localized corrosion attack in which small pits or holes form. This type of corrosion is very dangerous where it is undetected and with very little material loss until failure occurs.

Pitting corrosion of SS

Pitting corrosion of CS

ii. Crevice Corrosion

Crevice or contact corrosion is the corrosion produced at the region of contact of metals with metals or metals with nonmetals. Stainless steels are susceptible to this kind of corrosion.

Crevice corrosion of SS

iii. Galvanic Corrosion

Galvanic corrosion occurs when two metals or alloys having different compositions are electrically coupled while exposed to an electrolyte. Rate of galvanic attack depends on the relative anode to cathode surface areas that are exposed to the electrolyte

Galvanic corrosion of a helicopter rotor blade

iv. Galvanic Corrosion

Surface area effect in galvanic corrosion
Small anode Large cathode combination is NOT Acceptable

Small cathode

Large anode combination is Acceptable

Galvanic Corrosion

Galvanic corrosion of painted steel body in contact with SS wheel opening molding

Galvanic corrosion of steel pipe at brass fitting in humid marine atmosphere

v. Hydrogen Blistering

Grain Boundaries

Hydrogen Blistering

Cross-section of a carbon steel plate showing a large hydrogen blister

Hydrogen blistering of a carbon steel plate

vi. Hydrogen Embrittlement

vii. Intergranular Corrosion

Intergranular corrosion occurs preferentially along grain boundaries for some alloys and in specific environments

Intergranular corrosion attack of stainless steel in the heat affected zone of welding

viii. Erosion Corrosion

Erosion Corrosion arises from the combined action of chemical attack and mechanical abrasion or wear as a consequence of fluid motion.

Erosion corrosion for: Check valve (left) and ship rotor blade (right)

ix. Stress Corrosion Cracking

Stress corrosion cracking (SCC) is caused by the simultaneous effects of stress and a specific corrosive environment. Stresses may be due to applied loads, residual stresses from the manufacturing process, or a combination of both.

Stress corrosion cracking of stainless steel

Stress corrosion cracking of brass

7. Corrosion Control Techniques

Corrosion control techniques are based on the mechanisms of corrosion. These techniques are: 1. 2. 3. 4. 5. 6. Improved design. Proper Materials Selection. Environmental Process Control. Utilization of Corrosion Inhibitors. Application of Coatings and Paints. Application of Cathodic Protection.

7.1 Improved Design

Examples of Impingement Corrosion

7.1 Improved Design

Examples of avoiding impingement corrosion by design

7.1 Improved Design

Bad

Examples of avoiding crevice corrosion by design

Good

7.1 Improved Design

Improved Design, e.g.:

Incorporation of corrosion allowance

t (required) = t min + CA

Life time = corrosion allowance (mm) / corrosion rate (mm/year)

7.1 Improved Design

Incorporation of corrosion allowance
SPHERE SHELLS
PR PD

CYLINDRICAL SHELLS
PR

PIPES
t=
2 SE

T=
SE-0.6

+ C.A

T=
2SE-0.2P

+ C.A

FET + C.A

P: design pressure in N/mm2 mm R: inside radius, mm mm S: stress value of material, N/mm2 E: joint efficiency

CA: corrosion allowance,

T, t : min. Required thickness

7.1 Improved Design

Avoiding contact between dissimilar metals using Isolating Flange Kit
Non-metallic Gasket

Non-metallic Sleeve Non-metallic Washers

7.2 Chemical Treatment

Chemical treatment involves injecting chemicals that Retard the corrosion of a metal. Types of Treatment :
Neutralization ( pH control ) Removal of dissolved gases ( scavengers ) Corrosion inhibitors Biocides

A. pH Control

A. pH Control

To avoid acid corrosion, the pH of the medium shall be raised up to about 7 by injection of
Caustic Soda Ammonia Na OH NH3

Periodical check on pH by means of pH probes

B. Removal of Dissolved Gases

Dissolved oxygen can be removed by injection of oxygen scavengers Mechanical deaerator can also be used to remove all dissolved gases: O2, CO2, H2S Amine units can be used to remove CO2 & H2S Periodical checks on dissolved O2 concentration by means of O2 probes

C. Corrosion Inhibitors
NACE definition : Chemicals which reduce the corrosion rate when added to a normally corrosive medium in small concentrations.

Inhibitors selection is based on:

metal environmental chemical composition service condition (e.g. temperature, flow rate)

Classification of Inhibitors

Inhibitors for Acid media pH < 5 Inhibitors for Near-Neutral media pH 5 10

Above pH 10, the alkalinity (OH- ions) of the medium is self-inhibiting

Inhibitors for Acid Media

Usually organic compounds with long hydrocarbon chains with polar (charged) head

Efficiency of Inhibitors

Expressed as : Protective Power ( Z) where,

Z = [(RO-R) / RO] X 100

Ro: Corrosion rate in absence of inhibitor. R : Corrosion rate in presence of inhibitor.

Application of Corrosion Inhibitors

Application of Corrosion Inhibitors

- Oil refineries - Petrochemical plants - Oil and gas production - Desalination plants - Cooling water installations

- storage facilities
- Hydro tests
A Cooling Tower Unit

Application of Corrosion Inhibitors

Chemical injection system for a crude distillation column overhead

D. Biocides

Definition A substance that is capable of killing a certain micro-organism or spectrum of Micro-organisms

Biocidal activity
The concentration needed to kill the microorganisms MKC VALUE = minimum killing concentration

Biocides role in corrosion control

Kill micro-organisms that produce corrosive

metabolites

Sulfate-reducing bacteria ( SRB )

Control of Microbial Corrosion

Use of biocides in closed systems

- capable of killing wide range of microbes

- biodegradable, environmentally friendly - non-harmful for humans and other living organisms

- compatible with the metal, i.e. non-corrosive

- two different biocides to be used alternatively

Chemical Injection Skid

Stainless Steel Tanks

Non-metallic Tanks

Chemical Tanks
Chemical Injection ( Dosing ) Pumps

Chemical Injection Point

High Alloy Quell

Corrosion Control Evaluation

BAD CONTROL

GOOD CONTROL

Corrosion Control Evaluation

Corrosion Monitoring

Definition : the systematic measurement or evaluation of the corrosion rate and type of corrosion occurring on line

Corrosion Control Evaluation

Advantages of Corrosion Monitoring

avoids unplanned shutdowns avoids loss of production resulting from unforeseen corrosion failure

effective scheduling of maintenance works

reduction of inspection activities

Corrosion Control Evaluation

The efficiency of corrosion inhibitors is checked by means of monitoring system. Coupons Electrical Probes

Corrosion Control Evaluation

Corrosion Coupons

Strip Coupons

Cylindrical Coupons

Corrosion Control Evaluation

Typical corrosion monitoring point

Corrosion Control Evaluation

Coupon Handling

Retrieving the coupon

Removal of corrosion product by soft wire mesh

Removal of The coupon is corrosion accurately product by weighed soaking in inhibited acid

Corrosion Control Evaluation

Electrical Resistance (ER) Probe- Corrosometer

Wire-Loop
Flush

Cylindrical

Corrosion Control Evaluation

Electrical resistance probe measurements for mild steel coupons A. In corrosive media B. In non-corrosive media

A B

Corrosion Control Evaluation

Corrosion Monitoring Point Usually includes: Corrosion Coupon ; mainly for visual evaluation of corrosion type Electrochemical Probe ; for more accurate instantaneous corrosion rate determination, e.g. ER probe

Corrosion Control Evaluation

On-Line Wall Thickness ( UT ) Measurements Useful on-stream follow-up monitoring tool Base-line readings are taken at selected locations before and placing the equipment in service Types of UT : A-scan ( Spot ) , B-scan ( Linear ) , C-scan ( 3D )

Corrosion Control Evaluation

On-Line Wall Thickness ( UT ) Measurements Without Inhibition With Inhibition

CASE STUDY

Thank You For Listening