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    Corrosion

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    Shani Kanwal

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    © All Rights Reserved
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    Corrosion

    Uploaded by

    Shani Kanwal
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    7 views55 pages

    Corrosion

    Uploaded by

    Shani Kanwal

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    You are on page 1of 55

    CORROSION

    CORROSION
     DEFINATION
     BASIC CONCEPT OF CORROSION
     FORMS OF CORROSION
     CORROSION PROBLEMS AT ARL
     ACTION PLAN
    CORROSION

    Nature’s wasteful way of returning metals


    to their ore.
    or
    It is deterioration of metal or substance or
    its properties because of reaction with the
    environment.
    CORROSION MECHANISM

    Normally corrosion process is of two types


     Chemical
     Electrochemical
    CORROSION MECHANISM

    There are four factors required for


    electrochemical reaction.
     Anode
     Cathode
     Electrolyte
     Electronic circuit
    CORROSION MECHANISM

    ANODE

    This term is used to describe that portion of


    metal surface which is corroded and from
    which current leaves the metal to enter the
    solution.
    CORROSION MECHANISM

    CATHODE

    It is the metal surface from which current


    leaves the solution and returns to the metal.
    CORROSION MECHANISM

    ELECTROLYTE

    A solution capable of conducting


    electricity.
    Electrolyte may be water, soil, chemical
    solution etc.
    CORROSION MECHANISM

    ELECTRONIC CIRCUIT

    Electronic circuit between anode and


    cathode allowing current to flow from
    anode to cathode.
    CORROSION MECHANISM

    ELECTRODES
     The anode and cathode are also called
    electrodes.
     Electrodes may be two different kinds of
    metal or
     These may be different areas on the same
    metal.
    CORROSION MECHANISM

    OXIDATION
    Loss of electrons is oxidation process.
    Oxidation is a corrosion or anodic reaction.
    Corrosion takes place where current leaves
    the metal i.e. anode

    M M+n + ne
    CORROSION MECHANISM

    REDUCTION
    Gain of electron is reduction process. It is
    opposite of oxidation and is also called
    cathodic reaction.
    M+++ + e M+2
    during metallic corrosion, the rate of
    oxidation equals the rate of reduction.
    FORMS OF CORROSION

    1. Uniform Attack
    2. Galvanic or Two Metal Corrosion
    3. Crevice Corrosion
    4. Pitting
    5. Intergranular Corrosion
    6. Selective Leaching or Parting
    7. Erosion Corrosion
    8. Stress Corrosion
    FORMS OF CORROSION

    UNIFORM ATTACK
    It is general wasting away of metal at
    surface.
    The corrosion reaction may be chemical
    or electrochemical i.e. rusting of iron
    sheets in open atmosphere.
    FORMS OF CORROSION

    PREVENTION
    1. Selection of Proper Material
    2. Painting / Coating
    3. Inhibitors
    4. Cathodic Protection
    FORMS OF CORROSION

    GALVANIC CORROSION
    Because of electric current and dissimilar
    metal involved, it is called galvanic or two
    metal corrosion.
    The potential difference between two
    metal provided driving force for current
    and corrosion.
    FORMS OF CORROSION
    PREVENTION
    1. Select combination of metal as close
    together as possible in galvanic series.
    2. Insulate dissimilar metals completely.
    3. Add inhibitors to decrease the
    aggressiveness of the environment.
    4. Install a third metal which is anodic to
    both the metals in the galvanic contract.
    FORMS OF CORROSION

    CREVICE CORROSION

    It is localized corrosion which occurs


    within crevices and other shielded areas
    on metal surface exposed to corrosive
    environment.
    FORMS OF CORROSION

    PREVENTION
    1. Sound weld and complete penetration are
    necessary to avoid cavities and porosity.
    2. Close crevices in existing lap joints by
    continuous welding and caulking.
    3. Design vessels for complete drainage,
    avoid sharp corners & stagnant areas.
    FORMS OF CORROSION

    PREVENTION

    4. Provide uniform environment (e.g in case


    of back filling of piping trench)
    5. Weld instead of rolling tubes in tubes.
    FORMS OF CORROSION

    PITTING
    It is a form of extremely localized attack
    that results in holes in the metal
    A pit may be described as a cavity or hole
    with the surface diameter about the same
    as or less than the depth. Most pits
    develop and grow downwards from
    horizontal surface.
    FORMS OF CORROSION

    INTERGRANULAR CORROSION
    Localized corrosion at and near grain
    boundaries with relatively little corrosion
    of the grains.
    It may be caused by impurities at the grain
    boundaries, enrichment of one of the
    alloying elements or depletion of one of
    these elements in the grain boundary area.
    FORMS OF CORROSION

    EROSION CORROSION

    It is increase in the rate of deterioration or


    attack on metal because of relative
    movement between a corrosive fluid and
    the metal surface.
    FORMS OF CORROSION

    IMPORTANT FACTORS
    1. Surface Films
    2. Velocity
    3. Turbulence
    4. Impingement
    5. Cavitation Damage
    FORMS OF CORROSION

    CAVITATION
    Cavitation damage occurs due to corrosion and
    mechanical effect.
    1. A cavitation bubble forms on the protective film.
    2. The bubble collapses and destroys the film.
    3. The newly exposed metal surface corrodes, the
    film is reformed.
    FORMS OF CORROSION

    SELECTIVE LEACHING
    It is the removal of one element from a
    solid alloy by corrosion, e.G. Removal of
    zinc from brass and other alloy system in
    which aluminum, iron, chromium and
    other elements are removed.
    FORMS OF CORROSION

    FERTTIC CORROSION
    It is a special case of erosion corrosion which
    occurs in the atmosphere rather than aqueous
    condition.
    It occurs at contact areas between materials
    under load subjected to vibration and slip. It
    appears as pits or grooves in the metal
    surrounded by corrosion products.
    FORMS OF CORROSION

    STRESS CORROSION
    Stress corrosion cracking (SCC) refers to
    cracking caused by the simultaneous
    presence of tensile stress and a specific
    corrosion media.
    Both intergranular and transgranular
    cracking can occur.
    FORMS OF CORROSION

    PRINCIPAL FACTORS IN SCC


    1. Stress
    2. Environment
    3. Time
    4. Internal Structure of the Alloy
    HYDROGEN ATTACK

    Material failure by internal


    decarburization and consequent cracking
    is known as hydrogen attack.
    Hydrogen atom diffuses into metal wall
    and reacts with unstable carbides to form
    methane
    Fe3C + 4H CH4 +
    3Fe
    CORROSION PROBLEMS

    CORROSION PROBLEMS AT
    ARL
    HYDROGEN SULFIDE CORROSION

    Most of the sulfur components decompose


    or combine with hydrogen in various
    process atmospheres to form hydrogen
    sulfide.
    This hydrogen sulfide then react with iron
    to form iron sulfide.
    Fe + H2S FeS + H2
    HYDROGEN SULFIDE CORROSION

    Corrosion from sulfur compounds in crude


    units is an extremely complex problem.
    HYDROGEN SULFIDE CORROSION

    The principal variables in H2S corrosion are


    1. Material Composition
    2. Sulfur Contents of the Crude
    3. Vapor Content of Heated Crude
    4. Velocity
    5. Metal Temperature
    HYDROGEN SULFIDE CORROSION

    The sulfur present in crude is in a variety


    of forms, like:
    1. Elemental Sulfur
    2. Hydrogen Sulfide
    3. Aromatic Sulfur
    4. Poly Sulfides
    5. Mercaptans
    OVERHEAD CORROSION

    Formation of acids in the overhead system


    is major cause of corrosion.

    1. HCU O/H Corrosion


    2. HBU Reboiler Corrosion
    3. Reformer LSRN Corrosion
    LSRN COOLER (HT-E-004)
    SHELL
    HT-E-004 OUTLET NOZZLE
    FLANGE
    NAPHTHENIC ACID CORROSION

    Naphthenic acid corrosion increases when


    distillation temperature are 430-750 F.
    Below 450 f naphthenic acid corrosion of
    carbon steels, low alloy steels, and
    austenitic SS is of no concern
    SS-316L is used to counter naphthenic
    acid corrosion.
    CORROSION OF TANK BOTTOMS

    INTERNAL CORROSION
    Following factors contribute towards internal
    tank bottom corrosion
    1. Contents (Oil Type)
    2. Accumulated Water (PH, Cl, SO4)
    3. Deposits
    4. Material
    5. Damaged Coating
    HOLE IN THE BOTTOM
    PLATE OF TANK # 4A
    CORROSION OF TANK BOTTOMS

    EXTERNAL CORROSION
    Following factors contribute towards external
    tank bottom corrosion
    1. Underground Water Level
    2. Properties of Foundation Soil
    (Resistivity, Uniformity, PH, Cl, SO4)
    3. Temperature
    4. Water Infiltration.
    COOLING WATER CORROSION

    The problems suspected in an open


    recirculating cooling water system are

    1. Fouling and Biological Growth


    2. Under-Deposit Corrosion
    COOLING WATER CORROSION

    MECHANISM OF FOULING AND


    BIOLOGICAL GROWTH
    Living microorganisms are defined under
    slime.
    The slime is classified as
    1. Adhesion Type
    2. Accumulation Type
    COOLING WATER CORROSION

    SLIME ADHESION TYPE


    The problems caused by slime adhesion type are:
    1. Lowered efficiency of heat exchanger.
    2. Plugging of heat exchanger.
    3. Increased pump-pressure and lower flow
    rate.
    4. Accelerated under-deposit corrosion.
    5. Under utilization of water treatment
    chemicals.
    COOLING WATER CORROSION

    SLIME SLUDGE ACCUMULATION TYPE


    The problems caused by slime sludge
    accumulation type are:
    1. Accumulation of mud, dirt and sand.
    2. Adsorption of inorganic matter.
    3. Acceleration under deposit corrosion.
    4. Dirty appearance.
    COOLING WATER CORROSION

    UNDER-DEPOSIT CORROSION
    MECHANISM
    It is an electrochemical phenomenon. The
    oxidation-reduction reaction taking place
    are
    At anode
    Fe Fe+2 +2e
    COOLING WATER CORROSION

    UNDER-DEPOSIT CORROSION MECHANISM

    At cathode

    2e- + ½ O2 +H2O 2OH + 2H+

    2H+ + 2e- H2
    KEROSENE PRODUCT
    COOLER (HC-E-026)
    KEROSENE PRODUCT
    COOLER (HC-E-026)
    KEROSENE PRODUCT
    COOLER (HC-E-026)
    LDO COOLER (HC-E-017)
    ACTION PLAN
    1.COOLING WATER
    a. Installation of side stream filter for the
    control of total suspended solids.
    b. Desludging of cooling water basin.
    c. Addition of oil dispersant to cooling water
    system.
    d. Installation of dosing pump for precise
    injection of chemicals.
    e. Installation of corrosion probes
    ACTION PLAN

    2. TANK BOTTOMS
    a. Paint application method is changed
    from roller to airless spray gun.
    b.Surface preparation is improved.
    c. Berger paints are replaced with
    ICI paints.
    ACTION PLAN

    3. LSRN CORROSION

    a. Use of inhibitors.
    b. PH of tail water
    c. Chloride levels

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