CORROSION AND ITS PROTECTION IN OIL & GAS PRODUCTION

CORROSION IN OIL FILED : INTERNAL AND EXTERNAL THREATS

INTERNAL THREATS

CORROSION CAUSES
WELL TREATMENT INFLUENCED WATER CARRY OVER

UNDERDOSING DEMULSIFIER
INJECTION PUMP with LOW CAPACITY UNDERDOSING CORROSION INHIBITOR WATER SETTLE OUT

Typical E&P process conditions

Temperature Typical E&P process temperatures range from -100C to >200C Corrosion rates increase with temperature Pressure Pressure: up to 10,000psi Increase partial pressure of dissolved gases Flowrate & flow regime High-flow: erosion and corrosion-erosion. Low-flow or stagnant conditions promote bacteria
5

Internal corrosion
Hydrocarbon phase Not normally corrosive at temperatures experienced in production systems Corrosivity depends on extent and distribution of the aqueous and hydrocarbon phases. Aqueous phase Responsible for corrosion Corrosion exacerbated by acid gases & organic acids CO2, H2S and O2 are the most aggressive species Chlorides increase corrosion Generally, no water, no corrosion

Internal (process-side) damage mechanisms

H2S CO2 Solids & velocity effects Chlorides pitting, stress corrosion cracking Oxygen (crevice / under deposit / differential aeration) Galvanic corrosion Preferential weld corrosion (PWC) Microbially induced corrosion (MIC) Liquid metal embrittlement (LME) Chemicals

TYPICAL REACTIONS

Dissolved gas - effect on corrosion

Corroded seawater injection

25
Corrosion Rate of Carbon Steel

20 15 10 O2 CO2 H2S

5
0
O2 H2 S CO2 0 0 0 0 1 2 3 4 1 2 3 100 200 300 400 50 100 150 200 5 6 7 8 4 5 6 500 600 700 800 7 250 300 350 400

Dissolved Gas Concentration in Water Phase, ppm

There is no species more corrosive on a concentration basis than oxygen!

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H2S CORROSION

10

H2S corrosion metal loss

Formation of a thin protective FeS surface film often means general corrosion rates are low on steels Main risk is localised pitting corrosion where film is damaged Pitting will be galvanically driven

11

Wet H2S corrosion

H2S is soluble in water Produces a weak acid and lowers the pH H2S H+ + SH At low concentrations, H2S helps form protective FeS film Main risk is localised pitting corrosion which can be rapid H2S also poisons combination of atomic hydrogen into molecular hydrogen H+ + e- H H + H H2 Atomic hydrogen -

dangerous to steels!!

12

Cracking in sour service

H
2

H+ H

2+ Fe

S 2FeS Film Metal Matrix

Applied Stress
Higher Strength Steels YS > 500 MPa

No Applied Stress
Low Strength Steels YS < 550 MPa

H2

H H HH H

H2
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Sulphide stress cracking (SSC)

Key parameters: pH and pH2S Domain diagrams for carbon steel Material hardness High strength steels and areas of high hardness susceptible. Temperature Maximum susceptibility at low temperatures for carbon steels (1525C), higher for CRAs (5-70C). Stress Cracking promoted by high stress levels e.g. residual welding HAZ WELD HAZ

Hardness readings

14

Protection against SSC

Avoid wetness Minimise hardness Guidance on limits in ISO 15156 Optimise microstructure and minimise residual stresses Upgrade to CRAs Martensitic and duplex stainless steels have limited resistance H2S limits for duplex and superduplex steels are complex Function of temperature, pH, chlorides, pH2S Nickel-base alloys such as 625 and 825 have high resistance Testing: NACE TM0177

15

ISO 15156 SSC zones for carbon steel

Service Domain
0.0034bara 0.05psia

Max hardness (parent metal, HAZ, weld metal) No requirements 300HV 280HV 250HV root 275HV cap

0 1 2 3

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SSC limits for selected CRAs

Alloy 13% Cr martensitic pH2S limit (bara) 0.008

22% Cr duplex
25% Cr super-duplex Alloy 825 Alloy 625

0.10
0.25 No limit No limit

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HIC / SWC / blistering

Laminar cracking in plane of inclusions or blistering (HIC). Transverse cracking between laminar cracks on different planes (SWC).

Hydrogen blisters

Step-wise cracking

Blistering of CS plate
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Avoiding HIC / SWC

Avoid plate steels (rolled) otherwise qualify by HIC test Control impurities e.g. S, P Uniform microstructure Use internal coatings isolate steel from process fluid Testing: NACE TM0284

Banded

Uniform

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ISO 15156 (NACE MR0175)

ISO 15156 combination of NACE MR0175 and NACE testing requirements TM0177 & TM0284 European Federation of Corrosion Guidelines No.16 & 17 Part 1: General principles for selecting crack-resistant materials Part 2: Cracking resistant carbon & low-alloy steels & cast iron Part 3: Cracking resistant corrosion resistant alloys (CRAs) Covers all cracking mechanisms Goes beyond application of the 0.05 psia pH2S threshold for sour service It is the equipment users responsibility to select suitable materials HIC/SWC of flat rolled carbon steel products for environments containing even trace amounts of H2S to be evaluated BP ETP: GP 06-20 Materials for Sour Service

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Designing for H2S service

Materials requirements Reference ISO 15156 and GP 06-20 pH2S and pH Temperature Chlorides Hardness limits Welding QA/QC (HIC) Maintain hardness limits HIC testing for plate products

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CO2 CORROSION

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CO2 - containing environments

CO2 always present in produced fluids Corrosive to carbon steel when water present Most CRAs have good resistance to CO2 corrosion. Mechanism CO2 + H2O H2CO3 H2CO3 + e- HCO3- + H 2H H2 Fe Fe2+ + 2eFe + H2O + CO2 FeCO3 + H2

23

Types of CO2 damage

General & pitting corrosion

Mesa corrosion

Flow-assisted-corrosion (CO2)

Localised weld corrosion

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CO2 corrosion in a production flowline

6 CS production flowline (Magnus, 1983) 25mm thick, 90bar, 30C, 2%CO2

Heavily pitted pipe wall and welds (not necessarily uniform corrosion)
Didnt fail removed due to crevice corrosion of hub sealing faces
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Factors in CO2 corrosion

Main factors pCO2, temperature, velocity, pH - CO2 prediction model
For an ideal gas mixture, the partial pressure is the pressure exerted by one component if it alone occupied the volume. Total pressure is the sum of the partial pressures of each gas component in the mixture

Temperature, (C) 130 75 149

pCO2 (bar) 0.6 0.6 30

Carbon steel corrosion rate (mm/yr) 7 6 >50

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Effect of sand on CO2 corrosion

Produced sand can affect inhibitor efficiency Inhibitor adsorption loss Sand (and other solid) deposits give increased risk of localised corrosion; Prevent access of corrosion inhibitor to the metal Provide locations for bacteria proliferation Galvanic effects (area under deposit at more negative potential than area immediately adjacent to deposit) Formation of concentration cells/gradients

27

Mitigation of CO2 corrosion

Internal CO2 corrosion of carbon steel needs to be managed Usually mitigate by chemical inhibitors Simple geometries only (mainly pipelines) Assume inhibitor availability (90-95%) Inhibited corrosion rate of 0.1mm/year Remaining time at full predicted corrosion rate Apply a corrosion allowance for the design life If calculated corrosion allowance >8mm use CRAs

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CO2 corrosion inhibition

Filming type Retention time Continuous injection Adsorption onto clean surfaces

Clean steel

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CO2 + H2S corrosion metal loss

CO2/H2S > 500 500 > CO2/H2S > 20 20 > CO2/H2S > 0.05 CO2 dominates mixed CO2/H2S H2S dominates

H2S corrosion (CO2/H2S < 20) Initial corrosion rate high Protective FeS film quickly slows down corrosion to low level The corrosion rate is much less than the Cassandra prediction

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H2S + CO2 materials selection guide

Partial pressure CO2 (bar) Duplex SS 13% Cr SS

Nickel-based alloys

Carbon/low alloy steels

Partial pressure H2S (bar)

EROSION & EROSION-CORROSION

32

Flow regimes
Various multi-phase flow regimes possible;
erosion characteristics distribution of phases carrier phase for solids Flow regimes with particles in the gas show higher erosion rates than those with particles in the liquid phase.
Bubble (bubbly) flow

Liquid
Plug flow

Gas

Gas Liquid
Stratified flow

Gas Liquid
Wave (wavy) flow

Gas Liquid

Liquid

Gas
Slug flow

Annular flow

Churn flow

Mist (spray) flow

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Erosion & erosion-corrosion

Erosion Caused by high velocity impact & cutting action of liquid and/or solid particles Erosion failures can be rapid Erosion-corrosion Occurs in environments that are both erosive and corrosive. Erosion and corrosion can be independent or synergistic.

Erosion of tungsten carbide choke trim

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Typical vulnerable areas for erosion

Areas wherever flow is restricted or disturbed
T-pieces, bends, chokes, valves, weld beads

Areas exposed to excessive flow rates Sand washing

Trinidad

Washing infrequently allowing sand to accumulate High pressure drop during washing of separators

Sea water systems

High flow areas in water injection / cooling systems

Algeria (duplex)
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Erosion in piping
Sand accumulation
Build up of sand in a test separator

Pressure drop
Large pressure drop across sand drain pipework during washing

Rapid failure
Occurred within 2 minutes of opening the drain

Erosion at bend

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Erosion in a vessel
Sand allowed to accumulate in separator Wash nozzles embedded in sand PCV not working properly High pressure / flowrate Nozzle not erosion-resistant Erosion of wash nozzle Spray changed to a jet causing erosion of shell Local changes to operating procedures not communicated Frequency of sand washing Risk not captured or assessed in RBI

Water spray

Water jet

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Erosion of sandwash nozzle

Progressive nozzle damage

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Erosion-corrosion
Occurs in environments that can be erosive and corrosive. Erosion and corrosion can either be: independent of each other; wastage equals sum of individual wastage rates synergistic; wastage rate > sum of individual rates localised protective film breakdown at bends, elbows areas of turbulence

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Impingement

Water speed or local turbulence damages or removes protective film 90-10 Cu-Ni susceptible to internal erosion-corrosion (impingement) at velocities >3.5ms-1 Water-swept pits (horse-shoe shaped)
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Cavitation
Occurs at high fluid velocities Formation & collapse of vapour bubbles in liquid flow on metal surface. No solids required Typical locations
Pump impellers (rapid change in pressure which damages films) Stirrers, hydraulic propellers

Use erosion resistant materials

Stellite, tungsten carbide

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CORROSION IN SEAWATER

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Raw seawater
Composition of raw seawater varies around the world Temperature, pH, salinity, dissolved oxygen, marine life Very corrosive to unprotected carbon steel, other materials susceptible to pitting and crevice corrosion Select seawater resistant materials Super-duplex grades, 6Mo, CuNi, titanium Consider galvanic corrosion Most seawater resistant grades of stainless steel and Ni-Cr-Mo alloys are compatible with each other in seawater. Seawater can cause SCC of 300-series, duplex grades and 6Mo

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Pitting resistance of stainless steels

Pitting Resistance Equivalent Number (PREw) Formula for comparing relative pitting resistance Applicable to stainless steels & NiCr-Fe alloys Typically PREw 40 required for exposure to raw sea water <30C Alternatively, use titanium or GRE

Alloy 13Cr 316ss Alloy 825 22Cr duplex 25Cr super-duplex Alloy 625

PREw 13 23 28 33 40 46

PREw = %Cr + 3.3x (%Mo + 0.5%W) + 16%N

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Internal & external pitting

Internal pitting

Section of 3 316L pipe fitting Failed due to internal corrosion (pinhole leak) Poor hydrotest practice - seawater left within spool
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Failure of a seawater pump cooling coil

Indication on coil

External surface of coil

Internal surface of coil

316 SS coil, raw seawater service, hypochlorite added Shellside: lube oil up to 50C Tubeside: seawater inlet ~6C, return ~18C Failed due to localised internal pitting 316 SS has low PREw Material upgrade required
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Oxygen - concentration cells

Crevice corrosion O2 is consumed in the crevice and becomes the anode pH decreases in the crevice increasing attack Differential aeration cells Air/water interfaces with attack below the water line e.g. splash zone Pipelines in soils containing different amounts of oxygen Under deposit corrosion Deposits of scale, sand or sludge Produces differential concentration SRBs thrive - H2S pitting
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Crevice corrosion under baffle

Galvanic corrosion
Three conditions are required for galvanic corrosion; A conducting electrolyte (typically seawater). Two different metals in contact with the electrolyte. An electrical connection between the two metals. Relative positions within the electrochemical series (for given electrolyte) provides driving potential and affects rate. Corrosion of base metal (anode) stimulated by contact with noble metal (cathode). Relative area of anode and cathode can significantly affect corrosion rate. Higher conductivity increases corrosion e.g. presence of salts

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Galvanic corrosion firewater piping

Firewater CuNi / super duplex stainless steel connections. 4CuNi pipe with a 550mm isolation spool (i.e. 5x OD) Leaks experienced on CuNi spools at welds Same problems with CuNi / 6Mo

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Galvanic corrosion - seal rings

ETAP platform Techlok joints in a firewater piping system Piping: super-duplex Seal rings: 17-4PH

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Dealloying of brass
Brass tubesheet in seawater service Brass is Cu-Zn alloy Cu is more noble than Zn Zn dissolves preferentially leaving Cu behind Result Loss of strength Difficult to seal Remedy Add arsenic to the brass

51

Mitigation of galvanic corrosion

Avoid dissimilar materials in seawater system designs MoC for later changes Avoid small anode/large cathode Avoid graphite gaskets & seals Avoid connecting carbon steel to titanium alloys Galvanic corrosion or hydrogen charging of titanium may occur Electrical isolation between different alloy classes Install distance spools, separation of at least 20x pipe diameters Solid non-conducting spool e.g. GRP Line the noble metal internally with an electrically nonconducting material e.g. rubber Apply a non-conducting internal coating on the more noble material. Extend coating for 20 pipe diameters.

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Example : CuNi-Super duplex

Distance spool: solid, non-conducting material e.g. GRP

Distance spool: noble metal internally lined with an electrically non-conducting material such as rubber

Apply a non-conducting internal coating on the more noble material.

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Cathodic protection (CP) what is it?

By connecting an external anode to the component to be protected and passing a dc current, it becomes cathodic and does not corrode. External anode may be a galvanic (sacrificial) anode, the current is the result of the potential difference between the two metals External anode may be an impressed current anode, current is supplied from an external dc power source. CP is mostly applied to coated, immersed and buried structures The coating is the primary protection, acting as a barrier between the metal and the environment CP protects steel at coating defects Coating + CP is most practical and economic protection system. Primary principle in GP 06-31

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Cathodic protection how does it work?

CP works by making the component to be protected the cathode in an electrolytic cell When two metals are connected in an electrolyte, electrons flow from the anode to the cathode due difference in the electrical potential
ANODIC

Magnesium Zinc Aluminium Iron (steel) Copper Stainless steels Titanium Graphite
CATHODIC

Corrosion of steel by copper plating

Cathodic protection of steel by zinc plating

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Galvanic (sacrificial) CP
Aluminium anodes: require alloy additions to become active e.g. Zn + In, high efficiency (>90%). Typically used in seawater applications. Zinc anodes: ambient applications only. Alloyed with Al or Cd to improve efficiency. Typically used on coated pipelines in seawater Magnesium anodes: large driving potential, alloyed with e.g. Al or Zn to reduce rapid activation, limited efficiency (50-60%) Used in soils and other high-resistance environments (risk of over-protection/rapid consumption in seawater).

Sacrificial anodes, new and wasted (therefore working!)

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Applications of internal CP
Anodes in shell & tube seawater cooler water boxes

Oil storage tanks (in water bottom) Water tanks

Stainless steel piping systems in warm/hot chlorinated seawater. To avoid high anode consumption rates, resistor controlled CP (RCP) systems should be considered. E.g. RCP + 25Cr super duplex piping instead of titanium or other higher-alloy CRA.

Used on Greater Plutonio

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Chloride stress corrosion cracking (SCC)

Susceptibility varies considerably (no absolutes); Material grade, strength, residual stress, chlorides, oxygen and temperature 300-series austenitic stainless steels susceptible to at temps >50C Highly-alloyed austenitic and duplex SS have improved resistance Nickel-base alloys with Ni 42% are highly resistant, e.g. 825

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Chloride SCC (22Cr duplex vessel drain)

22Cr duplex drain ex-production separator

heat-traced to 60C (vessel temp up to 105C) Internal chloride SCC (cracking in parent metal, HAZ and weld metal) Contributory factors: Susceptible material Local stress concentration (weld toe and lack of support) Environment (elevated temperature, chlorides).
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Water injection systems (deaerated)

Oxygen: Trace amounts corrosive to carbon steel. As a guide: <20ppb O2 maintains general corrosion rates <0.25mm/yr Stricter limits often applied e.g. <10ppb if 13Cr completions Microbial-induced Corrosion, MIC SRB require anaerobic conditions deaerated water conditions within and under biofilms SRB use sulphate in water in their metabolisms to generate H2S Fluid Velocity: Areas of high fluid velocity or turbulence and O2 O2 from poor deaeration or air ingress susceptible areas include pump discharge piping, bends tees and reducers.

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Mitigation & monitoring

Deaeration and supplementary O2 scavenging Monitor O2 concentrations on-line (orbisphere) or colorimetric analysis Maintain oxygen scavenger residual to mop-up oxygen spikes. Chlorination u/s of deaerator, biocide applied into or d/s of deaerator Effective biociding based on; Type, frequency, dosage, duration Bacterial monitoring (sidestreams, scrapings or bioprobes) Corrosion monitoring

Leaking deaerator

Seawater injection tubing

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Preferential weld corrosion (PWC)

The selective corrosion of weld zones (WM/HAZ) Relevant factors include; Electrochemical properties of the materials and any corrosion cell forming around the weld joint Water phase liquid film thickness and conductivity Temperature and tendency to form protective scale Corrosion inhibitor effectiveness, (film formation, composition) Weld joint metallurgy Flow pattern and flow induced shear stress PWC rate of attack can be high, up to 12mm/yr observed

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Preferential weld corrosion (1%Ni)

Water Injection: 1% Ni-containing welds beneficial for avoiding PWC in WI systems. Weld cathodic to parent metal, protected by large area of parent metal. Wet hydrocarbon service: Lower conductivity, no benefit of selecting cathodic weld metal Reliant on intrinsic corrosion resistance of the weld metal Require corrosion inhibitor for protection (test against WM and PM) Attack of weld metal promoted by under-dosing of inhibitor (WM needs more inhibitor than PM)

Welds exposed to hydrocarbon service

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Lomond drains - PWC

TEG contactor scrubber drain pipework (hydrocarbon) Carbon steel parent metal ~2%Ni deposited in weld metal Groove along 6 oclock position Accelerated corrosion at the weld Large number of isolations, extensive inspection and repair

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MIC & DEADLEG CORROSION

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Microbially induced corrosion (MIC)

Anaerobic environments often support development of biofilms. Sulphate reducing bacteria (SRB) thrive in anaerobic conditions SRB biofilms generate H2S FeS corrosion product cathodic to bare steel, increasing corrosion rate. MIC of carbon steel usually localized pitting under biofilm. Corrosion rates of 5-10 mm/yr seen CRAs also susceptible

66

Bacterial growth factors

pH MIC growth in pH 5-9.5 range Temperature SRB can grow in temps of 5100C. Optimum temp <45C. Sulphates Necessary for SRB activity. Growth restricted if <10 ppm Carbon source SRB growth restricted if organic carbon (volatile fatty acids) not available (<20ppm) Nitrogen Important but at levels which are difficult to detect Flow Highest corrosion rates in stagnant conditions. Biofilms unstable at high flows.

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Deadlegs types & locations

A deadleg is a section of pipework or vessel which contains hydrocarbon fluids and/or water under stagnant conditions (permanent or intermittent) or where there is no measurable flow. Permanent or physical deadlegs (long term stagnation by design) Operational deadlegs (stagnant for operational reasons) Unprotected mothballed items (plus those temporarily out of service)

68

Examples of deadlegs

69

Deadlegs assessment factors

Consequence of failure Location of pipework Nutrients replenished by regularly opening /closing valves? Is draining of pipework possible? Is removal of deadleg possible? Presence of SRBs, deposits, biocide? Material of construction Wall thickness Fluid type (aqueous phase, sulphates, nutrients, oxygen ingress) Temperature Stagnant permanent/intermittent Prior history of corrosion

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Example of deadleg corrosion

Pin Hole leaks Releasing water

Crude oil recycle cooler bypass Scale-inhibited seawater left in line after leak test (of u/s valve) Severe corrosion rate at and around pinhole. Fortunately, a leak of water not crude. Two week shutdown
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Root causes
North

Failure to identify the bypass line as an operational deadleg No deadleg register Failure to recognise introduction of new corrosion hazard No mitigation measures.
Photo1

250mm

80mm

Area of internal corrosion 4.2 mm tapering out to average wall thickness of 10.0 mm

30mm 110mm

Area of internal corrosion reading from 3.5 mm tapering out to average of 10.7mm

VIEW LOOKING WEST

Corroded area approx 80mm x 110mm.

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Mitigation & inspection

Flush system of deposits and treat with biocide, nitrate Out of service items Biocide treat or mothball procedure Use treated water Hydrotest & washing Profile radiography or UT scanning low points, bottom of vertical sections etc. Lowest parts of vessel bridle together with any associated level gauges.

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OTHER CORROSION MECHANISMS

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Corrosion due to chemicals

Chemicals can be corrosive Carbon steel OK for non-corrosive chemical piping, e.g. methanol Corrosive chemicals (e.g. concentrated solutions of inhibitors and biocides) require CRAs vendor will specify
316 SS is typical

Notable exceptions:
Hypochlorite: very corrosive, titanium or GRP piping required Avoid titanium alloys in dry methanol service due SCC

SCC of a titanium seal exposed to pure methanol instead of 5% water content

75

Corrosion due to chemicals

Carbon steel open drain pipework. Seepage of scale inhibitor (passing valve) Scale inhibitor pH <2. Chemical entered drains, not flushed

76

Injection point issues

Inadequate mixing corrosion Intermittent use switch off when not flowing Areas affected Impingement / turbulent areas Bends and low points Use quill/other mixer Upgrade material Thicker schedule Valve arrangement Make self-draining Enable quill removal
Main Flow

Injected Fluid

Impingement

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High temperature corrosion

Environments less common in E&P Flare tips, fired heaters, boilers Oxidation Oxidation significant >530C Oxidation rate varies with temp, gas composition and alloy Cr content Firetubes: usually CS, but Cr-Mo alloys needed for high temps Flare tips: 310 SS, alloy 800H Other high temperature mechanisms sulphidation (H2S and SO2) carburizing, metal dusting, hot salt thermal fatigue and creep

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Amine stress corrosion cracking

Material: carbon/low-alloy steels Environment: aqueous amine systems Cracking due to residual stresses at/next to non-PWHTd weldments Cracking develops parallel to the weld Mitigation: PWHT all CS welds including repair and internal/external attachment welds. Use solid/clad stainless steel 304 SS or 316 SS

Intergranular cracking

Amine piping welds require PWHT to avoid SCC

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Corrosion in glycol system

Glycol usually regarded as benign Corrosion in glycol regeneration systems usually due to; Acid gases absorbed by rich glycol or Organic acids from oxidation of glycol and thermal decomposition products Condensation of low pH water giving carbonic acid attack. Risk recognised in design On-skid: CRA piping & clad vessels However, off-skid piping mix of regular CS and LTCS

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Corrosion fatigue
Combined action of cyclic tensile stress and a corrosive environment Fatigue is caused by cyclic stressing below the yield stress Cracks start at stress raisers Can occur due to vibration e.g. smallbore nozzles & with heavy valve attachments Presence of corrosive environment exacerbates the problem Can lead to pitting, which acts as stress concentrators

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Example of corrosion fatigue

2 A106 GrB carbon steel piping Wet gas service, 1.2%CO2 and 160ppm H2S Operating @ 120C and 70bar Elbow exposed to vibration (used in a gas compression train) Crack located at 12 o'clock position Crack initiated internally

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EXTERNAL CORROSION SURFACE FACILITIES

83

External corrosion
External corrosion of unprotected steel surfaces External corrosion of coated surfaces Corrosion under insulation (CUI) Corrosion under fireproofing (CUF) Pitting & crevice Corrosion Environmental cracking

84

Where does it occur?

Bare steel surfaces At locations of coating breakdown Under deposits such as dirt, adhesive tape or nameplates Mating faces between pipe/pipe support saddles & clamps Isolated equipment not maintained or adequately mothballed Water sources include: sea spray and green water (FPSO or semi-sub) rain deluge water leaking process water condensation downwind of cooling towers.

85

What does it look like?

Damage can be extensive or localised. Corrosion can be general attack, pitting or cracking. Seen as flaking, cracking, and blistering of coating with corrosion of the substrate.

86

Appearance
Carbon/low alloy steels usually covered in compact scale/thick scab Stainless steels have light stains on the surface possibly with stained water droplets and / or salts. Corroding copper alloys covered in blue/green corrosion products.

87

Piping, supports & clamps

88

Not just carbon steel

25Cr super-duplex (PREN 40) Seawater service 12 months exposure in tropical climate External corrosion along welds Poor quality fabrication

89

Corrosion of bolts and fasteners

Bolted joints Onshore and offshore: exposed to frequent wetting Low alloy bolts General or localised corrosion Galvanic corrosion in stainless steel flanges CRA bolts susceptible to pitting and/or SCC Crevice corrosion under bolt heads and nuts Hydrogen embrittlement possible Fatigue

90

Corrosion of bolts and fasteners

General corrosion

Galvanic corrosion

Crevice corrosion

Stress corrosion cracking

91

Flanged connections
Corrosion General surface corrosion Galvanic corrosion e.g. 316 SS / carbon steel Use of graphite gaskets Potential problems Failure of flanged connection due to corroded fasteners Joint leak Corrective actions Change gasket/fastener materials Replace graphite gaskets with nonasbestos or rubber material

92

Corroded fasteners (seawater service)

Location of graphite gaskets

93

Structures / valves
Valves Valve handles Chain-wheels Valve body Structures Stairways and walkways Gratings, ladders, handrails Cable trays and unistruts Threaded plugs Valve bodies, xmas trees, piping Dissimilar metals

94

Coating damage and breakdown

Deterioration of coating with time All paints let water through - continuously wet areas will fail Poor original surface preparation / paint application Mechanical damage Small area of damage can lead to major corrosion

95

External cathodic protection

Types of structures with external CP
Buried pipelines / structures / piping / tanks Floors of above-ground storage tanks Submerged jetty structures

Factors affecting corrosion

Extent of wetness Oxygen depends on depth Resistivity of soil & presence of salts Equipment temperature

96

Impressed current CP
Adjustable dc source Negative terminal connected to the steel structure Positive terminal connected to the anodes Typically used on larger structures where galvanic anodes cannot economically deliver enough current.

97

Corrosion under insulation (CUI) and Corrosion under fireproofing (CUF)

CUI Water seeps into insulation and becomes trapped, results in wetting and corrosion of the metal Carbon steel corrodes in the presence of water due to the availability of oxygen. CUF Same mechanism except water gets behind the fireproofing.

98

Insulation
Typical insulation types; Process Personnel protection (PP) Winterisation Acoustic Challenge the need Remove unnecessary insulation Replace PP with cages

Mitred joint

Lobster-back joint

Pre-formed bends

99

CUI incident
4 gas compression recycle line Operating pressure, 35bar 3 bar pressure surge Temperature: 50C 6.02mm nominal WT Rockwool insulation Extensive corrosion rupture Unusual, burst rather than leaked

100

CUI gas leak

2 fuel gas piping outside edge of platform - exposed CS, heat-traced, Rockwool Operating @ 5bar, 45C, 5.4mm NWT Failed during plant start-up External corrosion scale, CUI Focus on internal corrosion Previous survey found defect in an adjacent line. Failed line in survey but not failed area. Features selected from onshore not site survey

101

piping CUI
4 CS hydrocarbon line 55C, inlet to PSV (153 bar) Thermally-sprayed aluminium (TSA) CUI found, radiographed ok to refurbish. Found during needle-gunning (paint removal)

Max pit depth 10mm

Insulation permanently removed

102

CUI on pressure vessel

CS offshore vessel Operating at 85C and 11 bar PFP coating (passive fire protection) Extensive corrosion scabbing on both sides of vessel. Scaling runs in two horizontal distinct lines along each side. Scaling directly above lower seam of insulation location of water retention.

400x300x30mm

400x100x25mm

103

External pitting & crevice corrosion

Stainless steels in marine environments (chlorides, O2) 316L stainless steel commonly used for instrument tubing Particularly susceptible at supports and fittings. Primary mitigation is materials selection (higher PREw) Tungum, 6Mo, super-duplex Alternative mitigation methods (coating, cleaning), not easy or practical.

104

Instrument tubing (316 SS and super-duplex)

316 SS tubing super-duplex tubing

316 SS (pitting/crevice corrosion)

super-duplex (no pitting)

105

Crevice corrosion under clamps/supports

Pitting and crevice corrosion of 316ss piping Clamps Plastic retaining blocks

106

External chloride stress corrosion cracking

Mechanism same as internal chloride SCC however: Numerous variables influence susceptibility therefore guidance differs Material, stress, chlorides, oxygen and temperature No absolute guidance available, seek expert advice

Chloride SCC is characterised by transgranular crack paths

107

External stress corrosion cracking

UK HSE: Coat 22Cr duplex >80C NORSOK M-001 SCC temp limits: 22Cr duplex >100C 25Cr super-duplex >110C Recent testing has shown failures at 80C now recommend 70C as limit Reliant on external coatings to act as barrier (isolate from environment) Beware solar heating - can raise external temperature above threshold limits! SCC failure of 316L

108