Professional Documents
Culture Documents
By
Chem./ M.MOSTAFA
1
BASICS OF CORROSION
Corrosion of Metals
2
BASICS OF CORROSION
Corrosion of Metals
Wet Dry
3
BASICS OF CORROSION
Dry Corrosion
Direct chemical reaction between metal and environment
Occurs at high temperatures > 200 oC ; e.g.
Environment
5
BASICS OF CORROSION
i.e.
6
BASICS OF CORROSION
7
BASICS OF CORROSION
The extracted free metal has a high energy content. i.e. active state
8
BASICS OF CORROSION
9
BASICS OF CORROSION
Corrosion
Thermodynamic Cycle
Iron oxides
Oxides, Ore thermodynamically stable
+
Mining &
Extraction
Corrosion
Equipment fabrication,
thermodynamically unstable
Iron oxides
10
BASICS OF CORROSION
Thermodynamics of
Thermodynamics ofCorrosion
Corrosion
In a chemical reaction :
Reactants Products
∆G = Gprod – Greact
Reactant
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
13
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+ + ne-
As a result, metal loss occurs, i.e. metal dissolution
OILRIG
Oxidation Is Loss of electrons
Reduction Is Gain of electrons
14
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
15
THEORY OF CORROSION
Corrosion Process
16
THEORY OF CORROSION
Corrosion Process
A. Anodic Reaction (metal dissolution)
Fe Fe 2+ + 2e-
B. Cathodic Reaction
1. Oxygen reduction reaction
Predominates in aerated
Near-Neutral solutions pH > 5
17
THEORY OF CORROSION
B. Cathodic Reaction
2. Hydrogen evolution reaction
2H+ + 2e- 2H (adsorbed) H2 (gas)
Predominates in acid solutions pH < 5
18
THEORY OF CORROSION
2H++2e 2H H2
In conclusion:
Anode
Cathode
Electrical connection
19
THEORY OF CORROSION
In a corrosion cell:
20
THEORY OF CORROSION
21
THEORY OF CORROSION
Factors of Corrosion
1- Water
2- Oxygen
3- Acidity
22
THEORY OF CORROSION
Testimony
Fe
23
THEORY OF CORROSION
Corrosion Rate
The rate at which metal loss occurs due to corrosion is
expressed in terms of:
24
THEORY OF CORROSION
1-5 Moderate
5-10 Severe
>10 Intense
25
FORMS OF CORROSION
Types of Corrosion:
1. Localized Corrosion
Galvanic Corrosion
26
FORMS OF CORROSION
27
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, so:
Hence,
Anodic current density ( ia) = Cathodic current density ( ic)
The anode sites are being very small compared with the large cathode:
Anodic current ( Ia) = Cathodic current ( Ic) , and
29
FORMS OF CORROSION
Pitting corrosion
30
FORMS OF CORROSION
Pitting corrosion
31
FORMS OF CORROSION
Pitting corrosion
Pitting corrosion
33
-
Cl Cl -
Cl
-
-
Cl -
Cl
-
Cl -
-
Cl -
Cl
Cl
-
Cl -
Cl
-
Cl -
Cl
-
Cl O2
O2 Cl-Cl - -
Cl
-
Cl
Cl - -
Cl
-
Cl -
Cl -
Cl
Cl Cl
-
- -
Cl
-
OH
-
OH
Pitting corrosion
35
FORMS OF CORROSION
Crevice corrosion
36
FORMS OF CORROSION
37
FORMS OF CORROSION
Pitting corrosion on
free surface
Crevice corrosion
under washers
38
FORMS OF CORROSION
combination of both
39
FORMS OF CORROSION
Stress
In Air
In Environment
Strain
40
FORMS OF CORROSION
Stress Corrosion Cracking (SCC)
@
@Cathodes
Cathodes::
PhPh
PhPh++OH
OH-
-
Iron nails
Pink
PinkColor
Color
@
@Anodes
Anodes::
H.C.I.
H.C.I.++Fe
2+
Fe2+
Sites of Stress =
Sites of stress
Anodic Sites
Prussian
PrussianBlue
Blue 41
FORMS OF CORROSION
42
Stress Corrosion Cracking
43
FORMS OF CORROSION
Stress Corrosion Cracking
The crack is initiated at a pit or a crevice located within a stressed area
S2- Cl-
Along the grain boundaries
( in between the grains )
i.e. Intergranular Cracking
e.g. Chloride stress cracking
44
FORMS OF CORROSION
Transgranular SC
Intergranular SC
45
FORMS OF CORROSION
Hydrogen Damage
Hydrogen Blistering
Surface bulges, resulting from subsurface
voids produced in a metal by hydrogen
Grain Boundaries
absorption in (usually) low-strength alloys.
46
FORMS OF CORROSION
H+ H+
H H2 H H H H H
e
-
-
e H2
H2
47
FORMS OF CORROSION
Hydrogen Blistering
48
FORMS OF CORROSION
Hydrogen Embrittlement
49
FORMS OF CORROSION
Galvanic Corrosion
50
FORMS OF CORROSION
Nobel (+)
GALVANIC SERIES
OF METALS
Active (-)
51
FORMS OF CORROSION
Galvanic Corrosion
52
FORMS OF CORROSION
53
FORMS OF CORROSION
e e
V
54
FORMS OF CORROSION
Galvanic Corrosion
Carbon steel Inconel ring
Cu
Al
55
FORMS OF CORROSION
Stainless
Steel Valve
Carbon Steel
SS CS
56
FORMS OF CORROSION
X Carbon Steel
Valve
Stainless Steel
CS SS
57
FORMS OF CORROSION
Surface area effect in galvanic corrosion
Galvanic Corrosion
SS
59
CORROSION CONTROL
Corrosion Control
60
Corrosion Control Techniques
1. Materials Selection
1. Improved design
1. Chemical Treatment
1. Protective Coatings
1. Cathodic Protection
61
Corrosion Control Techniques
1. Materials Selection
A. Information needs
Process flow diagrams (PFD) showing design/ operating/
upset conditions of:
• Temperature (min. & max.)
• Pressure
Stream chemical analyses showing the corrosive
constituents and their concentrations:
• H2O
• Dissolved gases (O2, CO2, H2S)
• Cl-
• TDS (total dissolved salts)
• pH
• TAN (total acid number ) for crude oil
• Total Sulfur Content
62
Corrosion Control Techniques
1. Materials Selection
63
Corrosion Control Techniques
1. Materials Selection
<3 Non-corrosive
3-30 May indicate corrosion
>30 Indicates corrosion
64
Corrosion Control Techniques
1. Materials Selection
PREDICTING CO2 CORROSION
65
Corrosion Control Techniques
1. Materials Selection
66
Corrosion Control Techniques
1. Materials Selection
Stream Velocity
Corrosion rate and corrosion type are function of flow
velocity
CORROSION RATE
Corrosion Rate
68
Corrosion Control Techniques
1. Materials Selection
Stream Velocity
69
Corrosion Control Techniques
1. Materials Selection
Stream Velocity
70
Corrosion Control Techniques
1. Materials Selection
Cost Effectiveness
Mechanical
Properties
Availability
71
Corrosion Control Techniques
1. Materials Selection
Engineering Materials
Metallic Non-Metallic
PVC
Ferrous Non-Ferrous
Polyethylene
Copper Alloys Polypropylene
Cast Irons
Nickel Alloys Teflon
Carbon Steels
Aluminum GRE / GRP
Stainless Steels
Ceramics
72
Corrosion Control Techniques
1. Materials Selection
73
Corrosion Control Techniques
1. Materials Selection
Above-ground interconnecting
Under-ground GRP GRP piping
pipeline GRP piping
74
Corrosion Control Techniques
1. Materials Selection
75
Corrosion Control Techniques
1. Materials Selection
76
Corrosion Control Techniques
1. Materials Selection
Limitations of Non-metallics :
77
Corrosion Control Techniques
1. Materials Selection
78
Corrosion Control Techniques
1. Materials Selection
Cost of Material
79
Corrosion Control Techniques
1. Materials Selection
CLADDING
80
Corrosion Control Techniques
2. Improved Design
Examples of
Impingement Corrosion
81
Corrosion Control Techniques
2. Improved Design
Examples of avoiding
impingement corrosion
by design
82
Corrosion Control Techniques
2. Improved Design
Examples of avoiding
crevice corrosion by Good
design
Bad
83
Corrosion Control Techniques
2. Improved Design
Examples of avoiding
crevice corrosion by Improper Weldments
design
Proper Weldment
84
Corrosion Control Techniques
2. Improved Design
t (required) = t min + CA
85
Corrosion Control Techniques
2. Improved Design
86
Corrosion Control Techniques
2. Improved Design
Avoiding contact
between dissimilar
metals
Nobel
Active
87
Corrosion Control Techniques
3. Chemical Treatment
Types of Treatment :
Neutralization ( pH control )
Removal of dissolved gases ( scavengers )
Corrosion inhibitors
Biocides
88
Corrosion Control Techniques
3. Chemical Treatment
A. pH Control
89
Corrosion Control Techniques
3. Chemical Treatment
A. pH Control
Steel corrosion rate related to
hydrogen ion concentration in electrolyte
90
Corrosion Control Techniques
91
Corrosion Control Techniques
92
Corrosion Control Techniques
93
Corrosion Control Techniques
Process
Flow
94
Corrosion Control Techniques
95
Corrosion Control Techniques
96
Corrosion Control Techniques
3. Chemical Treatment
97
Corrosion Control Techniques
3. Chemical Treatment
98
Corrosion Control Techniques
3. Chemical Treatment
C. Corrosion Inhibitors
NACE definition :
“ Chemicals which reduce the corrosion rate when added
to a normally corrosive medium in small concentrations.”
metal
environmental chemical composition
service condition (e.g. temperature, flow rate)
99
Corrosion Control Techniques
3. Chemical Treatment
- Oil refineries
- Petrochemical plants
- Oil and gas production
- Desalination plants
- Cooling water installations
- storage facilities
- Hydro tests
A Cooling Tower Unit
100
Corrosion Control Techniques
3. Chemical Treatment
Classification of Inhibitors:
pH < 5
pH 5 – 10
101
Corrosion Control Techniques
3. Chemical Treatment
A. Inhibitors for Acid media
102
Corrosion Control Techniques
3. Chemical Treatment
Mechanism:
1) Formation of physical
barrier, thus blocking the
reaction sites (anode and
cathode sites).
103
Corrosion Control Techniques
3. Chemical Treatment
B. Inhibitors for Near Neutral Media
Anodic
Cathodic, or
104
Corrosion Control Techniques
3. Chemical Treatment
Inhibitors for Near Neutral Media
Safe or Dangerous
105
Corrosion Control Techniques
3. Chemical Treatment
Anodic Inhibitors
Zn 2+ + 2 OH- Zn (OH)2
Scale on cathode
at cathode
Ca 2+ + 2 OH- Ca (OH) 2
Scale on cathode
at cathode
107
Corrosion Control Techniques
3. Chemical Treatment
Mixed Inhibitors
Compatible mixture
108
Corrosion Control Techniques
3. Chemical Treatment
Efficiency of inhibitors :
Expressed as :
Protective Power ( Z)
where,
Z = [(RO-R) / RO] X 100
109
Corrosion Control Techniques
3. Chemical Treatment
Corrosion rate
Minimum Inhibitive
Concentration
Corrosion inhibitor
concentration
110
Corrosion Control Techniques
3. Chemical Treatment
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 micro-
organisms
111
Corrosion Control Techniques
3. Chemical Treatment
112
Corrosion Control Techniques
3. Chemical Treatment
113
Corrosion Control Techniques
3. Chemical Treatment
114
Corrosion Control Techniques
3. Chemical Treatment
115
Corrosion Control Techniques
3. Chemical Treatment
116
Corrosion Control Techniques
3. Chemical Treatment
117
Corrosion Control Techniques
3. Chemical Treatment
EXCHANGER
PERFORMANCE
118
Corrosion Control Techniques
3. Chemical Treatment
Chemical Injection
119
Corrosion Control Techniques
3. Chemical Treatment
Chemical Injection
High Alloy
Quell
120
Corrosion Control Techniques
3. Chemical Treatment
Chemical Injection
121
Corrosion Control Techniques
3. Chemical Treatment
Treatment
reserve Waste of Chemicals X
Ideal
No Protection
Time
BAD CONTROL
122
Corrosion Control Techniques
3. Chemical Treatment
Ideal
Time
GOOD CONTROL
123
Corrosion Control Techniques
4. Protective Coatings
Definition of a
124
Corrosion Control Techniques
4. Protective Coatings
Paints
Definition :
125
Corrosion Control Techniques
4. Protective Coatings
Criteria :
• Surface Cleanliness
Surface Roughness
126
Corrosion Control Techniques
4. Protective Coatings
Surface Cleaning
127
Corrosion Control Techniques
4. Protective Coatings
Surface Preparation
Surface Cleanliness
Done by :
Water jetting
Abrasive blasting ( provides surface roughness )
Sand blasting
Grit blasting
128
Corrosion Control Techniques
4. Protective Coatings
Surface Cleaning
Water Jetting
129
Corrosion Control Techniques
4. Protective Coatings
Abrasive Blasting
Sand blasting
Sand Blasting
Provides reasonable surface
roughness
130
Corrosion Control Techniques
4. Protective Coatings
Abrasive Blasting
Grit / Shot blasting
Grit Shot
Recommended as it does not cause
air pollution
Recyclable
131
Corrosion Control Techniques
4. Protective Coatings
Abrasive blasting
nozzles
Abrasive blasting
for pipe internal
Abrasive blasting
pot
132
Corrosion Control Techniques
4. Protective Coatings
Surface Profile
133
Corrosion Control Techniques
4. Protective Coatings
Surface Profile
3 parameters are important to obtain acceptable surface profile:
1- Peak to valley depth
135
Corrosion Control Techniques
4. Protective Coatings
136
Corrosion Control Techniques
4. Protective Coatings
Types of Coatings
137
Corrosion Control Techniques
4. Protective Coatings
Primary Components :
Resin ( binder / vehicle / base )
Hardener ( curing agent )
Solvent ( thinner )
Secondary Components :
Color Pigments
Cementing Particles
Corrosion Inhibitors
138
Corrosion Control Techniques
4. Protective Coatings
Classification of Paints
Chemically drying paints:
140
Corrosion Control Techniques
4. Protective Coatings
Classification of Paints
142
Corrosion Control Techniques
4. Protective Coatings
143
Corrosion Control Techniques
4. Protective Coatings
144
Corrosion Control Techniques
5. Protective Coatings
Painting Application
145
Corrosion Control Techniques
5. Protective Coatings
Brush
Roller
Spraying :
Air Spray
Airless Spray
Electrostatic Spray
146
Corrosion Control Techniques
5. Protective Coatings
Brush:
Very effective
Very slow
Used for small objects and touch-ups
Roller:
Ineffective
Porous film
Slow
Used for gates and fences
147
Corrosion Control Techniques
5. Protective Coatings
Fan
Spraying = Atomization
148
Corrosion Control Techniques
5. Protective Coatings
Spraying
Fast
Very effective
Uniform film
Requires skillful operators
Most commonly used method
20% approx. loss is expected
149
Corrosion Control Techniques
5. Protective Coatings
Air Spray :
Atomization of paint is assisted by air
150
Corrosion Control Techniques
5. Protective Coatings
Airless Spray :
Suitable for metal-containing paints
Requires high pressure pumps
Atomization is due to ∆P
151
Corrosion Control Techniques
5. Protective Coatings
Electrostatic Spray :
Needs DC power supply between
spray gun & work piece
Paint loss down to ~ 2%
Excellent uniform appearance
Most expensive
152
Corrosion Control Techniques
5. Protective Coatings
Electrostatic Spray :
153
Corrosion Control Techniques
5. Protective Coatings
Painting System ( Cycle )
The 3-layer paint system :
Primer :1st layer
provides corrosion protection
provides adhesion to metal surface
154
Corrosion Control Techniques
5. Protective Coatings
Typical 3-Layer Painting System :
For internal surfaces, No need for neither top coat Nor color
code. Use extra thicker inter-coat instead
155
Corrosion Control Techniques
5. Protective Coatings
3-Layer System
Polyethylene
Or
Polypropylene
2-3 mm thick
156
Corrosion Control Techniques
5. Protective Coatings
Typical Steps of 3-Layer Pipeline Coating
3
2
1
2 Copolymer Adhesive
3 Polyethylene ( PE ) or Polypropylene ( PP )
157
Corrosion Control Techniques
5. Protective Coatings
Typical Steps of 3-Layer Pipeline Coating
1 2 3
1- Surface Preparation
2- Surface Inspection
3- Induction Heating
4- Coating Application
4
158
Corrosion Control Techniques
5. Protective Coatings
2
1
159
Corrosion Control Techniques
5. Protective Coatings
Surface Preparation
Materials
Coating Application
Inspection
160
Corrosion Control Techniques
5. Protective Coatings
161
Corrosion Control Techniques
5. Protective Coatings
162
Corrosion Control Techniques
5. Protective Coatings
Dew Point Calculation Chart
163
Corrosion Control Techniques
5. Protective Coatings
164
Corrosion Control Techniques
5. Protective Coatings
4. Climatic conditions:
No rain
No dust
165
Corrosion Control Techniques
5. Protective Coatings
4. Climatic conditions:
Atmospheric temperature
should be above 10º C. At lower
temperatures :
Solvent evaporation may stop
altogether
Increased possibility of ice and frost
166
Corrosion Control Techniques
5. Protective Coatings
5. Accessibility of work piece
(Scaffolding )
167
Corrosion Control Techniques
5. Protective Coatings
6. Paint inspection
• integrity of cans
• Shelf-life
• Pot life
• Induction time
• Color code (top coat)
168
Corrosion Control Techniques
5. Protective Coatings
169
Corrosion Control Techniques
5. Protective Coatings
Operator Skills
170
Corrosion Control Techniques
5. Protective Coatings
Operator Skills
171
Corrosion Control Techniques
5. Protective Coatings
Steel Company
172
Corrosion Control Techniques
5. Protective Coatings
In order to perform effectively, a corrosion resistant painting must be
characterized by some essential properties.
– Water resistance
– Chemical resistance
– Proper adhesion
– Coherent
– Abrasion resistance
– Ability to expand and contract
Environmentally Friendly
– Weather resistance
– Non-porous Alligatoring / Crocodiling
– Pleasing appearance
Surface cleanliness
Surface roughness
Conditions of paint application & equipment
Coating defects & holidays
Coating adhesion
Coating dry film thickness
174
Corrosion Control Techniques
5. Protective Coatings
175
Corrosion Control Techniques
5. Protective Coatings
Surface Cleanliness
176
Corrosion Control Techniques
5. Protective Coatings
Surface Cleanliness
SA 2.5 : Near-white, for external
surfaces
SA 3 : White, for internal
surfaces
Comparator
177
Corrosion Control Techniques
5. Protective Coatings
Surface Roughness tools
1
178
Corrosion Control Techniques
5. Protective Coatings
179
Corrosion Control Techniques
5. Protective Coatings
Holiday detection is
carried out for external
coatings of buried piping
and pipelines.
Spring Coil
180
Corrosion Control Techniques
5. Protective Coatings
Holiday Detector
181
Corrosion Control Techniques
5. Protective Coatings
Holiday Detector
Holiday detection is
carried out for internal
coatings of piping and
pipelines.
182
Corrosion Control Techniques
5. Protective Coatings
183
Corrosion Control Techniques
5. Protective Coatings
184
Corrosion Control Techniques
5. Protective Coatings
185
Corrosion Control Techniques
5. Protective Coatings
Cross Hatch Adhesion Test
Test Tools
Masking tape
Muti-plade cutter
186
Corrosion Control Techniques
5. Protective Coatings
2- Apply tape
1- Using the cutter
onto lattice
make lattice. Cuts
must be deep enough
to reach metal surface
187
Corrosion Control Techniques
5. Protective Coatings
ASTM D - 4541
188
Corrosion Control Techniques
5. Protective Coatings
189
Corrosion Control Techniques
5. Protective Coatings
190
Corrosion Control Techniques
5. Protective Coatings
Calibration Shims
Magnetic ( Banana )
Gauge
192
Corrosion Control Techniques
5. Protective Coatings
193
Corrosion Control Techniques
5. Protective Coatings
194
Corrosion Control Techniques
5. Protective Coatings
Painting Cost
195
Corrosion Control Techniques
5. Protective Coatings
Important Remarks
196
Corrosion Control Techniques
5. Protective Coatings
Important Remarks
197
Corrosion Control Techniques
5. Protective Coatings
198
Corrosion Control Techniques
5. Protective Coatings
199
Corrosion Control Techniques
5. Protective Coatings
200
Corrosion Control Techniques
5. Protective Coatings
Blue
Red Yellow
Mixing any 2 1ry colors
Secondary Colors
201
Corrosion Control Techniques
5. Protective Coatings
202
Corrosion Control Techniques
5. Protective Coatings
Purpose of Color coding
In oil & gas plants, different equipment are usually painted
with different colors; i.e. each type of equipment has its
own Color Code
Color Code helps in :
Quick identification
Warning against deadly objects; e.g. radioactivity
Better visibility , specially off-shore
Avoiding risk of fire, specially in gas plants
203
Corrosion Control Techniques
5. Protective Coatings
Examples of Color coding :
205
Corrosion Monitoring Techniques
Corrosion Monitoring
Definition :
206
Corrosion Monitoring Techniques
207
Corrosion Monitoring Techniques
Coupons
Electrical Probes
208
Corrosion Monitoring Techniques
Corrosion Coupons
Strip Coupons
Cylindrical Coupons
209
Corrosion Monitoring Techniques
Scaling Coupons
210
Corrosion Monitoring Techniques
Corrosion Product :
211
Corrosion Monitoring Techniques
Corrosion Product :
1- In Aerated Near-Neutral Solutions: Oxygen Corrosion
2 Fe 2 Fe2+ + 4 e-
O2 + 2 H 2 O + 4 e - 4 OH-
2 Fe + O2 + 2 H2O 2 Fe(OH)2
Iron Hydroxide
Brown Rust
212
Corrosion Monitoring Techniques
Corrosion Product :
2- In Acidic Media , e.g. HCl / H2SO4
Fe Fe2+ + 2 e-
2 H+ + 2 e - 2H H2
Fe + 2H+ Fe 2+
+ H2 Hydrogen Gas
Soluble ions
Monitoring
No solid product
213
Corrosion Monitoring Techniques
[Fe2+]
Time
Graphical Presentation of Iron Ions Concentration
with Time Showing the Effect of Chemical Treatment
214
Corrosion Monitoring Techniques
215
Corrosion Monitoring Techniques
Corrosion Product :
3- In Solutions of CO2 ( Sweet Corrosion )
CO2 + H2O H2CO3 carbonic acid
H2CO3 H+ + HCO3-
Fe Fe2+ + 2 e-
2 H+ + 2 e - 2H H2
216
Corrosion Monitoring Techniques
Corrosion Product :
4- In Solutions of H2S ( Sour Corrosion / Service )
H2S + H2O H + + HS-
Fe Fe2+ + 2 e-
2 H+ + 2 e- 2H H2
217
Corrosion Monitoring Techniques
218
Corrosion Monitoring Techniques
Coupon Handling
219
Corrosion Monitoring Techniques
R=pL/a
R = resistance
p = resistivity of the material
L = length
A = cross sectional area
220
Corrosion Monitoring Techniques
Wire-Loop
Flush
Cylindrical
221
Corrosion Monitoring Techniques
A. In corrosive media
B. In non-corrosive media
A
B
222
Corrosion Monitoring Techniques
Usually includes:
Corrosion Coupon ; mainly for visual evaluation of
corrosion type
Electrochemical Probe ;
for more accurate
instantaneous corrosion
rate determination, e.g.
ER probe
223
Corrosion Monitoring Techniques
Transducer
Wall Thickness
Transmission Reflection 224
Calibration Block
Corrosion Monitoring Techniques
225
Corrosion Monitoring Techniques
C-scan ( 3D )
226
Corrosion Monitoring Techniques
227
Corrosion Monitoring Techniques
228
Corrosion Monitoring Techniques
Blackening the
medium indicates
presence of SRB
229
Corrosion Control Techniques
4.Cathodic Protection
230
Corrosion Control Techniques
4.Cathodic Protection
Cathodic Protection Principle
Sea Water
a) Without Cathodic Protection
Fe2+
Steel pipe wall corrodes freely O2 + 2H2O 4OH-
231
Corrosion Control Techniques
4.Cathodic Protection
Application of CP Systems
On-Shore
232
Corrosion Control Techniques
4.Cathodic Protection
Application of CP Systems Off-Shore
Vessels
Subsea Pipelines
Jackets
Piles
233
Corrosion Control Techniques
4.Cathodic Protection
Types of CP Systems
234
Corrosion Control Techniques
4.Cathodic Protection
Fe
235
Corrosion Control Techniques
4.Cathodic Protection
236
Corrosion Control Techniques
4.Cathodic Protection
Anode e- Fe
237
Corrosion Control Techniques
4.Cathodic Protection
238
Corrosion Control Techniques
4.Cathodic Protection
Generalization :
Aqueous media with low resistivity, Al anode are
preferred, e.g. seawater
Mg anodes are used in higher resistivity aqueous
media, e.g. wetted soils.
Water electric resistivity can be calculated using
this formula :
0.7
Rw = X 1,000,000 ohm.cm
TDS (ppm)
240
Corrosion Control Techniques
4.Cathodic Protection
Backfill:
75% Gypsum +
20% Bentonite clay +
5% Sodium sulfate
Role of Backfill: to absorb
and maintain the soil water,
so keeping the anode in
wet environment
241
Corrosion Control Techniques
4.Cathodic Protection
Main types and shapes of Al & Zn anodes:
1. Slender ( stand-off ) 1
2. Flush mounted
3. Half-shell bracelet 2
4. Spherical
5. Ribbon
4 3
242
Corrosion Control Techniques
4.Cathodic Protection
243
Corrosion Control Techniques
4.Cathodic Protection
244
Corrosion Control Techniques
4.Cathodic Protection
245
Corrosion Control Techniques
4.Cathodic Protection
Typical CP of a buried
pipeline with prepackaged
sacrificial anodes
246
Corrosion Control Techniques
4.Cathodic Protection
247
Corrosion Control Techniques
4.Cathodic Protection
248
Corrosion Control Techniques
4.Cathodic Protection
250
Corrosion Control Techniques
4.Cathodic Protection
Mist Eliminator
Sacrificial Anode
251
Corrosion Control Techniques
4.Cathodic Protection
252
Corrosion Control Techniques
4.Cathodic Protection
Anodes Distribution on
Tank Shell
N
N
HH Level
LL Level
SEC A-A EL +500
SEC B-B
253
Corrosion Control Techniques
4.Cathodic Protection
Sacrificial Anodes
Layout on Tank
Bottom
254
Corrosion Control Techniques
4.Cathodic Protection
255
Corrosion Control Techniques
4.Cathodic Protection
DC source
Ground bed
e
I
256
Corrosion Control Techniques
4.Cathodic Protection
258
Corrosion Control Techniques
4.Cathodic Protection
Transformer Rectifiers (T/R)
• AC input
Voltage, Single/ three phase, Frequency
259
Corrosion Control Techniques
4.Cathodic Protection
Transformer Rectifiers
261
Corrosion Control Techniques
4.Cathodic Protection
Transformer Rectifier
262
Corrosion Control Techniques
4.Cathodic Protection
Si – Cr – Fe Platinized
Graphite
263
Corrosion Control Techniques
4.Cathodic Protection
Si – Cr – Fe
264
Corrosion Control Techniques
5.Cathodic Protection
Fe Si Anodes
265
Corrosion Control Techniques
4.Cathodic Protection
266
Corrosion Control Techniques
4.Cathodic Protection
MMO Coating
267
Corrosion Control Techniques
4.Cathodic Protection
Graphite Anodes
268
Corrosion Control Techniques
4.Cathodic Protection
Platinized Anodes
269
Corrosion Control Techniques
4.Cathodic Protection
• Deep-well GB
• Horizontal shallow GB
• Distributed Anodes
270
Corrosion Control Techniques
4.Cathodic Protection
Sand topping
271
Corrosion Control Techniques
4.Cathodic Protection
Shallow Bed
Depth 3-5m
272
Corrosion Control Techniques
4.Cathodic Protection
273
Corrosion Control Techniques
4.Cathodic Protection
Distributed Impressed Current Anodes Arrangement
Distributed Impressed Current Anodes Arrangement
274
Corrosion Control Techniques
4.Cathodic Protection
Anode Connection :
Anodes cables are connected to anode / positive junction box
Each anode can be connected via a variable resistance to
control the current output
A header cable connects the PJB to e +ve terminal of T/R
275
Corrosion Control Techniques
4.Cathodic Protection
Anode Connection :
277
Corrosion Control Techniques
4.Cathodic Protection
Carbonaceous backfill
Property 218-L 4518
• Resistivity,
0.02 0.01
ohm-inch
• Resistivity,
0.05 0.03
ohm-cm
• Carbon (L.O.I.
99.0 99.9%
method)
• Moisture 0.10% 0.02%
• Ash 0.35% 0.10%
• VCM 0.30% 0/22%
• Sulfur 3.75% 4.3%
• Bulk Density
46-50 62-66
(lbs/ft3)
• General Sizing
+ 4 Mesh +4M < 10% 4M 10%
+ 8 Mesh +8M > 90% +20M > 80%
- 8 Mesh -8M < 10% -20M 10%
278
Corrosion Control Techniques
4.Cathodic Protection
Ground Bed
279
Corrosion Control Techniques
4.Cathodic Protection
280
Corrosion Control Techniques
4.Cathodic Protection
V vs CSE
GB1 GB2 GB3
281
Corrosion Control Techniques
4.Cathodic Protection
282
Corrosion Control Techniques
4.Cathodic Protection
Under tank
cathodic protection
MMO anode grid
283
Corrosion Control Techniques
4.Cathodic Protection
SCH. 40" 3
Concrete Ring
Compacted
Soil
SCH. 40" 3
PVC END CAP
Tank
To T/R
ICCP Anode Grit
Compacted Soil
285
Corrosion Control Techniques
4.Cathodic Protection
MMO strip
Horizontal GB
anode
286
Corrosion Control Techniques
4.Cathodic Protection
Hanging
ICCP
anode
287
Corrosion Control Techniques
4.Cathodic Protection
288
Corrosion Control Techniques
4.Cathodic Protection
1- Hanging Anodes
289
Corrosion Control Techniques
4.Cathodic Protection
2- Sub-sea Sleds
290
Corrosion Control Techniques
4.Cathodic Protection
Potential
theoretical conditions for
0.4
corrosion, passivation, and Fe2+ Passivity
immunity of iron in water and 0.0
dilute aqueous solutions -0.4 Corrosion
-0.8
-1.2 Immunity
-1.6
0 7 14
pH
291
Corrosion Control Techniques
4.Cathodic Protection
Fe-to-Soil Potential in Potential vs Cu/CuSO4 Description
Low Resistivity Soils mV
showing the degree of -500
corrosion Intense Corrosion
-800 Zone
Zoneof
ofCathodic
CathodicProtection
Protection
292
Corrosion Control Techniques
4.Cathodic Protection
293
Corrosion Control Techniques
4.Cathodic Protection
Lead -600
Copper -500
Aluminum -950 (2)
294
Corrosion Control Techniques
4.Cathodic Protection
295
Corrosion Control Techniques
4.Cathodic Protection
i.e., the value of – 850 mV is only for soils with p < 10,000 ohm.cm
296
Corrosion Control Techniques
4.Cathodic Protection
Potential Measurement
297
Corrosion Control Techniques
4.Cathodic Protection
Portable Type
298
Corrosion Control Techniques
4.Cathodic Protection
299
Corrosion Control Techniques
4.Cathodic Protection
SO42-
Porous Disc
300
Corrosion Control Techniques
4.Cathodic Protection
Prepackage CSE
301
Corrosion Control Techniques
4.Cathodic Protection
Electrode Placement
302
Corrosion Control Techniques
4.Cathodic Protection
303
Corrosion Control Techniques
4.Cathodic Protection
304
Corrosion Control Techniques
4.Cathodic Protection
305
Corrosion Control Techniques
4.Cathodic Protection
Reference Electrodes Locations for
Under - Tank CP Systems
306
Corrosion Control Techniques
4.Cathodic Protection
Test Posts for CP Monitoring
Flush – to – ground
307
Corrosion Control Techniques
4.Cathodic Protection
Concrete / Asphalt
Buried Pipe
308
Corrosion Control Techniques
4.Cathodic Protection
Potential Measurement of jackets / platform legs
309
Corrosion Control Techniques
4.Cathodic Protection
Potential Measurement of jackets / platform legs
Transponder CP
monitoring
310
Corrosion Control Techniques
4.Cathodic Protection
311
Corrosion Control Techniques
4.Cathodic Protection
Potential Measurement of subsea pipelines
Trailing-wire potential survey
312
Corrosion Control Techniques
4.Cathodic Protection
CP System Design :
Basic information for design considerations
1. Type of electrolyte (environment)
• Soil
• Fresh/ saline water.
2. Availability of power supply
3. Temperature
4. Type of coating
5. For pipelines:
• Pipeline route
• Crossings (foreign pipeline, roads, rivers, etc.)
• Presence of high transmission power lines
• Presence of foreign metallic structures.
313
Corrosion Control Techniques
4.Cathodic Protection
Soil resistivity
Soil represents the electrolyte
NACE ranking
Four-Terminals (Wenner)
Measurement of Soil Resistivity.
316
Corrosion Control Techniques
4.Cathodic Protection
4-Terminals Arrangement
R : Resistance (ohm)
V : Applied Voltage
a a a
I : Recorded Amperage
Depth = a
317
Corrosion Control Techniques
4.Cathodic Protection
Current demand for CP:
Current density : it is the current required to cathodically protect
1 meter2 of bare steel in a given electrolyte.
318
Corrosion Control Techniques
4.Cathodic Protection
319
Corrosion Control Techniques
4.Cathodic Protection
Power Supply :
320
Corrosion Control Techniques
4.Cathodic Protection
321
Corrosion Control Techniques
4.Cathodic Protection
Sun
Regulator
Junction Box
Converter
GB Pipe to be protected
322
Corrosion Control Techniques
4.Cathodic Protection
Fair 5,000-10,000
good 25,000-50,000
Excellent 100,000-500,000
323
Corrosion Control Techniques
4.Cathodic Protection
CP current
epoxy
Polypropylene (25 0.5 2 5
yrs)
Polyethylene (25 yrs) 0.5 1 3
324
Corrosion Control Techniques
4.Cathodic Protection
Asphalt Enamel -2
Epoxy coal tar -1.5
Fusion bonded epoxy -1.5
Tape wrap -1.5
Polyethylene -1.0
325
Corrosion Control Techniques
4.Cathodic Protection
Pipeline Route
326
Corrosion Control Techniques
4.Cathodic Protection
Pipeline Route
327
Corrosion Control Techniques
4.Cathodic Protection
328
Corrosion Control Techniques
4.Cathodic Protection
329
Corrosion Control Techniques
4.Cathodic Protection
Stray current interference
In case of pipe-crossing of cathodically
protected pipelines BONDING is
required by means of :
Solid boning, or
Resistance bonding
330
Corrosion Control Techniques
4.Cathodic Protection
Electrical Isolation
Structures to be protected shall be
electrically isolated from portions that
doesn’t require protection.
Electrical isolation is made by :
Isolating flange kit ( IFK )
331
Corrosion Control Techniques
4.Cathodic Protection
332
Corrosion Control Techniques
4.Cathodic Protection
Electrical Isolation
Monolithic Blocks
333
Corrosion Control Techniques
4.Cathodic Protection
335
Corrosion Control Techniques
4.Cathodic Protection
336
Middle_east@night.oil
Forest Fires
City Lights
Oil/Gas Fields Flares
337