Corrosion prevention
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Transcript of Corrosion prevention
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AL-KHODARI AL-KHODARI INDUSTRIAL TRADING & INDUSTRIAL TRADING &
SERVICESSERVICES
Dealing with corrosionDealing with corrosion
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Company headlines
Know-how in processes and installations for powders and liquids, Consulting and implementing installations with optimal R.O.I., Reliable process solutions with minimal complexity, Innovative and active supporting in process issues.
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Services
Process engineeringEngineering• Mechanical• Electrical
ProductionProcess controlMechanical installationElectrical installationMaintenance & service
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Experience & know-how
Milk of lime• Storage & dosing of (quick) lime• Mixing, storage & dosing of milk of lime
Slurry handling• Coal, sand, sulfur, magnesium oxide, etc.
Paint & compoundingStorage, dosing and handling of hard-to-handle materialsGlue preparation• Preparing, cooking & dosing of PVA or starch
based glueLiquid handling• Dosing skids
Storage & handling corrosive materials
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References
Akzo NobelAkzo Salt Chemistry Carmeuse ChemetallDegussaInterbrew Nederland Koninklijke Marine – Royal Dutch NavyNestlé Nederland PPG - SigmaKalon Coatings Rockwool Lapinus B.V. Sabic MelafSHELL Ned. ChemieSmurfit Kappa PackagingFokker Nederland – Parts for JSF and Apache 9 helicopterWaterschap Zuiveringschap Limburg – waste water treatmentWaterschap Zuiveringschap Brabant – waste water treatment
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Designing & engineering on material behavior
CorrosionErosionViscosityChemistryHazard
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Corrosion
General CorrosionPitting CorrosionCrevice CorrosionStress Corrosion CrackingGalvanic CorrosionMicrobiologically Influenced CorrosionSulphide Stress Corrosion CrackingIntergranular Corrosion
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Pitting corrosionDefect in passive layer allows metal to dissolve
Passive oxide layer
Concentrated iron chloride solutionCathodi
c
Anodic
Corrosion products
Electrochemical processElectrochemical process
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Pitting corrosion
Inhibitors:Inhibitors:Chloride (catalyst)High temperaturesAcidic conditions, low pH, such as CO2, H2S
Damaged oxide layer (chemically inhibited)
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Pitting corrosion
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Crevice corrosion
Similar to pitting corrosion
Occurring:Occurring:Under gaskets, Sharp re-entrant corners Incomplete weld penetration Overlapping surfaces
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Pipe weldings
Welding pre-
treatment
Sufficient weld
penetration
Sufficient weld
penetration
Insufficient weld
penetration
Sufficient weld
penetration
crevice
crevice
crevice
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Crevice corrosion
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Pitting & crevice resistance
High grades of chromium, molybdenum and nitrogenPitting Resistance Equivalent number (PRE):
PRE = %Cr + 3.3 x %Mo + 16 x %NPRE = %Cr + 3.3 x %Mo + 16 x %N
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Pitting & Crevice resistance
316L
316L
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Chloride content water
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Chloride content water
Temperature 88-100 °F 31-38 °C
75% recoveryFlow rate
[GPM]Chloride [ppm]
Feed Flow 1667 1400
Brine Flow 417 5595
Permeate Flow 1250 0,5
68% recoveryFlow rate
[GPM]Chloride [ppm]
Feed Flow 1838 1400
Brine Flow 588 4375
Permeate Flow 1250 0,5
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Chloride content water
316L
316L
FEED
68% 75%
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Stress Corrosion Cracking
InhibitorsInhibitors::Stress and corrosive environmentStainless steelElevated temperature
Only applicable to austenitic Only applicable to austenitic steelsteel
(201, 301, 303, 304, 305, 316, 321, 347, 631)
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Stress Corrosion Cracking
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Galvanic corrosion
Contact of dissimilar metals in electrically conductive liquid Welds, containing ferrites and due to different structureContact metal with corrosion products
Contact corrosion accelerates pitting & crevice corrosion
Contact corrosionContact corrosion
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Galvanic corrosion
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Microbiologically Influenced Corrosion (MIC)
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Microbiologically Influenced Corrosion (MIC)
InhibitorsInhibitors::Stagnant areas of flowMicro-organismsBio-films of (other) micro-organismsSurface roughnessNutrientsOxygen!
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Microbiologically Influenced Corrosion (MIC)
Types of organismsTypes of organisms::Algae (Probable in saltwater with O2)
Fungi (Improbable)Bacteria (Aerobic & Anaerobic)
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Microbiologically Influenced Corrosion (MIC)
Tubercles formation facilitating
pitting/crevice corrosion
Corrosion underneath biofilm
Bio-film creating isolated
environment
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Microbiologically Influenced Corrosion (MIC)
Prevention / resistancePrevention / resistance::Maintaining cleanlinessMonitoring quality of waterSmooth surfacesAvoiding stagnant areas
Stainless steels with Stainless steels with molybdenum > 6% are molybdenum > 6% are
virtually resistant to MICvirtually resistant to MIC
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PRE = %Cr + 3.3 x %Mo + 16 x PRE = %Cr + 3.3 x %Mo + 16 x %N%N
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Sequence of corrosion
1. Crevice corrosion at gaskets, crevice / galvanic corrosion at welds.
2. Contact corrosion due to corrosion products.
3. Algae settle on corrosion induced roughness
4. Bacteria settling at algae/roughness5. Formation bio-films and degrading agents6. Acceleration of corrosion processes up to
1000 times of ‘normal’ process
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Unusual and excessive degree Unusual and excessive degree of corrosion can occur of corrosion can occur
unpredictably, due to specific unpredictably, due to specific local conditions local conditions
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Chloride content water
316L
316L
FEED
68% 75%
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Pictures RO skid
Penetrated weld
Crevice corrosion
Contact/galvanic corrosion
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Pictures RO skid
Pitting corrosion
Facilitated by stagnant water
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Pictures RO skid
Contact corrosion
Corrosion by polluted welding material
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Pictures RO skid
Contact corrosion by polluted welds
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Pictures RO skid
Contact corrosionConsequential MIT on rough surface
Density MIT related to lines
Corrosion processes related to stagnant water
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Conclusions
Basic types corrosion: pitting & crevice corrosionPrimary corrosion propagated by contact corrosion and Microbiological Influenced CorrosionStagnant areas over a longer period of time are facilitating & accelerating corrosion enormouslyStainless steel 316L in RO skid willwill corrodeWorst case circumstances were availableSerious riskSerious risk is unpredictability of corrosion reaction velocity; several cases of sudden unusual degree of corrosion are known
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AL-KHODARI AL-KHODARI INDUSTRIAL TRADING & INDUSTRIAL TRADING &
SERVICESSERVICES
Specialized in process installations Specialized in process installations for handling dry and liquid materialsfor handling dry and liquid materials
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Proposed actions
Survey of similar installations at Aramco:• Compare differences in materials / set-up• Examine water compositions• Compare biological analyses• Evaluate state of corrosion to age
Conclude either whether risk level incurred in common practice is acceptable or common practice is to be re-defined