Corrosion Presentation

Corrosion in Petroleum Industry
By
Chem./ M.MOSTAFA
1
BASICS OF CORROSION
Corrosion of Metals
All interactions between a metal ( or alloy )

with its environment.
2
BASICS OF CORROSION
Corrosion of Metals
Wet Dry
Occurs in wet Occurs in dry

environments environments @ high
or elevated temp.
3
BASICS OF CORROSION
Dry Corrosion
Direct chemical reaction between metal and environment
Occurs at high temperatures > 200 oC ; e.g.
Oxidation : reaction of iron with O2
Carburization : reaction of iron with CO2
Sulphidation : reaction of iron with S or H2S

4
BASICS OF CORROSION
Wet / Aqueous Corrosion of Metals

Occurs in water – containing environments
Occurs at ambient temperatures
Environment
Water ( fresh or sea water )

Soil ( wetted )
Atmospheric air ( humid )
5
BASICS OF CORROSION
Electrochemical Nature of Corrosion
Corrosion of metals (e.g. iron) in water is basically an

electrochemical reaction in nature,
i.e.
A chemical reaction accompanied by the passage of an

electric current ( due to movement of electrons ).
6
BASICS OF CORROSION
Why Metals Corrode?

Metals tend to corrode in order to retain their natural
form (ore).
Metals are usually extracted and purified from their
ores via high-energy input processes.
For example :
Thermal energy (high furnace for Fe)
Electric energy (electrolytic paths for Al)
7
BASICS OF CORROSION
Electrolytic reduction of Al oxide to Al
Blast furnace of reducing iron

ore to iron
The extracted free metal has a high energy content. i.e. active state
8
BASICS OF CORROSION
Active free metals tend to react easily to produce

compounds, such as salts and oxides.
Metals in the compounded forms have less energy

content, i.e. stable state.
Corrosion is governed by the Law of

Conservation of Energy :
Energy Gained = Energy Lost
9
BASICS OF CORROSION
Corrosion
Thermodynamic Cycle
Iron oxides
Oxides, Ore thermodynamically stable
+
Mining &
Extraction
Corrosion
Mining & Extraction Steel

+
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
In all corrosion reactions

Gprod < Greact. Therefore,
Product
∆G is –ve
Hence, the corrosion reaction is :
spontaneous
irreversible
11
BASICS OF CORROSION
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
(a) (b) (c)

Schematic model of a free metal surface
Atom Degree of Freedom
C , Terrace (Plane) 1
B , Step (Ledge) 2
A , Kink 3
Activity Order : A > B >C
Dislocation
12
THEORY OF CORROSION
Corrosion Process
Due to the electrochemical nature of corrosion, there shall
be electron transfer
Electron transfer requires presence of anode sites and

cathode sites on the metal surface
Due to potential difference ( ∆V ) between anodes and

cathodes electrons migrate from anodes to cathodes
Electrons liberated at anodes should be consumed at

cathodes
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
The corrosion process involves two reactions:
A. Anodic Reaction (metal dissolution / oxidation )
B. Cathodic Reaction ( reduction )
16
THEORY OF CORROSION
Corrosion Process
A. Anodic Reaction (metal dissolution)
Fe Fe 2+ + 2e-
B. Cathodic Reaction
1. Oxygen reduction reaction
O2 + 2H2O + 4e- 4 OH-
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:
A piece of metal immersed

in an electrolyte acts as its
own:
Anode
Cathode
Electrical connection
19
THEORY OF CORROSION
The Corrosion Cell 2H++2e 2H H2
In a corrosion cell:
Electrons leave the anode

and migrate to cathode
within the metal;
i.e. electronic movement
The circuit is close by

migration of +ve & -ve
ions between anode and
cathode in the electrolyte;
i.e. ionic movement
20
THEORY OF CORROSION
For Corrosion to occur :
There must be a positive or anodic area,

referred to as the “anode”
There must be a negative or cathodic area,

referred to as the “cathode”
There must be a path for ionic current flow,

or “electrolyte”
There must be a path for electronic current

flow which is normally a “metallic path”
21
THEORY OF CORROSION
Factors of Corrosion
1- Water
2- Oxygen
3- Acidity
22
THEORY OF CORROSION
Testimony
An environment is considered corrosive if it contains

Water with dissolved Oxygen and / or Acidity ( H+ ions )
Fe
23
THEORY OF CORROSION
Corrosion Rate
The rate at which metal loss occurs due to corrosion is
expressed in terms of:
mpy milli- inch per year

Or
mmpy milli- meter per year
24
THEORY OF CORROSION
NACE International Ranking for Steel Corrosion

Corrosion Rate Level of corrosion
(mpy)
<1 Low
1-5 Moderate
5-10 Severe
>10 Intense
NACE= National Association for Corrosion Engineers
25
FORMS OF CORROSION
Types of Corrosion:
1. Uniform (General) Corrosion
1. Localized Corrosion
Pitting and Crevice Corrosion
Stress Corrosion Cracking
Hydrogen Damage ( Embrittlement / Blistering )
Galvanic Corrosion
26
FORMS OF CORROSION
According to the National Physical Laboratory – UK :
30% of equipment failures are due to uniform corrosion
70% of equipment failures are due to localized 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:
Anodic current ( Ia) = Cathodic current ( Ic) , and
Area of anode ( Aa) = Area of cathode ( Ac)
Hence,
Anodic current density ( ia) = Cathodic current density ( ic)
Therefore, the metal loss is equally and uniformly distributed all

over the surface, i.e. corrosion proceeds horizontally along the
metal surface
28
FORMS OF CORROSION
Localized Corrosion
In localized corrosion there is clear distinction between the anode and
the cathode sites
The anode sites are being very small compared with the large cathode:
Anodic current ( Ia) = Cathodic current ( Ic) , and
Area of anode ( Aa) << Area of cathode ( Ac)

Hence,
Anodic current density ( ia) >> Cathodic current density ( ic)
Therefore, the metal loss is concentrated in local areas, i.e. corrosion

proceeds downwards perpendicular to the metal surface
29
FORMS OF CORROSION
Pitting corrosion
Occurs with metals having oxide ( Passive )

film
I.e. the metal is in the zone of Passivity, e.g.
stainless steels, due to film local film
breakdown
Chloride ions (Cl-) have damaging effect on
oxide film of stainless steels
30
FORMS OF CORROSION
Pitting corrosion
31
FORMS OF CORROSION
Pitting corrosion
In Absence of Chloride Ions
Intact Oxide Film Scratched Oxide Film Film Self-repair

32
FORMS OF CORROSION
Pitting corrosion
What is the role of chloride ions in localized corrosion;

pitting ?
Help in breaking down the passive oxide film, specially
at weak point
Allow a very low pH to be achieved inside the pit, due
to the formation of HCl
Metal chlorides are very soluble
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
MCl + H2O = MOHH++ HCl

H + -
OH e
-
-
e
H+ H+ -OH
+
M
+
M
O2 + 2H2O
H + 4e -> 4(OH ) +
H+ - H+
H+ -
e
-
-
e H+
-
OH +
M
+
M -
OH
-
e
H+
-
e Pitting
-
OH
+
M
+
M Corrosion
34
FORMS OF CORROSION
Pitting corrosion
Pitting may lead to pipe perforation
35
FORMS OF CORROSION
Crevice corrosion
36
FORMS OF CORROSION
Crevice corrosion under gasket
37
FORMS OF CORROSION
Pitting corrosion on
free surface
Crevice corrosion
under washers
38
FORMS OF CORROSION
Stress Corrosion Cracking (SCC)
Caused by the simultaneous effects of tensile stress and a

specific corrosive environment.
Stresses may be due to:

applied loads ( static / dynamic )
residual stresses from the

manufacturing process, or
combination of both
39
FORMS OF CORROSION

Dynamic Test :
Slow Strain Rate Test
Stress
In Air
In Environment
Strain
40
FORMS OF CORROSION
Agar gel containing : Phenolphthalein

& HexaCyanoIron Fe(CN)6-
@
@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

Atoms of metal at stressed areas have high energy ,
i.e. very active
High localized corrosion rates at such areas
Localized metal loss leading to cracking
Cracked Pipe Cracked weld
42
Stress corrosion cracking of brass
43
FORMS OF CORROSION
The crack is initiated at a pit or a crevice located within a stressed area
The crack growth may be:
Cutting through the grains ,

i.e. Transgranular Cracking
e.g. Sulfide stress cracking
Cl- or S2-
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
Hydrogen Blistering Mechanism:
H+ H+
H H2 H H H H H
e
-
-
e H2
H2
47
FORMS OF CORROSION
Hydrogen Blistering
Cross-section of a carbon steel plate

Hydrogen blistering of
showing a large hydrogen blister
a carbon steel plate
48
FORMS OF CORROSION
Hydrogen Embrittlement
49
FORMS OF CORROSION
Galvanic Corrosion
Occurs when two dissimilar metals are in

direct electric contact
Dissimilar metals have different reactivities

since they have different positions in the
Electrochemical Series
50
FORMS OF CORROSION
Nobel (+)
GALVANIC SERIES
OF METALS
Active (-)
51
FORMS OF CORROSION
Galvanic Corrosion
Due to the potential difference

between dissimilar metals :
The less noble metal is more Active

and acts as Anode ; i.e. it dissolves
The more noble metal acts as

Cathode ; i.e. it remains intact.
52
FORMS OF CORROSION
Uncoupled Dissimilar Metals
Anodic rxn : Zn = Zn2+ + 2e- Fe = Fe2+ + 2e-

Cathodic rxn: 2H+ + 2e- = H2 2H+ + 2e- = H2
Zn strip Fe strip
Both metals corrode but @

different rates
More active metal ( Zn )
H2 gas
being FASTER
bubbles
Dil. HCl soln
53
FORMS OF CORROSION
Coupled Dissimilar Metals
e e
V
Anodic rxn: Zn = Zn2+ + 2e- Cathodic rxn: 2H+ + 2e- = H2
More active Less active

metal is eaten metal remains
away rapidly, intact with H2
gas evolution
i.e. corrodes
Dil. HCl soln
54
FORMS OF CORROSION
Galvanic Corrosion
Carbon steel Inconel ring
Cu
Al
55
FORMS OF CORROSION
Surface area effect in galvanic corrosion
Small cathode Large anode combination is Acceptable
Stainless
Steel Valve
Carbon Steel
SS CS
56
FORMS OF CORROSION
Small anode Large cathode combination is NOT Acceptable
X Carbon Steel
Valve
Stainless Steel
CS SS
57
FORMS OF CORROSION
Which is better ???

X
Brass bolt in a steel structure Steel bolt in a brass structure
Small brass cathode will
cause small increase in Small steel anode will
corrosion of steel suffer large increase in
structure. Bolt will be corrosion due to
protected from corrosion coupling with brass
by coupling to steel structure.
58
FORMS OF CORROSION
Galvanic Corrosion
SS
Carbon Steel Bolt
59
CORROSION CONTROL
Corrosion Control
1. Anodic : by blocking the anodic reaction
2. Cathodic : by blocking the cathodic reaction
3. Mixed : by blocking both anodic & cathodic reactions
60
Corrosion Control Techniques
1. Materials Selection
1. Improved design
1. Chemical Treatment
1. Protective Coatings
1. Cathodic Protection
61
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
Effect of dissolved gases
63
Effect of dissolved gases

GUIDANCE FOR PREDICTING CO2 CORROSION
PPCO2 (psi) Expected corrosion
<3 Non-corrosive
3-30 May indicate corrosion
>30 Indicates corrosion
64
PREDICTING CO2 CORROSION
65
Effect of dissolved salts
Dissolved salts ions speed up

the corrosion process due to
ionic movement
a) Pure water b) NaCl solution
66
Effect of dissolved salts
Sea water is an excellent

electrolyte, i.e. very corrosive
At high salts concentrations,

corrosion rate drops due to :
Lesser
dissolved O2
Lesser ionic movement

because of crowdedness
67
Stream Velocity
Corrosion rate and corrosion type are function of flow
velocity
CORROSION RATE
Corrosion Rate
GENERAL CORROSION EROSION CORROSION CAVITATION CORROSION

LAMINAR FLOW TURBULENT FLOW CAVITATION
Ucrit FLOW VELOCITY
68
Stream Velocity
69
Stream Velocity
70
C. Materials Selection Factors:

Corrosion Resistance
Cost Effectiveness
Mechanical
Properties
Availability
71
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
Fiber glass vessels
73
Fiber glass pipes
Above-ground interconnecting
Under-ground GRP GRP piping
pipeline GRP piping
74
Fiber glass piping connections
Flanged Connection Bell-Spigot Connection

with Key Lock
75
Advantages of Using Non-Metallics :
No need for any corrosion control method, e.g. chemical

treatment, cathodic protection, painting
Ease of handling and transport
Ease of installation
76
Limitations of Non-metallics :
The use of most non-metallics is restricted to relatively

narrow range of temperature and pressure
Under-ground structures can be easily damaged in case of
soil movement
Care must be taken not to damage above-ground structures
77
Important Notice on Non-Metallics Application
Always check and make sure of :

Compatibility of material with the medium chemical
analysis, such as pH, organic solvents
Suitability of material for the service conditions of
temperature and pressure
Possibility of soil movement in case of buried piping
78
Cost of Material
Criteria: to reach a compromise between the capital

expenditure (CAPEX) and operation expenditure (OPEX)
Usually select a cost effective material, e.g. CS, in association

with one or more Supportive Corrosion Control Techniques
79
CLADDING
Can be used for

economical reasons
80
2. Improved Design
Examples of
Impingement Corrosion
81
2. Improved Design
Examples of avoiding
impingement corrosion
by design
82
2. Improved Design
crevice corrosion by Good
design
Bad
83
2. Improved Design
crevice corrosion by Improper Weldments
design
Proper Weldment
84
2. Improved Design
Improved Design, e.g.:
Incorporation of corrosion allowance
t (required) = t min + CA
Life time = corrosion allowance (mm) / corrosion rate (mm/year )
85
2. Improved Design
• Incorporation of corrosion allowance

CYLINDRICAL SHELLS SPHERE SHELS PIPES
PR PR PR
T= + C.A T= + C.A T= + C.A
SE-0.6 2SE-0.2P SE-0.6P
P: design pressure in N/mm2 CA: corrosion allowance, mm

R: inside radius, mm t : min. corroded thickness, mm
S: stress value of material, N/mm2
E: joint efficiency
86
2. Improved Design
Avoiding contact
between dissimilar
metals
Nobel
Active
87
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
88
A. pH Control
89
A. pH Control
Steel corrosion rate related to
hydrogen ion concentration in electrolyte
To avoid acid corrosion, the pH of the

medium shall be raised up to about 7
by injection of
• Caustic Soda NaOH
• Ammonia NH3
Periodical check on pH by means of pH probes
90
Crude Oil Fractional Distillation
91
92
Prior allowing the crude

into the distillation
tower, most of water &
dissolved salts are
removed by
Desalter and Hydro-
treater
93
Process
Flow
94
Inside the lower section of the crude

distillation tower, hydrolysis of remaining
dissolved salts occurs at high temperatures:
MgCl2 + 2H2O Mg (OH)2 + 2HCl

CaCl2 + 2H2O Ca (OH)2 + 2HCl
NaCl + H2O no reaction
95
Water condenses in the colder overhead section of the

tower along with HCl acid.
Condensed water has pH of 1.5
Hence, acid corrosion occurs
96
B. Removal of Dissolved Gases
Dissolved oxygen can be removed by injection of oxygen

scavengers
Amine unit can be used for removal of CO 2 & H2S
Mechanical deaerator can also be used to remove all

dissolved gases: O2, CO2, H2S
Periodical checks on dissolved O2 concentration by means

of O2 probes
97
Mechanical Removal of Dissolved Gases

by Deaerator
98
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)
99
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
100
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
101
A. Inhibitors for Acid media
Usually organic compounds with long hydrocarbon chains

with polar (charged) head
102
Film forming theory
Mechanism:
1) Formation of physical
barrier, thus blocking the
reaction sites (anode and
cathode sites).
2) Interference with adsorbed

H- atoms, thus prevents
H- embitterment / blistering.
103
B. Inhibitors for Near Neutral Media
Usually are inorganic compounds
Anodic
Cathodic, or
Mixed ( Mixtures of both anodic and cathodic inhibitors )
104
Inhibitors for Near Neutral Media
In case of absence of the inhibitor: usually are categorized as:
Safe or Dangerous
• Safe General Corrosion

• Dangerous Localized Corrosion
105
Anodic Inhibitors
- Block the anodic sites by formation of iron oxides

- All are O-containing
- All are dangerous
e.g. Chromates CrO4-2
Molybdates MoO4-2
Silicates SiO4-2
nitrites NO2-
COO-
benzoate
phosphates PO4-3
106
Cathodic Inhibitors
- Block the cathodic sites by formation of scales

- All are safe inhibitors
e.g. Zinc ions Zn 2+
Calcium ions Ca 2+
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
Mixed Inhibitors
Mixtures of both anodic and cathodic inhibitors
Block both anodes and cathode
Compatible mixture
108
Efficiency of inhibitors :
Expressed as :
Protective Power ( Z)
where,
Z = [(RO-R) / RO] X 100
Ro: Corrosion rate in absence of inhibitor.
R : Corrosion rare in presence of inhibitor.
109
Curve showing drop in corrosion

rate as a function of inhibitor
concentration
Corrosion rate
Minimum Inhibitive
Concentration
Corrosion inhibitor
concentration
110
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
MKC VALUE = minimum killing concentration
111
Biocides role in corrosion control:
Kill micro-organisms that feed on the corrosion inhibitors
Kill micro-organisms that produce corrosive metabolites
Sulfate-reducing bacteria ( SRB )
112
113
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
114
Scale Inhibitors ( Anti-scaling

Agents ) ( Scale Removers )
Chemicals added to the stream to prevent or

remove scales ( deposits )
Corrosion can proceed underneath the deposit ,
Under- Deposit Corrosion
Microbial ( SRB ) Corrosion is initiated under the
deposits
Scaling tendency is determined by process
engineers
115
Scale Inhibitors ( Anti-scaling Agents )

( Scale Removers )
Under- Deposit Corrosion
116
Typically fouled ( heavy scale )

heat exchanger tube resulting
in poor heat transfer
117
EXCHANGER
PERFORMANCE
118
Chemical Injection
Chemical Injection Skid :
Chemical Tanks &

Non-metallic Tanks
Chemical Injection
( Dosing ) Pumps
Stainless Steel Tanks
119
Chemical Injection
Chemical Injection Point
High Alloy
Quell
120
Chemical Injection
Chemical Injection Using

Internal Jet
121
Treatment
reserve Waste of Chemicals X
Ideal
No Protection
Time
BAD CONTROL
122
Ideal
Time
GOOD CONTROL
123
Definition of a
A material that adheres to and covers the metal surface
The coating can be applied :

onto external surfaces; external coating
and / or
onto internal surfaces; internal coating ( Lining )
124
Paints
Definition :
“ a liquid material, which can be applied on a surface,

and which – after drying – forms a thin, cohesive,
non-porous film with good adhesion to the surface “.
125
Surface Preparation : prior to coating application
Criteria :
• Surface Cleanliness
Surface Roughness
126
Surface Cleaning
The surface has to be free of dust
The surface has to be

free of salts
Presence of salts causes

paint blistering by osmosis,
i.e. osmotic blistering
127
Surface Preparation
Surface Cleanliness
Removal of scales, rust, dirt, grease, etc…
Done by :
Water jetting
Abrasive blasting ( provides surface roughness )
Sand blasting
Grit blasting
128
Surface Cleaning
Water Jetting
129
Abrasive Blasting
Sand blasting
not recommended as it causes

air pollution by increasing the
amount of suspended solids
Sand Blasting
Provides reasonable surface
roughness
130
Abrasive Blasting
Grit / Shot blasting
By using metal shots with sharp

edges
Grit Shot
Recommended as it does not cause
air pollution
Provides excellent surface

roughness ( profile )
Recyclable
131
Abrasive blasting
nozzles
Abrasive blasting
for pipe internal
Abrasive blasting
pot
132
Surface Profile
The blasted metal surface is Rough

The roughness is due to presence of Profile or Anchorage
The surface ( anchor ) profile consists of Peaks & Valleys
Peaks (Craters) Valleys
133
Surface Profile
3 parameters are important to obtain acceptable surface profile:
1- Peak to valley depth
2- Shape of craters Rmax
3- Density of peaks: number of craters per linear inch or cm
Sharp & Dense

3 different
surfaces Sharp but less
of same Dense (grit)
Rmax
Dimpled (shot)
134
Surface Cleanliness International Standards
Surface USA Spec. British Std. Swedish SIS Japanese Std.

Finish NACE
SSPC BS 4232 05 5900 SPSS
White Metal SSPC-SP 5 NACE 1 st quality 1 SA 3
Near White JA Sh2 or
Metal SSPC-SP 10 NACE 2 nd quality 2 SA2 1/2
JA Sd2
Commercial JA Sh1 or
Blast SSPC-SP 6 NACE 3 rd quality 3 SA 2
JA Sd1
Brush Off
Blast SSPC-SP 7 NACE 4 - SA 1 -
135
Surface Preparation Affects Coating Durability
136
Types of Coatings
Paints Wrapping Heat-Shrinkable

Sleeves
Applied Applied
Applied
externally & externally only
externally only
internally
137
Chemical Composition of Paints
Primary Components :
Resin ( binder / vehicle / base )
Hardener ( curing agent )
Solvent ( thinner )
Secondary Components :
Color Pigments
Cementing Particles
Corrosion Inhibitors
138
Classification of Paints
Chemically drying paints:
initially by solvent evaporation
then a chemical reaction between the resin and the

hardener (curing agent): Resin + Hardener Polymer
They are irreversible paints,

i.e. solvent non-sensitive
supplied in TWO cans
e.g. Epoxies, Polyurethanes

139
Chemically drying paints:
The curing agent can be the Binder + O2(air) Polymer

atmospheric oxygen. In this
case, the paint is called
oxidative drying paint Oxidation is the polymerization
process of alkyds, modified
alkyds and epoxy-ester binders
Oxidative paints are
supplied in Single cans
Chemically drying paints take into consideration Pot

Life and in some cases Induction Time.
140
Classification of Paints
According to the paint drying mechanism :
Physically drying paints :
drying by evaporation of solvent / thinner
they are known as reversible paints, i.e. solvent sensitive
supplied in single cans
e.g. Zinc-rich paints

141
Wrapping & Sleeves

Used mainly for field joints
142
Wrapping & Sleeves

Used mainly for field joints
143
Wrapping & Sleeves

Wrapping can be used for under- ground in-plant
piping, e.g. open & closed drain piping network
144
Painting Application
Paint Application Methods

Paint Application Conditions
Paint Application Defects
Paint Inspection
145
Brush
Roller
Spraying :
Air Spray
Airless Spray
Electrostatic Spray
146
Brush:
Very effective
Very slow
Used for small objects and touch-ups
Roller:
Ineffective
Porous film
Slow
Used for gates and fences
147
Fan
Spraying = Atomization
Atomization : converting a liquid into

tiny minute droplets
148
Spraying
Fast
Very effective
Uniform film
Requires skillful operators
Most commonly used method
20% approx. loss is expected
149
Air Spray :
Atomization of paint is assisted by air
Requires air compressor + air filters
Air quality is a must
Not suitable for paints containing

oxidizable metal particles ,
e.g. zinc-rich paints
150
Airless Spray :
Suitable for metal-containing paints
Requires high pressure pumps
Atomization is due to ∆P
151
Electrostatic Spray :
Needs DC power supply between
spray gun & work piece
Paint loss down to ~ 2%
Excellent uniform appearance
Most expensive
152
Electrostatic Spray :
153
Painting System ( Cycle )
The 3-layer paint system :
Primer :1st layer
provides corrosion protection
provides adhesion to metal surface
Inter-coat : 2nd layer

provides mechanical strength to the system
Top (Finish) : 3rd outmost layer

provides UV resistance Steel
provides abrasion resistance
provides the specified color code
154
Typical 3-Layer Painting System :
Primer : Zinc-rich compounds

Inter-coat : High build / solids epoxy
Top (Finish) : Polyurethanes
Recommended paint system For external steel surfaces

at ambient temp. up to 940C
For higher temperatures, special painting systems

to be specified
For internal surfaces, No need for neither top coat Nor color
code. Use extra thicker inter-coat instead
155
Typical Pipeline Coating
3-Layer System
Polyethylene
Or
Polypropylene
2-3 mm thick
156
Typical Steps of 3-Layer Pipeline Coating
3
2
1
1 Fusion Bonded Epoxy ( FBE )
2 Copolymer Adhesive
3 Polyethylene ( PE ) or Polypropylene ( PP )
157
Typical Steps of 3-Layer Pipeline Coating
1 2 3
1- Surface Preparation
2- Surface Inspection
3- Induction Heating
4- Coating Application
4
158
2
1
1 Anti-corrosion Painting System
2 Concrete Weight Coating
159
Keys of Coating Success :
Surface Preparation
Materials
Coating Application
Inspection
160
Conditions of Successful Painting Application :
1. Adequate lighting 500-1000 lumen / m2
2. Proper ventilation for confined or closed areas

to ensure paint drying
161
3. Temperature of steel structure (skin temp.)

should be above the dew point by 3º C (5o F) min. and
does not exceed 45º C. Since at high temperatures the drying
and curing of paint is rather rapid.
Rapid drying causes:

Paint defects
Dry spray: i.e. loss of solvent
during application
162
Dew Point Calculation Chart
163
Dew Point Instrument
164
4. Climatic conditions:
No rain
No dust
Relative humidity does not

exceed 85%, since solvent
evaporation slows down
in saturated atmospheres
165
4. Climatic conditions:
No winds to avoid over-spraying
Atmospheric temperature
should be above 10º C. At lower
temperatures :
Solvent evaporation may stop
altogether
Increased possibility of ice and frost
166
5. Accessibility of work piece
(Scaffolding )
167
6. Paint inspection
• integrity of cans
• Shelf-life
• Pot life
• Induction time
• Color code (top coat)
7. Paint system / cycle

• Primer
• Inter-coat Steel
• Top or finish coat
168
8. Paint technical data sheet

• Generic type
• Curing time
• DFT (dry film thickness) limits
9. Paint application data sheet

• Mixing ratio
• Safety regulations during application
10. Paint safety data sheet
11. Operator skills ( Workmanship )
169
Operator Skills
Cross Spraying is required

when very high and uniform
film thickness is required
170
Operator Skills
The spray gun must be perpendicular to

the steel surface and ~ 50 cm away from it
Operators must stick to

Safety Regulations
171
Steel Company
172
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
Rigid non-flexible paint

173
Inspection : a certified paint inspector shall check for :
Surface cleanliness
Surface roughness
Conditions of paint application & equipment
Coating defects & holidays
Coating adhesion
Coating dry film thickness
174
Steel skin temperature devices
Left for 5 min. in contact with steel surface Instantaneous read-out
175
Surface Cleanliness
Visual inspection for surface

solid particles, e.g. dust
Magnifying Lenses Torch Masking Tape
176
Surface Cleanliness
SA 2.5 : Near-white, for external
surfaces
SA 3 : White, for internal
surfaces
Comparator
177
Surface Roughness tools
1
Press – O – Film ( Replica )

For curved surfaces, e.g.
piping 2
178
Surface Roughness tools

For flat surfaces
Analog Gauge Digital Gauge
179
Paint Inspection by Holiday Detector
Holiday detection is
carried out for external
coatings of buried piping
and pipelines.
Spring Coil
180
Holiday Detector
181
Holiday Detector
Holiday detection is
carried out for internal
coatings of piping and
pipelines.
182
Painting inspection by Wet Sponge Holiday Detector for flat surfaces
183
Painting inspection by Brush Holiday Detector for flat surfaces
184
Holiday Detector Voltage
The applicable voltage depends on the coating thickness
The required voltage can be calculated by NACE equation :
Testing voltage = V = 7900 (t)1/2

Where t = average coating thickness in mm
Testing voltage = V = 1250 (t)1/2

Where t = average coating thickness in mils
185
Cross Hatch Adhesion Test
Test Tools
Masking tape
Muti-plade cutter
186

Test Procedure
2- Apply tape
1- Using the cutter
onto lattice
make lattice. Cuts
must be deep enough
to reach metal surface
187

Test Procedure
3- Remove tape and

evaluate coating flaking
due to loss of adhesion
ASTM D - 4541
188
X- Hatch Test Evaluation : According To German / American

Specification
Description DIN ASTM

No edges are detached 0 5
area affected at intersections of cuts 5%< 1 4
area detached at edges 5-15% 2 3
area detached, coating flaked at edges 15-35% 3 2
area detached 35-65% 4 1
area detached 65%> 5 0
189
Simple Cross Hatch ( Peal-off ) Test
190
Dry film thickness ( DFT )
Ultrasonic Thickness (UT) Gauges
Calibration Shims
UT gauges require calibration

before usage
191
Dry film thickness ( DFT )
Magnetic ( Banana )
Gauge
192
Wet film thickness
Wheel Triangle Comb
193
Painting Supplier Factors
194
Painting Cost
195
Important Remarks
Paints containing Lead (Pb), Chromium (Cr), and other heavy

metals are environmentally prohibited.
Surface roughness is measured in microns. Recommended

range 50-75 micron. Must refer to paint data sheet.
Internal coatings of potable water tanks should be approved

from international health organizations, e.g. WHO, FAD.
196
Important Remarks
Stainless steel surfaces exposed to marine environment need

to be painted against atmospheric corrosion. Paints should
be Zn-free epoxies.
Grit blasting of stainless steel surfaces to be done using

chloride-free non-ferrous shots, e.g. Al2O3.
Best protection is achieved by coatings + cathodic protection.

Coating being the 1st line of defense, whereas CP the 2nd line.
197
Paint Color Coding System
Since 1927, color charts have been

the standard for precise coloring worldwide
= Reichsausschuss fur Lieferbedingungen

= Committee of the German Reich for Terms
and Conditions of Sale
198
RAL started with only 40 colors
Recently, RAL includes about

2000 colors & shades
199
According to the RAL

system, each color or
shade is given a
specific RAL number
200
There are 3 Primary Colors
Blue
Red Yellow
Mixing any 2 1ry colors
Secondary Colors
201
Mixing the 3 1ry colors

Or Tertiary Color
Mixing 1ry color + 2ry color
Black & White are added to vary the shade;

i.e. darker or lighter
202
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
Examples of Color coding :
Fire Fighting Safety Red

LPG spheres/condensate Light Gray
& crude tanks
Steel structure Light Gray
Nitrogen lines Blue
Water lines Green
Crane moving parts Black + Yellow
Platform deck Yellow - Orange
Fired heater/Stakes Black
204
Examples of Color coding :
205
Corrosion Monitoring Techniques
Corrosion Monitoring
Definition :
“ the systematic measurement or evaluation of the

corrosion rate and type of corrosion occurring on
an equipment “ .
206
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
207
The efficiency of corrosion inhibitors is checked by

means of monitoring system.
Coupons
Electrical Probes
208
Corrosion Coupons
Strip Coupons
Cylindrical Coupons
209
Scaling Coupons
210
Description of Type of Attack on a Coupon
Corrosion Product :
If the coupon surface was covered by corrosion product,

scale or deposit, they will be removed and collected for
chemical analysis
211
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 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
[Fe2+]
Time
Graphical Presentation of Iron Ions Concentration
with Time Showing the Effect of Chemical Treatment
214
Monitoring of Acid Inhibitors by Iron Count
Graph of Corrosion rate
Start of Treatment Program
215
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
2Fe2+ + 2HCO3- 2 FeCO 3– White

Iron Carbonate + 2H +
Scale
Precipitation is Temperature Dependant
216
Corrosion Product :
4- In Solutions of H2S ( Sour Corrosion / Service )
H2S + H2O H + + HS-
Fe Fe2+ + 2 e-
2 H+ + 2 e- 2H H2
Fe2+ + HS- FeS + H +

Iron Sulfide
Black ppt.
217
Typical corrosion monitoring point
218
Coupon Handling
Retrieving the coupon Removal of Removal of The coupon is

corrosion corrosion accurately
product by soft product by weighed
wire mesh soaking in
inhibited acid
219
Electrical Resistance (ER)

Probe- Corrosometer
For a wire or cylindrical shape :
R=pL/a
R = resistance
p = resistivity of the material
L = length
A = cross sectional area
220
Electrical Resistance (ER)

Probe- Corrosometer
Wire-Loop
Flush
Cylindrical
221
Electrical resistance probe

measurements for mild steel
coupons
A. In corrosive media
B. In non-corrosive media
A
B
222
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
223
On-Line Wall Thickness ( UT ) Measurements

Useful on-stream follow-up monitoring
tool
Transducer
Wall Thickness
Transmission Reflection 224
Calibration Block
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 )
225
C-scan ( 3D )
226
227
Without Inhibition With Inhibition
228
Monitoring of SRB Biocide Performance by Cultivation
Blackening the
medium indicates
presence of SRB
229
4.Cathodic Protection
Idea of Cathodic Protection
Cathodic protection system controls corrosion by making

the whole metal surface a cathode
230
Cathodic Protection Principle
Sea Water
a) Without Cathodic Protection
Fe2+
Steel pipe wall corrodes freely O2 + 2H2O 4OH-
Both anodic & cathodic e- e- Pipe Wall

reactions occur
Pipe Inside
b) With Cathodic Protection

Sea Water
Anodic reaction stops
Cathodic reaction continues O2 + 2H2O 4OH-
External Supply of e- e- e- e- e- e- e- e- e- Pipe Wall

Electrons
Pipe Inside
231
Application of CP Systems
On-Shore
232
Application of CP Systems Off-Shore
Vessels
Subsea Pipelines
Jackets
Piles
233
Types of CP Systems
According to the source of external supply of electrons,

there are two types of CP systems:
1- Sacrificial anode system
2 - Impressed current system
234
1- Sacrificial anode system Magnesium ACTIVE

Zinc
Simplified Galvanic Aluminum
Series Iron
Lead
Tin
e- Nickel (Active)
Brass
Copper
Nickel (Passive)
410 Stainless
Titanium
304 Stainless
Zn Silver
Gold
Platinum NOBLE
Fe
235
Galvanic Couples in Saline Water
Fe/Al Fe Fe/Cu Fe/Ag Cu/Ag
Without electrolyte With electrolyte
236
Arrangement of a Sacrificial CP System
Anode e- Fe
237
Common Sacrificial Anodes
238
Common Sacrificial Anodes

Anode Recommended Electrolyte
Magnesium (Mg) Soils & hot water
Zinc (Zn) Soils & fresh / sea water
Aluminum (Al) Sea waters
At temp. > 600 C : Al & Zn oxidize leading to Reverse Polarity
Indium is added to Al anodes to prevent its oxidation

239
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
Prepackaged Sacrificial Anode
For soil applications: prepackaged Mg & Zn anodes
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
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
5 Ribbon Anodes ( Zinc / Magnesium )
243
Applications of sacrificial cathodic protection system:
Buried / sub sea pipelines

Buried piping
Platforms and rigs
Maine piles
Tank internals
244
Sacrificial anodes for

onshore piping
245
Typical CP of a buried
pipeline with prepackaged
sacrificial anodes
246

platform jackets
247

offshore pipeline
248
Subsea pipeline laying Bracelet anode FLUSH with

cement coating
249
Sacrificial Anode Cathodic

Protection for External Side
of Tank Bottom
250
Sacrificial anodes for vessel internals
Mist Eliminator
Sacrificial Anode
251
Sacrificial anodes for tank internals
252
Anodes Distribution on
Tank Shell
N
N
HH Level
SEC A-A EL +7500
SEC B-B EL +5500
SEC A-A SEC A-A EL +3500
SEC B-B EL +1500
LL Level
SEC A-A EL +500
SEC B-B
253
Sacrificial Anodes
Layout on Tank
Bottom
254
Sacrificial Anodes for Ship Hulls
255
2- Impressed current system
DC source
Ground bed
e
I
256
Basics of Impressed current system
Steel nails fixed to The steel nails Results:

dry battery terminals immersed in saline 1- The nail at +ve
water terminal Corrodes
2- The nail at –ve
terminal remains
Uncorroded
257
Impressed current system
Nothing happens since

the nails are in different
electrolytes
258
Transformer Rectifiers (T/R)
• AC input
Voltage, Single/ three phase, Frequency
• DC maximum output Amp, Volt
• Air Cooled: with sun-shade

Oil Cooled: with thermometer
• Location: according to area classification

• Explosion proof (hazardous area)
• Non-explosion proof (non-hazardous area)
• Maximum ambient temperature
259
Transformer Rectifiers
T/R with sun-shade

260
Transformer Rectifiers
Explosion-proof Wall-mounted/indoors Pole-mounted
261
Transformer Rectifier
Alternating Current Direct Current
262
Common Impressed current anodes:
Consumable Anodes Non Consumable Anodes
Si – Fe Mixed Metal Oxide (MMO)
Si – Cr – Fe Platinized
Graphite
263

Si – Fe
Si – Cr – Fe
264
Fe Si Anodes
• Are the most common impressed current anodes
• Are used in soil, water or sea water
• Come in two grades; FeSi and FeSiCr for sea water

applications
• Cable connection to anode shall be handled with great

care.
265
Mixed Metal Oxide (MMO) Anodes
MMO is an electrically conductive

coating that is applied onto a
Titanium substrate in order to
make it act as an Anode
266
Mixed Metal Oxide (MMO) Anodes
MMO Coating
267
Graphite Anodes
268
Platinized Anodes
269
Types of ground beds:
• Deep-well GB
• Horizontal shallow GB
• Distributed Anodes
270
Deep well > 50m depth
Sand topping
Carbonaceous backfill Non-metallic

for anodes section vent tube
271
Shallow Bed
Depth 3-5m
272
273
Distributed Impressed Current Anodes Arrangement
Distributed Impressed Current Anodes Arrangement
274
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
Anode Connection :
Connection via Direct connection

variable resistance to +ve bus bar
276
• Impressed current anodes are

some times cannistered with the
Carbonaceous backfill.
277
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
Typical Impressed Current System Arrangement
Ground Bed
279
Positive current flux through soil to buried

pipeline and resulting distribution of current
density on pipe wall
280
Pipeline attenuation and

multiple ground beds
V vs CSE
GB1 GB2 GB3
281
Typical Under-Tank Cathodic Protection

System for New Tanks
282
Under tank
cathodic protection
MMO anode grid
283
SCH. 40" 3
Solution Installation of Under-Tank Watering System

PVC END CAP
Concrete Ring
Compacted
Soil
Laser Slotted PVC Tubes
Slotted PVC Pipes

284
SCH. 40" 3
PVC END CAP
Installation of Under-Tank Watering System

PVC Watering Pipe
Tank
To T/R
ICCP Anode Grit
Compacted Soil
285
Peripheral Anode Cathodic Protection

System for Existing Tanks
Existing Tank
Protecting outermost bottom
MMO strip
Horizontal GB
anode
286
Impressed Current Cathodic

Protection for Tank Internals
Hanging
ICCP
anode
287
Impressed Current Cathodic

Protection for Tank Internals
PVC Support ICCP anode
Anode Cable extended to

outside along vent tube
288
ICCP for jackets
1- Hanging Anodes
289
ICCP for jackets
2- Sub-sea Sleds
290
Cathodic Protection Criteria

2.0
1.6
1.2 3+
Fe
Pourbaix diagram showing the 0.8
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
Fe-to-Soil Potential in Potential vs Cu/CuSO4 Description
Low Resistivity Soils mV
showing the degree of -500
corrosion Intense Corrosion
-600 Free Corrosion
-700 Some Protection
-800 Zone
Zoneof
ofCathodic
CathodicProtection
Protection
The value – 850 mV is -900 Some Over-Protection

the CP criterion for -1000 Increased Over-Protection
protecting steel in
aggressive soils -1100 Sever
SeverOver-Protection
Over-Protection
Problems
Problems
-1200
292
Excessive negative potentials

can cause :
Cathodic Disbonding : i.e.

loss of adhesion between
the coating and the metal
surface
Hydrogen Damage : due
hydrogen evolution at –ve
potentials
293
Potential criteria for cathodic protection of some metals

and alloys at 25º C (1)
Metal/ Alloy Potential criterion (mV)
vs Cu/ Cu SO4
Iron, steel, stainless steel:
Aerobic conditions -850
Anaerobic conditions -950
Lead -600
Copper -500
Aluminum -950 (2)
294
According to ISO 15589-1 Part 1, 2003 concerning the

CP protection criteria of On-Land Pipelines :
“The CP system shall be capable of :

polarizing all parts of the buried pipeline to
potentials more negative than – 850 mV referred to
CSE,
&
to maintain such potentials throughout the design
life of the pipeline”.
295
According to ISO 15589-1 Part 1, 2003 concerning the

CP protection criteria of On-Land Pipelines :
“For pipelines operating in soils with very resistivity,

a protection potential more positive than – 850 mV
referred to CSE may be considered, e.g. as follows”:
- 750 mV for 10,000 < p < 100,000 ohm.cm

- 650 mV for p > 100,000 ohm.cm p = Soil Resistivity
i.e., the value of – 850 mV is only for soils with p < 10,000 ohm.cm
296
Cathodic protection monitoring
Potential Measurement
Structure/Electrolyte Potential is measure by means of a

reference electrode :
Copper / Copper Sulfate Soil
Silver / Silver Chloride Sea Water
297
Copper / Copper Sulfate

reference electrode
Portable Type
298
Copper / Copper Sulfate

reference electrode
In order to measure the structure – to – soil potential,

the CSE must become part of the soil
This is fulfilled by inter-mixing of the CSE content with

the soil content due to diffusion down a concentration
gradient
299
Typical Arrangement for Pipe

– to – Soil Measurement
CuSO4 Saturated Copper Rod
Solution
HIGH SO42- IONS AVO meter
CONTENT
SO42-
Porous Disc
SO42- H2O (Soil) HIGH WATER CONTENT Pipe

Sulfate ions migrate Water molecules
from CSE to soil migrate into CSE
300
Permanent Copper / Copper Sulfate

reference electrode
Prepackage CSE
301
Electrode Placement
For structures : closest
For pipelines : on-the-line
302
Structure-to-Soil potential measurement using Voltmeter.
303
Permanently Installed Reference Electrode & Test Post
304
Permanent Monitoring for

Under Tank Cathodic
Protection
Tank Diameter (m) No. of Electrodes

Required
5-10 1
10-23 2
23-36 3
45 and above 4
305
Reference Electrodes Locations for
Under - Tank CP Systems
1/8D 1/6D 1/4D

3/8D
2/8D
2/6D
D=45m and above D=23-36m D=10.5-22.5m D=5-10m

Key : Reference Electrode
306
Test Posts for CP Monitoring
Flush – to – ground
307
Correct method for measuring structure

potentials when surface is covered with
concrete or asphalt.
AVO
CSE in Wet Soil
Concrete / Asphalt
Buried Pipe
308
Potential Measurement of jackets / platform legs
Diver with portable

reference electrode
309
Potential Measurement of jackets / platform legs
Transponder CP
monitoring
310
Potential plot after data

analysis
311
Potential Measurement of subsea pipelines
Trailing-wire potential survey
312
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
There are numerous codes and references that shall be

referred to when dealing with cathodic protection among
these are:
NACE RP 0169
NACE RP 0176
NACE RP 177
NACE RP 575
ISO 15589-1, PART I – 2003, “On-land Pipelines”
ISO 15589-2, PART II – 2004, “Offshore Pipelines”
DnV RP B 401
API 651
J. Morgan, “Cathodic Protection”
A.W. Peabody, “Control of Pipeline Corrosion”
314
Soil resistivity
Soil represents the electrolyte
Soils with low resistivity have high conductivity; i.e.

corrosive
NACE ranking
Soil resistivity (ohm. m) Corrosivity

up to 10 Severely corrosive
10-50 Corrosive
50-100 Moderately corrosive
100-200 Slightly corrosive
200 and above Non-corrosive 315
Four-Terminals (Wenner)
Measurement of Soil Resistivity.
316
4-Terminals Arrangement
Ohm’s Low : R = V/I
R : Resistance (ohm)
V : Applied Voltage
a a a
I : Recorded Amperage
Depth = a
317
Current demand for CP:
Current density : it is the current required to cathodically protect
1 meter2 of bare steel in a given electrolyte.
Temperature : current demand shall be increased by 25% per

every 10º C incremental rise above 30º C. This requirement is
described by the following equation:
i = i0 + [i0 x 0.25 (t-t0)] / 10

Where,
i = current density at operating temperature, Amp/m2
i0 = base current density at standard temperature, Amp/m2
t = operating temperature ºC
t0 = standard temperature (30ºC)
318
Current density determined in mA/m2 is dependant on the

media aggressivity.
Therefore if soil resistivity is low then current density shall be
high
Current density increases with increasing temperature
Media Current Density
mA/m2
Aggressive Soil 10
Normal soil 5
Sea water 90
Fresh water 30
319
Power Supply :
The T/R is fed with AC current from the nearest power

supply.
If there is no power supply available, Solar Units to be

used instead of T/R.
320
240 Watt Solar Array

0-24 Volt
321
Sun
Regulator
Junction Box
Converter
(+) (-) Structure

Solar Modules
Batteries
Typical Arrangement for ICCP Using Solar Energy
GB Pipe to be protected
322
Typical Coating Resistances for various coating qualities
Coating quality Range of specific

leakage resistance
(RC), ohm.m2
Poor 1,000-2,500
Fair 5,000-10,000
good 25,000-50,000
Excellent 100,000-500,000
323
Typical Coating Breakdown Values
Coating type % breakdown

Initial Mean Final
Thick coating ≤1 5 10
Epoxy coal tar ≤2 5-10 10-20
Fusion bonded 1-2 5-10 5-20
CP current
epoxy
Polypropylene (25 0.5 2 5
yrs)
Polyethylene (25 yrs) 0.5 1 3
324
Recommended potential limits for different coatings

to avoid coating disbondment
Coating type Volt (vs Cu/ CuSO4)
Asphalt Enamel -2
Epoxy coal tar -1.5
Fusion bonded epoxy -1.5
Tape wrap -1.5
Polyethylene -1.0
325
Pipeline Route
Cross-country P/L’s pass through different types of soils,

i.e. different electrolytes
Presence of high voltage power transmission lines
326
Pipeline Route
327
Pipeline AC interference from

electromagnetic field
328
For protection against stray

current from high tension lines,
zinc ribbon and polarization
cells are used
329
Stray current interference
In case of pipe-crossing of cathodically
protected pipelines BONDING is
required by means of :
Solid boning, or
Resistance bonding
330
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
Isolating flange kits

In hazardous areas , IFK’s are
protected by means of Spark Gaps Spark Gap
332
Electrical Isolation
Monolithic Blocks
333
The monolithic blocks are

protected against electrostatic
Monolithic Blocks
charges and lightening by
polarization cell + Polarization Cell
334
Sacrificial VS Impressed Current CP
Sacrificial Impressed current
No need for external power source Requires an external power source
Easy to design and install Requires skillful design and
installation
uncontrollable Can be controlled
Used only for limited surface areas Can be used for uncoated surfaces
and well coated structures and used for any surfaces
Has no detrimental effects Can cause serious problems if not
handled carefully
Is limited to low resistivity can be used at any resistivity
Low maintenance High maintenance
335
Sacrificial VS Impressed Current CP
336
Middle_east@night.oil
Thank You Good Luck
Forest Fires
City Lights
Oil/Gas Fields Flares
337

Corrosion Presentation

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Corrosion Presentation

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Corrosion in Petroleum Industry

All interactions between a metal ( or alloy )

Occurs in wet Occurs in dry

Oxidation : reaction of iron with O2

Carburization : reaction of iron with CO2

Sulphidation : reaction of iron with S or H2S

Wet / Aqueous Corrosion of Metals

Water ( fresh or sea water )

Electrochemical Nature of Corrosion

Corrosion of metals (e.g. iron) in water is basically an

A chemical reaction accompanied by the passage of an

Why Metals Corrode?

Thermal energy (high furnace for Fe)

Electric energy (electrolytic paths for Al)

Electrolytic reduction of Al oxide to Al

Blast furnace of reducing iron

Active free metals tend to react easily to produce

Metals in the compounded forms have less energy

Corrosion is governed by the Law of

Energy Gained = Energy Lost

Mining & Extraction Steel

In all corrosion reactions

(a) (b) (c)

Electron transfer requires presence of anode sites and

Due to potential difference ( ∆V ) between anodes and

Electrons liberated at anodes should be consumed at

The corrosion process involves two reactions:

A. Anodic Reaction (metal dissolution / oxidation )

B. Cathodic Reaction ( reduction )

O2 + 2H2O + 4e- 4 OH-

A piece of metal immersed

The Corrosion Cell 2H++2e 2H H2

Electrons leave the anode

The circuit is close by

For Corrosion to occur :

There must be a positive or anodic area,

There must be a negative or cathodic area,

There must be a path for ionic current flow,

There must be a path for electronic current

An environment is considered corrosive if it contains

mpy milli- inch per year

NACE International Ranking for Steel Corrosion

NACE= National Association for Corrosion Engineers

1. Uniform (General) Corrosion

Pitting and Crevice Corrosion

Stress Corrosion Cracking

Hydrogen Damage ( Embrittlement / Blistering )

According to the National Physical Laboratory – UK :

30% of equipment failures are due to uniform corrosion

70% of equipment failures are due to localized corrosion

Anodic current ( Ia) = Cathodic current ( Ic) , and

Area of anode ( Aa) = Area of cathode ( Ac)

Therefore, the metal loss is equally and uniformly distributed all

Area of anode ( Aa) << Area of cathode ( Ac)

Therefore, the metal loss is concentrated in local areas, i.e. corrosion

Occurs with metals having oxide ( Passive )

In Absence of Chloride Ions

Intact Oxide Film Scratched Oxide Film Film Self-repair

What is the role of chloride ions in localized corrosion;

MCl + H2O = MOHH++ HCl

Pitting may lead to pipe perforation

Crevice corrosion under gasket

Stress Corrosion Cracking (SCC)

Caused by the simultaneous effects of tensile stress and a