Aluminium Corrosion Alodine Protective Coating

Alodine EC2-Protective Coating from Mercury attack to aluminum and titanium alloys in Oil&Gas equipment By Fernando Vicente Reliability and Integrity Engineer

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],The Advantage of aluminum

[object Object],[object Object],[object Object],Introduction

TYPICAL MERCURY CONCENTRATION IN NATURAL GAS LOCATION (μg/Nm3) Groningen (Hol.) (gas well) 180 - 200 Arun (Indonesia) (gas well) 250 – 300 Germany North (gas well) 15 – 450 Germany South (gas well) <0,1 - 0,3 EE.UU. east (pipeline) 0,02 – 0,4 Algeria (pipeline) 0,1 – 89 Skikda (Algeria) (plant) 0,001 – 0,65 Wyoming (EE.UU.) (plant) 8 – 24 Venezuela (plant) 0,6 – 1,3

[object Object],[object Object],[object Object],[object Object],Hg the primary enemy of Al in gas stream

[object Object],[object Object],[object Object],[object Object],Aluminum corrosion-General

[object Object],[object Object],[object Object],[object Object],Impact in aluminum alloys Catastrophic failure in Skikda plant Source: “ The 50 Major Engineering Failures “(1977-2007)

Failure mechanism affecting aluminium in Gas Plant (reaction with Hg) There are three mechanism that Hg attack to aluminum

[object Object],[object Object],[object Object],[object Object],[object Object],Amalgam Hg AL

Amalgam corrosion ,[object Object],[object Object],[object Object],[object Object],Due to Hg regenerate itself, the reaction is self propagating while water exist . The amalgam corrosion is accelerate in O 2 presence, and creates a filiform corrosion (Al 2 O 3 feather)

[object Object],Amalgam corrosion

[object Object],[object Object],[object Object],[object Object],[object Object],Amalgam corrosion

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],LME (Liquified Metal Embrittlement)

LME process AL 2 O 3 Aluminum Liquid Hg (-38,9C) Crack For crack propagation stress are required

Alloys composition susceptible to aluminum LME attack (% p/p) ALLOY Cr Cu Mg Others 5083 0,05 -0,25 < 0,1 4,0 – 4,9 Mn 0,4 – 1,0 5086 0,05- 0,25 <0,1 3,5 – 4,5 Mn 0,2 – 0,7 6061 0,04 -0,35 0,15 -0,40 0,8 – 1,2 Si 0,4 – 0,8 7075 0,18 -0,28 1,2 – 2,0 2,1 – 2,9 Zn 5,1 - 6,1

[object Object],[object Object],LME failure history

5083 ó 5086 Alloys Alloy 3003 ( Cold box )

LME (Crack in circumferential weld seam)

[object Object],[object Object],LME failure history Source:B. Bavarian, CORROSION 2004 (NACE), paper 558

LME cracks in rotor, alloy 7075

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],LME

LME ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

[object Object],[object Object],[object Object],[object Object],Mercury levels for cryogenic gas plant

Typical cryogenic plant Affected equipment

[object Object],[object Object],Typical process parameters

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Benefit from protective coating

[object Object],[object Object],[object Object],[object Object],Summary

[object Object],[object Object],[object Object],[object Object],[object Object],Bibliography

Aluminium Corrosion Alodine Protective Coating

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