This document discusses engineering considerations for corrosion including materials selection, testing, equipment design, and inspection. Key points covered include:
- Evaluating operating conditions and process components to select appropriate construction materials.
- Testing materials to understand corrosion behavior and ensure suitability for the application.
- Designing equipment to minimize corrosion, such as avoiding crevices, using proper welding techniques, and including corrosion allowances.
- Inspecting plants regularly to identify corrosion issues, using visual checks, ultrasonics, and boroscopes depending on the area inspected.
INHIBITION OF CO2 CORROSION BY FORMATE FLUIDS IN HIGH TEMPERATURE ENVIRONMENTS John Downs
Presentation to the Royal Society of Chemistry's "Chemicals in the Oilfield" conference, November 2005
The paper describes how formate brines protect steels against CO2 corrosion. It also shows the results of stress corrosion cracking tests on CRA steel samples exposed to high-density completion brines containing oxygen at 160 deg C. The 13Cr, 22Cr and 25Cr steels all cracked in the presence of calcium bromide brine containing oxygen.
Mainly focused on how hydrogen will get trapped in the weld bead and how it will causes the embrittlement which sometimes leads to hydrogen induced cracking.
INHIBITION OF CO2 CORROSION BY FORMATE FLUIDS IN HIGH TEMPERATURE ENVIRONMENTS John Downs
Presentation to the Royal Society of Chemistry's "Chemicals in the Oilfield" conference, November 2005
The paper describes how formate brines protect steels against CO2 corrosion. It also shows the results of stress corrosion cracking tests on CRA steel samples exposed to high-density completion brines containing oxygen at 160 deg C. The 13Cr, 22Cr and 25Cr steels all cracked in the presence of calcium bromide brine containing oxygen.
Mainly focused on how hydrogen will get trapped in the weld bead and how it will causes the embrittlement which sometimes leads to hydrogen induced cracking.
This is a presentation on hydrogen induced cracking ,sulfide stress cracking and test procedure for HIC resistant steel
DENZIL D’SOUZA
denzil22@gmail.com
Corrosion monitoring in petroleum refineriesK R SONI
In petroleum refineries, corrosion of equipment takes place all through its operating life. It is essential to monitor the corrosion damage so that timely corrective actions like maintenance / repairs / rehabilitation of equipment can be undertaken before it causes unsafe plant operations.
The techniques employed for systematic corrosion monitoring of refinery equipment have been described in this presentation.
As the oil and gas market moves towards new corrosion-resistant materials and alloys, specifying products has become increasingly complex.
When no single material performs well in every application, how can specifiers determine the best fit for a project? And what can be done to predict the expected service life of a component?
This technical seminar, run by Parker on its stand at the major oil and gas event Offshore Europe 2017, looks at:
• Common types of corrosion and their triggers
• Key factors to consider when selecting materials for a project
• Different manufacturer perspectives and the science behind their arguments
• Risks associated with mixing dissimilar materials.
About Clara Moyanno: As an innovation engineer and expert metallurgist working across the globe, Ms. Moyanno, innovation engineer with Parker Hannifin, deals with all sorts of challenges. She is often involved in discussions on materials selection, including advice to oil and gas producers working on new platforms around the world.
Clara specializes in areas such as tackling corrosion, and materials selection for design specifications. She also advises on quality certifications and regulations around the manufacturing of metals.
Learn more http://parker.com/ipd
This topic describes two main categories of corrosion. It also explains the electrochemical corrosion phenomena and the differences between the types of corrosion. This topic also states the corrosion preventive steps.
Customer Bulletin 0610 Polyisocyanurate vs. Cellular Glass InsulationJoe Hughes
This Customer Bulletin is another in our series of white papers aimed at providing our clients, engineers, contractors, fabricators, and friends with objective information on our products and those of our competitors. This Bulletin focuses on a comparison of the physical properties of closed cell polyisocyanurate (PIR or polyiso) rigid foam insulation with those of cellular glass insulation for below ambient applications such as chilled water through cryogenic application where moisture intrusion or condensation can be an issue.
NACE is the corrosion engineer institute. As now, material corrosion exist in our daily life, no matter in the industry application or usual commercial product. They all suffer corrosion impact. As one of member valve industry, I would like to introduce NACE and its related code in upstream and downstream area for stimulating more idea and opponent for make our working environment safe and green.
As an old adage says, corrosion prevention must start at the blackboard, at the design stage. A good design at the blackboard is no more costly than a bad design, a bad design is always more expensive than a good design in reality. Technical design inclu- des the aspects of design that directly bear on the proper technical functioning of the product attributes that describe how it works and how it is made. Design configuration has a critical role to play in the service life of components
Introduction to stress corrosion cracking and nace material requirementsMahendra Prabhu S
Corrosion is one of the major areas of interest for Design / plant operator and maintenance personnel to keep the plant in good shape. The understanding of corrosion mechanism is important for the design engineers to tackle this problem by choosing right metallurgy / manufacturing methods and Inspection techniques. This presentation gives an overview about Sulfide stress corrosion in refining environment and the NACE MR0103 employed to control this phenomena.
Galvanization or galvanizing is the process of applying a protective zinc coating to steel or iron, to prevent rusting. The most common method is hot-dip galvanizing, in which the parts are submerged in a bath of molten zinc.
This is a presentation on hydrogen induced cracking ,sulfide stress cracking and test procedure for HIC resistant steel
DENZIL D’SOUZA
denzil22@gmail.com
Corrosion monitoring in petroleum refineriesK R SONI
In petroleum refineries, corrosion of equipment takes place all through its operating life. It is essential to monitor the corrosion damage so that timely corrective actions like maintenance / repairs / rehabilitation of equipment can be undertaken before it causes unsafe plant operations.
The techniques employed for systematic corrosion monitoring of refinery equipment have been described in this presentation.
As the oil and gas market moves towards new corrosion-resistant materials and alloys, specifying products has become increasingly complex.
When no single material performs well in every application, how can specifiers determine the best fit for a project? And what can be done to predict the expected service life of a component?
This technical seminar, run by Parker on its stand at the major oil and gas event Offshore Europe 2017, looks at:
• Common types of corrosion and their triggers
• Key factors to consider when selecting materials for a project
• Different manufacturer perspectives and the science behind their arguments
• Risks associated with mixing dissimilar materials.
About Clara Moyanno: As an innovation engineer and expert metallurgist working across the globe, Ms. Moyanno, innovation engineer with Parker Hannifin, deals with all sorts of challenges. She is often involved in discussions on materials selection, including advice to oil and gas producers working on new platforms around the world.
Clara specializes in areas such as tackling corrosion, and materials selection for design specifications. She also advises on quality certifications and regulations around the manufacturing of metals.
Learn more http://parker.com/ipd
This topic describes two main categories of corrosion. It also explains the electrochemical corrosion phenomena and the differences between the types of corrosion. This topic also states the corrosion preventive steps.
Customer Bulletin 0610 Polyisocyanurate vs. Cellular Glass InsulationJoe Hughes
This Customer Bulletin is another in our series of white papers aimed at providing our clients, engineers, contractors, fabricators, and friends with objective information on our products and those of our competitors. This Bulletin focuses on a comparison of the physical properties of closed cell polyisocyanurate (PIR or polyiso) rigid foam insulation with those of cellular glass insulation for below ambient applications such as chilled water through cryogenic application where moisture intrusion or condensation can be an issue.
NACE is the corrosion engineer institute. As now, material corrosion exist in our daily life, no matter in the industry application or usual commercial product. They all suffer corrosion impact. As one of member valve industry, I would like to introduce NACE and its related code in upstream and downstream area for stimulating more idea and opponent for make our working environment safe and green.
As an old adage says, corrosion prevention must start at the blackboard, at the design stage. A good design at the blackboard is no more costly than a bad design, a bad design is always more expensive than a good design in reality. Technical design inclu- des the aspects of design that directly bear on the proper technical functioning of the product attributes that describe how it works and how it is made. Design configuration has a critical role to play in the service life of components
Introduction to stress corrosion cracking and nace material requirementsMahendra Prabhu S
Corrosion is one of the major areas of interest for Design / plant operator and maintenance personnel to keep the plant in good shape. The understanding of corrosion mechanism is important for the design engineers to tackle this problem by choosing right metallurgy / manufacturing methods and Inspection techniques. This presentation gives an overview about Sulfide stress corrosion in refining environment and the NACE MR0103 employed to control this phenomena.
Galvanization or galvanizing is the process of applying a protective zinc coating to steel or iron, to prevent rusting. The most common method is hot-dip galvanizing, in which the parts are submerged in a bath of molten zinc.
After the Second World War, Altshuller, a patent officer in the Soviet Navy, started a systematic study of patents –
his aim was to find out what makes a successful invention!
Can there be an algorithm for inventing?
His expedition culminated in TRIZ,
dispelling some innovation myths along the way . . .
My Field is Unique
Experts know Best
Systems Evolve Randomly
Innovation is the search for the Optimal Solution
Crafitti Consulting Private Limited (Crafitti) has developed on the TRIZ way of doing problem solving, patent analysis, and breakthrough concepts development by reinforcing TRIZ with other techniques to build powerful frameworks for Inventing, problem solving and innovation. We offer a unique service for Empowering an Enterprise with TRIZ.
Material Design is Google's new vision for how software looks. Here is a brief introductory guide to visual, motion and interactive design. With the use of material design, there is a hope to build products that give users a great experience.
Discover the secret to a lower coefficient of friction while permitting translational motion or movement with the supporting element. Learn about the different types of slide plates and pipe rollers used for various applications. View the design, load capabilities, and installation and maintenance guidelines for both slide plates and pipe rollers. See numerous photos featuring combinations with other critical pipe supports in order to allow for movement or a low coefficient of friction.
Discover the secret to a lower coefficient of friction while permitting translational motion or movement with the supporting element. Learn about the different types of slide plates and pipe rollers used for various applications. View the design, load capabilities, and installation and maintenance guidelines for both slide plates and pipe rollers. See numerous photos featuring combinations with other critical pipe supports in order to allow for movement or a low coefficient of friction.
Discover the secret to a lower coefficient of friction while premitting translational motion or movement with the supporting element. Learn about the different types of slide plates and pipe rollers used for various applications. View the design, load capabilities, and installation and maintenance guidelines for both slide plates and pipe rollers.
Discover the secret to a lower coefficient of friction while permitting translational motion or movement with the supporting element. Learn about the different types of slide plates and pipe rollers used for various applications. View the design, load capabilities, and installation and maintenance guidelines for both slide plates and pipe rollers. See numerous photos featuring combinations with other critical pipe supports in order to allow for movement or a low coefficient of friction.
Case studies on improving testing processes for batteries, interior components, composites and electronics.
Presented at Automotive Testing Expo Europe 2016.
3. Processes and packages are made out of many different types of materials of construction Depicted here pumps, valves and tanks to show variables that add complexity All at different corrosion potentials Raw Materials Final Products
15. Enough distance for coating Not Desirable DESIRABLE Weld not accessible for grinding Not enough distance for coating No radius Weld accessible Radius Design Considerations
16. Steel P i t (anode) Alloy (cathode) Protective coating Joining Dissimilar Metals Coating holiday-undesirable
19. Flush Rough Smooth Smooth contour (as-welded or ground) for coating Undercut Rollover Porosity Welding Considerations Good Undesirable
20. Corrosion source Threaded parts Round corners Sharp corner Inside of vessel Desirable Flange outlets Weld Inside of vessel 2” Min. Higher Energy state
21. Grind smooth Undesirable Desirable Continuous fillet weld Gap Weld Inside of vessel Gap Crevice Crevice
62. Inhibitors Cathodic protection Coatings and Linings Materials Selection and Design NACE Technical Committees NACE “International Corrosion Society” Water NACE International
63.
64.
Editor's Notes
There are several options to consider when combating corrosion issues. A familiarity of the options is useful to be able to select the right course of action to avoid a particular form of corrosion. Areas in Colgate where there have been issues with corrosion are displayed for discussion. MEIR stands for Materials of Engineering Information Requests. The database is a record of department testing, materials of construction recommendations, and plant surveys. There is a methodology for materials engineering selection. This is discussed in some detail and backed up with a handout. Having a question and not having anyone to answer can be very frustrating and not only that, not addressing it could lead to a serious issue later on. It is better to consult with experts to determine the right answer and direction. A large number of consulting contacts are included in the handout. The “specialist” recommendations for Colgate to avoid issues due to corrosion.
Operating Conditions- Precise definition of the chemical environment, including the presence of trace compounds is vital. Conditions to be defined include, temperature, pressures, flow rates, liquids vs. gaseous phases, aqueous vs. anhydrous phases, continuous vs. intermittent operation. Abnormal or upset conditions should also be defined. Review of Design- the most important consideration are the welds. Will they have adequate corrosion resistance. Other items to consider are the welds should be free of surface defects, such as porosity, slag inclusions, incomplete penetration, or lack of fusion. Low carbon stainless steel needs to be considered. Consideration of materials of construction , first base it on reliable past experience. The list of materials to choose from is large and getting larger all the time. Exclusions examples, pressure to high for FRP, temperature to high for plastics, or environment to aggressive for carbons steel, chlorides and pH for 304 or 316 SS. Other areas to consult are literature surveys or an in-house materials expert. Evaluation of materials- the keys for this to happen are 1) Degree of uncertainty after available information has been considered, 2) The consequences of making a less than optimum selection. 3) The time available for evaluation. Follow-UP Monitoring- once built installed and commissioned the process should be monitored by the materials engineering expert to confirm the selection of materials of construction as adequate. Changeovers and shutdown times are generally good times for inspection.
This conceptually shows that our processes are made of various types of parts with different shapes, geometries and materials of construction. When these parts are subjected to various chemistries, our products, the parts can become reactive. Why because they are at different potential energies based on their shapes, geometries and materials of construction.
Operating conditions is the most important piece of information that you can convey to a corrosion/materials engineer. With all of the information given a corrosion engineer can give the process engineer the forecast on what sort of corrosion issues you need to avoid.
The more complex a process is from a component point of view the more critical it is to make sure it is designed properly and out of the correct materials of construction.
The most valuable information for a engineer is similar case histories. Corrosion is very difficult to predict exactly and it is always best to look at other real life data first.
It cannot be overstated.. Corrosion testing is very important when you do not have data to base a materials of construction decision on. As we have seen, 316L SS is often times not the right answer.
There are so many different types of corrosion tests that it is best to consult someone with experience in corrosion testing. You can very easily be mislead by a corrosion test if it is not conducted in the right way to simulate the real life conditions.
Welded U-bends are an excellent way to study stress corrosion cracking possibilities. In addition data on pitting and crevice corrosion is obtained at the same time. Crevice corrosion where the teflon bushings touch the metal.
There is a lot of corrosion information on 304 SS as it is the most common engineering material out there. This shows the effect again of salt and pH on it.
The design of a structure is frequently as important as the choice of materials of construction. Design should consider mechanical and strength requirements together with an allowance for corrosion. In all cases, the mechanical design of a component should be based on the materials of construction. This is important to recognize , since materials of construction used for corrosion resistance vary widely in their mechanical characteristics.
The most general rule for design is avoid heterogeneity. Dissimilar metals, vapor spaces, uneven heat and stress distributions, and other differences between points in the system lead to corrosion damage. Hence, in design, attempt to make all conditions as uniform as possible throughout the system.
Self explanatory.
Sometimes a design requires different metals and a coating to protect them from corrosion. In that case make sure you have coating that is thick enough to avoid pinholes where the environment could prematurely fail the anode of the two metals.
Skip welding leads to crevice corrosion and should be avoided.
Self explanatory
This slides shows the issue of not using ground welds. Rough surfaces lead to corrosion.
This slides points out that sharp corners and threaded parts lead to corrosion issues. Threaded parts are crevices and sharp corners are at higher stress.
The point here is that seamless tube can have defects. Secondly that welded tube heat exchangers should be leak testes at a higher pressure than the working pressure.
This is a general slide and that is should be mentioned that velocity of fluids can various effect on engineering materials. There are cases where increased velocity can slow down corrosion processes.
The first refers to heat treatment of steels. There are several different types of heat treatment depending on the alloy and the results you are trying to achieve. The basic idea is to relieve locked in stresses from fabrication and to homogenize the chemistry in welds for example. Mechanical refers to forces used to dimple the surface to relieve surface stresses.
By knowing the expected general corrosion rate and the anticipated plant life, the designer can calculate the extra wall thickness required for corrosion resistance of the process equipment he is designing.
It is necessary for reliable plant operation that process equipment be inspected on a regular basis in an effort to anticipate failures and prevent unscheduled shutdowns. Some plant operations schedule an annual shutdown or turnaround at which time it is convenient to inspect suspect equipment.
As shown in the beginning of the course, we have had failures of 316 SS. We need to be more prudent in the future, to examine our processes and equipment for corrosion issues.
Elevated temperatures above 140 F , stress corrosion cracking is a threat. Strong acid such as sulfuric, and hydrochloric. Strong bases such as NaOH. Salt causes pitting corrosion. Abrasives cause erosion. High flow rates cause erosion.
Tanks, Piping, Mixers, Heat Exchangers, Valves- Looking for general, pitting, or stress corrosion cracking Moving Parts- Looking for wear Crevices- Sites for crevice corrosion to occur. A good example would be tank pads. Heterogeneity- Look for galvanic corrosion issues Pressure and Vacuum leave equipment more sensitive to corrosion issues .
Water piping because it could be a source of contamination. Steam and Utility piping because of possible erosion corrosion and the importance of it to the running of the plant Underground lines because of the threat to the environment.