Corrosion and Its Prevention in Petroleum Industries

CORROSION
CORROSION AND
AND ITS
ITS PREVENTION
PREVENTION IN
IN PETROLEUM
PETROLEUM INDUSTRIES
INDUSTRIES
INTRODUCTION TO CORROSION
Humans have most likely been trying to

understand and control corrosion for as long
as they have been using metal objects. The
most important periods of prerecorded
history are named for the metals that were
used for tools and weapons (Iron Age, Bronze
Age).
DEFINITION OF CORROSION
Corrosion is an irreversible interfacial

reaction of a material (metal, ceramic,
polymer) with its environment which results
in consumption of the material or in
dissolution into the material of a component
of the environment.
 The deterioration of a metal by chemical or
electrochemical reaction with its environment
 A chemical action that causes the gradual

deterioration of the surface of a metal by
oxidation or chemical reaction.
 The deterioration of metal by chemical or

electrochemical reactions with substances in
its environment
Factors Which Vary Mainly with the
Environment
 Hydrogen-ion concentration (pH) in the solution
 Influence of oxygen in solution adjacent to the
metal
 Specific nature and concentration of other ions in
solution
 Rate of flow of the solution in contact with the metal
 Ability of environment to form a protective deposit
on the metal
 Temperature Cyclic stress (corrosion fatigue)
Contact between dissimilar metals or other
materials as affecting localized corrosion.
FORMS OF CORROSION
 THERE ARE MANY FORMS OF CORROSION IN
PETROLEUM REFINERY
THE MOST COMMON ARE:
• HIGH-TEMPERATUREGASEOUS CORROSION
• CREVICE CORROSION
• PITTING CORROSION
HIGH-TEMPERATURE GASEOUS CORROSION
 WHEN METAL IS EXPOSED TO AN OXIDIZING GAS at
elevated temperature, corrosion can occur by
direct reaction with the gas, without the need for
the presence of a liquid electrolyte.
 This type of corrosion is referred to as tarnishing,
high-temperature oxidation, scaling, or gaseous
corrosion.
 Initial film growth is usually very rapid. If the scale
is a nonporous solid and completely covers the
metal surface, the reaction rate will decrease when
the thickness reaches a few thousand angstroms as
the transport of reactive species through the film
becomes rate controlling.
Protective and non protective scales formed on alloy 800. (a) Cr2O3-base protective oxide scale
formed in sulfur-free oxidizing gas. (b) Sulfide-oxide scale formed in reducing conditions containing
hydrogen sulfide. Courtesy of I.G. Wright, Battelle Columbus Division
CREVICE CORROSION
Crevice corrosion occurs when a wetted

metallic surface is in close proximity to
another surface, as shown
schematically
PITTING CORROSION
 pitting corrosion occur during active
dissolution if certain regions of the sample
are more susceptible and dissolve faster than
the rest of the surface. This section
concentrates on the better-known and widely
studied phenomenon of pitting corrosion of
passive metals.
CORROSION IN PETROLEUM REFINERY
 Introduction
 CORROSION has always been an unavoidable part of
petroleum refining and petrochemical operations.
 Although certain materials problems are caused by
other factors, a predominant number are due to
various aspects of corrosion.
 Corrosion problems increase operating and
maintenance costs substantially. Scheduled and
unscheduled shutdowns for repairing corrosion
damage in piping and equipment can be extremely
expensive,
and anything that can be safely done to keep a
process unit on stream for long periods of time will
be of great benefit.
 A large proportion of corrosion problems are
actually caused by shutdowns.

 When equipment is opened to the atmosphere for
inspection and repair, metal surfaces covered with

corrosion products will be exposed to air and
moisture.
 This can lead to pitting corrosion and stress
corrosion cracking unless preventive measures are

implemented. When equipment is washed with
water during a shutdown, corrosion can be caused
by pockets of water left to dry.
High-temperature sulfidic corrosion of 150-mm (6-in.) dia carbon steel tube from
radiant section of crude preheat furnace at crude distillation unit. Note accelerated
attack on fire side
Naphthenic acid corrosion on top of 150-mm (6-in.) bubble caps made from
type 317 (S31700) stainless steel containing 2.95% Mo. Tray temperature was
305 °C (580 °F)
Chloride SCC of type 329 (S32900) stainless steel by chloride salts that
concentrated as water evaporated
CORROSION MONITERING
 FSM-IT (Field Signature Method – Inspection
Tool) is a new NDT technology for inspection
and monitoring of metallic pipes and
structures.
 The system is designed to monitor internal
metal loss, or pitting due to corrosion or

erosion with very high sensitivity and without
operator variation. Wall changes, such as
cracking, are also detected.
The FSM principle
 An electric field is set up across the area to
be monitored, in this case a weld Corrosion
causes metal loss which causes increased
resistance across the weld at that point, while
a crack along the weld ‘disturbs’ the current
in a similar manner .
 The resultant changes in the electric field are
measured and converted back to metal loss

figures.
DESIGN TO MINIMIZE CORROSION IN
PETROLEUM REFINERY
 MATERIAL SELECTION
 DESIGN DETAILS
 MECHANICAL FACTORS
 The first step in the materials selection process is
a thorough review of the corrosive environment
and equipment operating conditions. This review
requires input from knowledgeable process
engineers. Precise definition of the chemical
environment, including the presence of trace
compounds, is vital.
 It is always desirable to minimize the list of
materials; this allows in-depth evaluation. In

other cases, the initial list may be exceptionally
small because of limited knowledge about the
operating conditions or the complex chemical
environment.
The following sections will demonstrate the
aspects of design detail that may accelerate
corrosion:-
SHAPE :
 Geometrical form is basic to design. The
objective is to minimize or avoid situations

that worsen corrosion.
 The general problems include localized
corrosion associated with differential aeration

(oxygen concentration cells), crevice
corrosion, and deposit corrosion.
Examples of how design and assembly can affect localized corrosion by
creating crevices and traps where corrosive liquids can accumulate.
Effect of design features on flow
MECHANICAL FACTORS:
 Environments that promote metal dissolution

can be considered more damaging if stresses
are involved.
 In such circumstances, materials may fail
catastrophically and unexpectedly. Safety and

health may be significantly affected.
 Figure below shows cases in which design
detail is used to minimize stress. Perfection is

rarely attained in general practice, and some
compromise on materials limitations, both
chemical and mechanical, is necessary.
The difficulty is that mechanical fault can contribute to corrosion
and that corrosion (as a corrosive environment) can initiate or
cause mechanical failure. Quality control and assurance can
eliminate the former.
PRESENTED BY
 ABDUL WAHAB KHAN ABID
 MOHAMMED ABDUL RAHMAN
 MOHAMMED IBRAHIM HUSSAIN
 MOHAMMED SIBGATHULLAH ZEESHAN

SPECIAL THANKS TO,
INTERNAL GUIDE :
KVSK KISHORE SIR

THE
END

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CORROSION

Humans have most likely been trying to

Corrosion is an irreversible interfacial

 A chemical action that causes the gradual

 The deterioration of metal by chemical or

THE MOST COMMON ARE:

Crevice corrosion occurs when a wetted

actually caused by shutdowns.

inspection and repair, metal surfaces covered with

corrosion cracking unless preventive measures are

metal loss, or pitting due to corrosion or

measured and converted back to metal loss

materials; this allows in-depth evaluation. In

objective is to minimize or avoid situations

corrosion associated with differential aeration

 Environments that promote metal dissolution

catastrophically and unexpectedly. Safety and

detail is used to minimize stress. Perfection is

 MOHAMMED ABDUL RAHMAN

 MOHAMMED IBRAHIM HUSSAIN

 MOHAMMED SIBGATHULLAH ZEESHAN

KVSK KISHORE SIR

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