Corrosion The Understanding of Basic
Corrosion The Understanding of Basic
Corrosion The Understanding of Basic
Thus, for example, iron and steel have a natural tendency to combine with other
chemical elements to return to their lowest energy states
REACTION
A : Anode C : Cathode
Classification
based on 3
factors :
Mechanism of corrosion: This involves either electrochemical or
direct chemical reactions.
/ Galvanik
MATERIALS
METALS
• Carbon and low alloy steels
• Martensitic stainless steels
• Austenitic / super-austenitic stainless steels
• Duplex / super-duplex stainless steels
• Nickel alloys
• Copper alloys
• Titanium
NON-METALS
• Elastomers
• Glass fibre reinforced plastics
• Thermal insulation
◼ Castings
◼ Forgings
◼ Rolled products
plate
sheet
bar
◼ Seamless pipe and tube
◼ Welded pipe and tube
◼ Extruded sections
◼ Hot isostatic pressings
(powder metallurgy)
❑ Relatively
inexpensive
❑ Complex shapes
but……
❑ Relatively simple
shapes
❑ Good mechanical
properties
Open forging Closed die forging
❑ Forging defects less
likely than castings
Hot working
Recrystallisation
Homogeneity
Closure of defects
Cold working
Increase in strength
Dimensional control
Surface finish
◼ Pierced solid
◼ Hot and cold drawing
◼ No weld defects
◼ Uniform properties
Seamless pipe
manufacture
Longitudinally welded
◼ Made from plate or strip
◼ Uniform wall thickness
◼ Concentricity
◼ Lower cost than
seamless
Longitudinally fusion welded pipe
Spirally welded
◼ Made from coiled strip
◼ Non-preferred for HC
duty
◼ QA/QC requirements
◼ Water pipe and piling
ERW
◼ Lowest cost
◼ Projects only, not maintenance
◼ Approved suppliers only !!
◼ Not suitable for duties that can
support:
stress corrosion cracking
preferential weld corrosion
900
Furnace cool
(anneal)
Temperature, °C
Time
Fine ferrite / pearlite: good
strength and toughness
Martensite: high
strength but brittle
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Welding
❑ Complex shapes
❑ Versatile
but……
❑ QA / QC (defects)
Single sided butt weld in steel
❑ Carbon equivalent
CE = C + Mn + Cr + Mo + V + Ni + Cu
Water cool, Air cool, alloy 6 5 15
carbon steel steel
100
Time
Martensite in heat
affected zone if
cooling rate too fast
Cast structure of
weld metal
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Avoiding martensite formation in welding
Carbon steels
Regular grades
◼ Pressure vessel plate, A 285, A 515
◼ Seamless pipe, A 106B
◼ Forgings, A 105
◼ Fittings, A 234
◼ Bolting, A 193 B7
Impact tested grades
◼ Pressure vessel plate A 516
◼ Seamless and welded pipe, A 333
◼ Forgings, A 350
◼ Fittings, A 420
◼ Bolting, A 320 L7
All grades of carbon steel used for welded
construction are supplied in the normalised
condition. Bolting will be Q+T
Composition
Fe, 18%Cr, 8%Ni or “18-8”
Benefits
General corrosion / oxidation
resistance
No ductile-brittle transition
Highly ductile
Readily weldable (use “L” grade)
Limitations
Low yield strength
Localized corrosion resistance
304 SS is widely used in
◼ Pitting, crevice, SCC by chloride
domestic, medical, food
ions and pharmaceutical
applications
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Austenitic stainless steel – type 316
Composition
Fe, 18%Cr 10%Ni 2.5%Mo
Benefits
Same as type 304, plus…
Improved localised corrosion
316 SS is the standard alloy for
resistance
instrument and control systems
Limitations
Low yield strength
Still not suitable for seawater
Composition
Higher Ni & other alloy elements
compared with standard austenitics,
e.g. Fe, 25%Ni, 20%Cr, 6%Mo
Benefits (compared with 316SS)
Improved resistance to
◼ localised corrosion
◼ environmental cracking
Composition
Regular grade is 22%Cr, 5%Ni, 3%Mo
Austenite islands
Benefits (over 316SS)
Double yield strength
Improved localised corrosion resistance
Much improved chloride SCC resistance
Limitations
Greater care required for welding
Limited H2S cracking resistance
Not seawater resistant
Limited to -50ºC impact toughness
Ferrite matrix
Composition
316 SS tubing
Typically 25%Cr, 7%Ni, 3.5%Mo
Benefits (over 22% Cr DSS)
25% higher yield strength
Improved localised corrosion resistance
Improved chloride SCC resistance
Seawater resistant to ~ 20ºC
Limitations
Higher cost
Even greater care required for welding and heat treatments
25%Cr super-duplex
Limited H2S cracking resistance
Limited to -50ºC impact toughness
Inter-metallics
Slow cool
Fast cool
600 1 10 min
0.01 1 100
Time, h
Ideal “clean” duplex
structure requires fast
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cooling 65
Avoiding embrittlement of duplex SS
Inter-metallics
Fast cool
600 1 10 min
0.01 1 100
WELDING
Time, h • no preheat
• cool between passes
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• use low heat input process
66
Nickel, copper and titanium for pressure systems
Benefits
− No ductile-brittle transition
− Customised corrosion resistance
− Chloride SCC resistance
− Some are seawater resistant to ~ 30ºC
− Good weldability: ideal for cladding
Limitations
− High materials and fabrication costs
− Some have low yield strength
Clad materials
Carbon steel pipe, fittings, and
vessels
Ni alloy of choice (usually 625)
Benefits
Corrosion resistance of the nickel
alloy
Cost-effectiveness
Manufacturing processes
Overlay welded
Hot-rolled clad pipes
Explosion welded clad plate
Benefits
Lower cost “nickel” alloy
Good H2S / CO2 resistance
Welding / fabrication
Limitations
Low yield strength
Low PREw (~28)
Not seawater resistant
Benefits
Excellent all-round corrosion resistance
Welding & fabrication
Good mechanical properties
Limitations
High cost
Benefits
Excellent all-round corrosion resistance
PREw = 64
Good mechanical properties
Limitations
Specialist alloy – limited supply
Cold bending only (no heat)
Limitations
High cost due to nickel content
Rarely used today in E&P
Characteristics
Simple to manufacture by forming
High heat conductivity makes
welding challenging
Readily available & easy to repair
Use
Mainly for sea water Copper-bottomed hulls resist
build-up of marine growth
Resist marine growth due to their
inherent poisoning effect
Not suitable for hydrocarbon duty
90-10 CuNi seawater filter vessel 90-10 CuNi pipe and fittings for
seawater system
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Designing with copper alloys
Galvanic corrosion
Contact should be avoided with
stainless steels and titanium: these
materials are more noble
Avoid graphite-containing gaskets
CuNi
Carbon steel
Stainless steel
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Calculate t min as per ASME B31.3 2018
Equation 304.1.2
Seamless Pipes : Design Thickness
t = (PD)/2(SE+PY)
Where,
P : Internal Design Gauge Pressure
D : Outside diameter of pipe
1. ASME B36.10 : Welded and Seamless Wrought Steel Pipe.
2. ASME B36.19 : Stainless Steel Pipes.
S : Allowable Stress value for material from Table A-1 ASME B31.3
S : Allowable Stress value for material from Table A-1 ASME B31.3
Addition of Allowances
Corrosion Allowance, Mechanical Allowance for Grooving, Threading etc and
Manufacturing Tolerance to arrive at final value.
Calculator
https://www.pipingengineer.org/pipe-thickness-calculator/
➢ Longitudinal ➢ Transversal
SURFACE CALIBRATION
PREPARATION ULTRASONIC TESTER
OBSERVATION RECORD
CLEANING
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Ultrasonic Testing (UT)
4. Calibration Methods
a. Reference Test Piece
▪ STB A-1 (IIW) (check performance, adjust measurement range, measure incidence, and
refraction angle of the probe).
▪ The Miniature Angle-Beam or ROMPAS Calibration Block (beam angle & exit point of
transducer, sensitivity calibrations, metal distance).
Sensitivity Calibration Distance Calibration (DC) Block Resolution Calibration (RC) Block
(DSC) Block (check resolution & gain setting of
angle beam)
▪ Resolution Reference Block ( evaluate the near-surface resolution and flaw size/depth
sensitivity of a normal-beam setup, calibrate high-resolution thickness gages).
b. Disadvantages
▪ Surface must be accessible to probe and couplant.
▪ Skill and training required is more extensive than other technique.
▪ Surface finish and roughness can interfere with inspection.
▪ Thin parts may be difficult to inspect.
▪ Linear defects oriented parallel to the sound beam can go undetected.
▪ Reference standards are often needed.
Speciment 3