Corrosion Study Process

Process Review

Common processes:
Upstream: Crude/gas stabilization, gas dehydration, gas compression, produced water
treatment.
Downstream: Crude refining, catalytic reforming, catalytic cracking, hydrotreating, gas
sweetening, etc.
Staff must be able to:

Identify major equipment and their functions and process changes that take place
inside i.e. reaction, heating, cooling, condensation, vaporization, dehydration, etc.
Identify major process streams i.e. feed, product, waste, etc.

Suggested reference:

API RP 571 Second Edition, April 2011

Corrosive Species/Corrodents

Common corrosive species:

Upstream: Hydrogen sulfide (H2S), Carbon dioxide (CO2), chlorides, seawater, produced
water
Downstream: Chlorides, seawater, fresh water, acids, chemicals, hydrogen
Staff must be able to:

Find out stream composition from Heat Material Balance or Process Description
Determine corrosivity of chemicals from MSDS

Material Review

Common materials used:

Carbon steel, stainless steel, copper nickel, low alloy
Staff must be able to:

Determine the material used from GA drawing, piping material classes (this may differ
from one client to another) or/and P&IDs

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Corrosion Damage Mechanisms

Damage mechanisms can be identified based on the corrosive species and the material of
construction. Internal and external corrosion shall be analyzed separately. Examples of
common mechanisms encountered are shown in the following table. For detailed description
of various corrosion damage mechanisms, refer to API RP 571.
Material

Corrodent

Potential Damage Mechanism

Carbon steel

H2S

wet H2S damage

CO2

CO2 corrosion

Sulphate Reducing Bacteria

(SRB)

Microbiologically Induced Corrosion

(MIC)

Chloride

Chloride Stress Corrosion Cracking

(CLSCC)

Stainless steel

High temperature corrosion does not require water present (temperature > 204oC)
Common high temperature corrosion mechanisms:

Carbon steel oxidation, sulfidation,High Temperature Hydrogen Attack (HTHA), etc.

Stainless steel oxidation, sulfidation, sensitization & polythionic acid stress
corrosion cracking, etc.

Staff must be able to:

Identify relevant and possible corrosion mechanisms from the material of

construction, process fluid and operating conditions
Determine the degree of susceptibility
Set safe operating window or IOW for relevant operating parameters based on the
identified corrosion mechanism i.e. pH, temperature

Suggested references:

API RP 571 Second Edition, April 2011

API RP 581 Second Edition, September 2008
API RP 941, Fifth Edition, January 1997 & Supplement 1, April 1998

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5
5.1

Corrosion Rate Prediction

Internal Corrosion Rate

Numerical models are available to predict CO2 corrosion rates i.e. NORSOK M-506,
Freecorp, Electronic Corrosion Engineer (ECE), Hydrocorr, etc. However, when H 2S or/and
organic acids are present, the corrosion rates predicted using the CO 2 corrosion models may
not be reliable. The reason is due to the different dominant scales formed on the metal
surface depending on the ratio of partial pressures of CO2 and H2S.
For

For

For

pC O 2
<20 , the dominant scale is FeS,
p H2 S

20

pC O 2
500 , the scale is a mixed of FeS and FeCO
3
pH2S

pC O2
>500 , the dominant scale is FeCO (protective scale)
3
p H2 S

In other cases, the internal corrosion rate can be estimated as shown in the following table:
N
o

Description

Corrosion Rate
(mm/yr)

Assumption

Raw seawater (CS)

0.1
0.1-0.9

Water velocity < 0.8 m/s

0.8 m/s < water velocity < 6 m/s

Treated seawater (CS)

0.0100

Low oxygen/biocide/chlorination

Fresh water (CS)

0.25

Chloride < 200 ppm

Open drain (marine)

(CS)

0.10

Water velocity < 1 m/s

Closed drain (CS)

0.05

calculate CR from CA/design life

Dry Gas (CS)

0.01

Gas is dry

Nitrogen, instrument air

(CS)

0.025

Nitrogen is dry

Produced Water (CS)

Atmospheric Vents (CS)

0.10

Equivalent to ext. CR at ambient temp.

10

Diesel, potable water

0.03

No oxygen present

11

Utility air (CS)

0.10

Oxygen and moisture present

12

CuNi/SS/DSS

0.01

Corrosion Resistant Alloy

calculate CR from CA/design life

Note: Values for CS can be applied to low alloys.

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5.2

External Corrosion Rate

External corrosion rates can be estimated by interpolating values in API RP 581.

Staff must be able to:

Know the limits of the model used i.e. temperature, pH, CO2 partial pressure
Source of input values from design documents
Correctly convert units for input values i.e. Sm3/day (Standard Flowrate)

Sm3/day = m3/day (actual flowrate) x (actual pressure in psia / 14.5 psi) x (273.15K / actual temp in
Kelvin)
Note: Standard condition refers to 273.15K, 14.5 psi

Corrosion loops

Corrosion loops can be identified gradually. Make 2 (two) sets of the Process Flow Diagram
before starting this process.

If a stream enters a separator (i.e. distillation column, dehydration column, K.O. pot,
etc.) or a reactor, mark all output streams using different colors.
At this stage, use a color to represent a process stream i.e. crude, wet gas, dry gas,
produced water, injection water.
Next, analyze the material of construction. If there is any change in material within
each process fluid/color, mark the place of material change. Do this for all major
streams previously identified.
Now break down each color into smaller groups depending on the material of
construction. For example, seawater system is usually divided into GRE-loop (before
deaeration) and CS-loop (after deaeration) sections.
Next, analyze the stream temperature and pressure. Smaller groups can be formed if
temperature difference is significant (if high temperature corrosion may be a threat).
Next, mark all injection points (if any).

Use a fresh set of PFD for the next steps:

Highlight major process lines using different colors for different corrosion loops.
Assign a corrosion loop number to all groups such as PG-01, PG-02, etc. (Note: Get
client to agree on a naming convention before completing the corrosion study)
Assign corrosion loop numbers to all utility streams such as cooling water, steam,
nitrogen.
Construct a table to summarize all corrosion loops. List the following information of
each loop:
Corrosion Loop Name i.e. PG-01
Corrosion Loop Description i.e. Wet Gas
Starting Point i.e. Insulating flange at gas riser
Ending Point i.e. Production Separator
Fluid : Hydrocarbon Gas (C1), Water
Temperature
Pressure

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6.1

Material
Chemical Injection (Yes/No)

Corrosion Circuits

Corrosion circuits are identified using a set of P&IDs.

Start with one corrosion loop mark all the relevant lines on P&IDs using PFD as a
guide.
Revise the Corrosion Loop Summary Table if necessary to accurately describe the
starting and ending points for the loop.
It is common practice to terminate a loop at a block valve, unless it is not possible.
Break the loop into circuits based on the following rules (assign a circuit number i.e.
001, 002, 003....):
Where the stream enters static equipment or rotating equipment
Where chemicals are injected
Piping diameters (do not put small bore piping in the same circuit as bigger
piping)
Repeat this process for all the remaining corrosion loops.

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