Engineering Failure Analysis 102 (2019) 293–302

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Engineering Failure Analysis

journal homepage: www.elsevier.com/locate/engfailanal

Inspection of internal erosion-corrosion of elbow pipe in the

T
desalination station
⁎
Bassam Gamal Nasser Muthannaa, Mouna Amaraa, Mohammed Hadj Meliania, ,
Boualem Mettaib, Željko Božićc, Rami Suleimand, A.A. Sorourd
a
LRM, Faculty of Technology, Hassiba BenBouali University of Chlef, Chlef 02000, Algeria
b
Laboratoire eau-environnement, Université Hassiba Ben Bouali, Chlef, Algeria
c
Faculty of Mechanical Engineering, University of Zagreb, Nav. Arch. I. Lučića 5, Zagreb 10000, Croatia
d
Center of Research Excellence in Corrosion (CoRE-C), King Fahd University of Petroleum & Minerals (KFUPM), Dhahran 31261, Saudi Arabia

A R T IC LE I N F O ABS TRA CT

Keywords: Due to the worldwide decrease in the quantity of potable water in the last decade, the desali-
Corrosion nation station is among one of the most important methods to treat seawater to supply the dry
Desalination regions, Sahara regions and the offshore regions with purified water. During the desalination
Pipe elbow process, many problems can appear including the corrosion problems that attribute to the ma-
SEM
terials of piping systems and theirs geometrical shapes, and the chemical composition of water
XRF
taking into account the conditions of transporting. Pipe elbow is one of the necessary parts to
XRD
build the integrated piping system which is considered as a linking point between different parts
of the transport systems. Because of its effective role and complex forms that based mainly on
welding processes, the pipe elbow is vulnerable to corrosion problems considering the liquid
nature of the effluent, and the surrounding pressure and temperature. The results of the me-
chanical characterizations tests such as metallurgical examinations using optical microscopy,
scanning electron microscopy (SEM), X-ray diffraction (XRD) and X-ray fluorescence (XRF) al-
lowed us to analyze the main causes of the defect in this part. The obtained results showed that
many technical solutions can be employed to mitigate and relief the encountered internal cor-
rosion in pipe elbow, which helps greatly in enhancing the energy development in desalination
industry.

1. Introduction

A long time ago, water wealth played a major role in the emergence of many civilizations and wars between human nations.
Recently, the water crisis has become a serious issue due to the aspect of shortage and increasing demand of fresh water and other
aspect is the shortage resulted from thermal emissions and water pollution activities. For these reasons, many countries decided to
adopt the seawater desalination methodology as a solution to the water-shortage problem. The solid-fluid interaction in the com-
ponents of the desalination industry leads to chemical reactions in the elbow part which represents the critical zone in the piping
systems. The transport of corrosive liquids (simple or complexes) can be achieved using difference ways such as pipeline, pipeline
offshore, cargo tanks for chemical tankers, storage tank, road tankers, rail tank wagons and many other solutions. The processes of
water treatment and its transport depend on the piping systems especially the elbow who is one of among an important parts. Indeed,

⁎
Corresponding author.
E-mail address: m.hadjmeliani@univ-chlef.dz (M.H. Meliani).

https://doi.org/10.1016/j.engfailanal.2019.04.062
Received 16 February 2019; Received in revised form 8 April 2019; Accepted 25 April 2019
Available online 26 April 2019
1350-6307/ © 2019 Elsevier Ltd. All rights reserved.
B.G.N. Muthanna, et al. Engineering Failure Analysis 102 (2019) 293–302

the piping systems is still the best tool and safest way to transport the corrosive liquids such as carbon dioxide (CO2), hydrogen,
methanol, hydrogen sulfide (H2S), hydrochloric acid (HCl), sulfuric acid (H2SO4) and ammonia (NH3) [1–6]. Carbon steel is con-
sidered as the best material to manufacture the pipelines due to the distinctive mechanical properties and low cost of this material but
with relatively low corrosion resistance properties [7,8]. Due to the several factors which occur to piping systems such as the
chemical reactions and interactions (fluid-solid) the Pipeline defects are among principal challenges facing the desalination water
stations taking into consideration the operating conditions. It is reported in literature that the fundamental parameters that controls
the corrosion of the elbow in the piping systems of desalination stations are CO2, thermal effect, H2S, chloride (Cl−), NH3, sulphate
(SO42−), water and organic acids [9–11]. Tawancy et al. [7] have thoroughly studied a corroded elbow made of carbon steel to
understand the effect of the operating conditions of the pipe on its corrosion phenomenon.
The corrosion issue is mainly found on the bottom of elbow pipe where the chlorination and sulfidation reactions in addition to
the presence of inorganic salts in the fluid, calcium chloride and hydrogen sulfide allows the formation of a layer on wall of the
elbow. Ilman et al. have studied the internal corrosion of a subsea pipeline occurred on the bottom side of an elbow made of API 5 L
X52 steel. The study has proved that the presence of water and oxidation have led to the corrosion occurrence in the teardrop shaped
pits and grooves [8]. Kusmono et al. have analyzed a failure occurred at the bottom of piping systems' elbow as a result of erosion-
corrosion processes on the elbow in the presence of steam, water, and solid particles [12].
The production of CO2 is one of the principal processes in the desalination station. This operation needs the mixing of mono-
ethanolamine (MEA, 11%) with one liter of water in order to absorb CO2 from the flue gas. Moreover, sodium carbonate (Na2CO3)
can help in controlling the final corrected pH which will prevent or reduce the corrosion of the pipeline as a result of the trans-
portation of CO2-rich MEA solution inside the pipe. The presence of undesirable components on the surface of elbow will reduce its
quality where the penetration of the CO2-rich MEA solution to the steel will help in the dissociation of materials that are in contact
with the steel surface. In order to get more insight on this process, we aimed in this study to investigate the influences of various
process parameters such as the type of welding material, sodium carbonate contact time, the nature of liquid solution, and finally the
boundary conditions on the internal erosion-corrosion of elbow pipe in a desalination station. The results of the failure phenomenon
were carefully studied by analyzing the microstructure and the composition of the surface films on the surface of the corroded
specimens using scanning electron microscope (SEM), X-ray diffraction (XRD) and X-ray fluorescence (XRF) techniques.

2. Experimental procedure

2.1. Materials

The test specimens in our study were prepared using samples from a failed carbon-steel elbows. These corroded elbow samples
were taken from the desalination plant in Chlef, Algeria. The positions of these corroded elbows are depicted in Fig. 1 and identified
as part I and II. The two elbows transport the CO2-rich MEA solution. As stated above, the corrosion phenomena in the samples have
been analyzed based on the results of SEM, XRD and XRF analyses.
Fig. 1 shows a schematic presentation for the solution process and the location of the failed elbows. The liquid solution passes
through the pipe in a vertical direction as shown in the figure. There are two elbows shown in Fig. 1; the valve of the first elbow (Part

Fig. 1. (a) A schematic view of the carbon steel elbows at the corroded location and (b) a photo-digital image of the real installed elbows.

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Fig. 2. General view of the external surface of failed pipe elbows, (a) 3 o'clock of part I (b) 9 o'clock part I, and (c) 6 o'clock of part II.

I) is opened completely for 90° while the valve of the second elbow (Part II) is opened partially with 35°.
Fig. 2 shows an external view of the corroded positions in three regions of the elbow pipe (indicated by arrows). During the
service operation, the internal inlet pressure is in the range 3.5 to 4 bars whereas the outlet pressure reaches only up to 1 bar (Fig. 1a).
The flowing temperature reaches about 85 °C. The corroded area in the two positions (3 and 9 o'clock) of the first elbow (Part I) is
clearly shown in Fig. 2a,b and the damaged area for the second elbow (Part II) can be seen in Fig. 2c and is indicated by arrow 3 (6
o'clock).

2.2. External surface

Depending on the elbow material, the presence of CO2 with MEA solution leads to corrosion in the zone of interaction fluid-solid.
The attack concentration of the flow on the inner surface of pipe elbow which represents the areas around the valves is one of the
serious reasons which create the erosion-corrosion due to the opening of the valve and its design as seen in Fig. 2.
Under the operation conditions, the valve is opening where it allows the distribution of the flow directly between the two internal
zones. In addition to the interaction between the wall of elbow and the solution (solid-liquid interaction) under complex corrosive
conditions, the type of welding encountered in the elbow has also an impact on creating the corrosion problem. In fact, the first
corrosion problem occurred in zone 3 (Part II) near the critical welding position was due to the great pressure oriented towards the
elbow surface. Successive welding treatments (five times) did not help in solving this problem as corrosion occurred again on the
same location. This complicated issue spur us to investigate in detail this corrosion phenomenon.

2.3. Visual observation

According to the operating system of the desalination plant, the carbon steel piping should be inspected in the locations having
the highest interaction with effluents especially in the critical zones that surround the valves. Indeed, the degree of elbow bend plays
an important role in changing the direction of the pressure towards to the internal wall taking into account the pressure let-down
valves. In this section, samples from the heavily corroded elbow of the two parts I and II (shown in Fig. 2) were used to find out the
reasons for the erosion-corrosion occurrence. During experiment, the corrosion position of these samples was analyzed. The degree of

Fig. 3. General view of the internal surface of failed pipe elbows.

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Fig. 4. Degradation of wall thickness (a) elbow pipe (part I), and (b) flange steel.

corrosion occurred on the two elbows is shown in Fig. 2. Overall, it was observed that the corrosion of elbow just occurred near of the
welding zone. Figs. 3 and 4 show the visual observations of the corroded sites in the internal surface along the elbow in varying
degrees.
The elbow corrosion takes the form of pits and grooves stretching in the same direction of fluid flow. It can be observed also that
the thicknesses of the elbow pipe and flange (part I) are degraded as shown in Figs. 3 and 4 and Tables 1 and 2. This is due to the
attack of the flowing fluid and the opening of valves and the two factors contribute greatly in eroding the thickness of the pipe. Such
type of problems leads to hypothesize that the leaks are resulted from the attack of the flowing fluid that is rich with CO2. The
verification of this preliminary observations has been carefully attempted in this study and the results of the detailed analysis will
appear later in this manuscript.

2.4. Chemical composition and mechanical characterization

Knowing the mechanical behaviour of the piping system is necessary to predict and avoid corrosion problems. The chemical
composition of the carbon steel corroded elbow was studied via microstructural and mechanical properties investigations including
the tensile and hardness measurement tests. In this part, the chemical composition of the standard materiel (DIN 17175 steel) is
shown in Table 3 [13]. Table 4 shows the mechanical properties of the steel elbow and its dimensions.

2.5. Metallurgical examination

MEA is considered so far as a very effective chemical substance that can be used as a solvent to minimize the generation of
intermediate molecules. Moreover, the molecules are retrievable through the thermal process. MEA substance reacts with compounds
containing sulphur element Wolsky et al.[14]. Among the advantages of MEA substance is its ability to reduce pollution that resulted
from the presence of sulphur components in emitted CO2 gas. The presence of SO2 in the gas stream reacted with the MEA indicates
that this operation depends on the interaction between MEA and CO2 [15,16].

3. Results

Erosion-corrosion in the pipe elbow is still a complicated problem due to its impact on changing the structural and mechanical
properties of this important component in the infrastructure of desalination industry. Understanding the behaviour of the corroded
elbow is greatly associated with the fluid-solid interaction inside the pipe. In this study, samples for different zones of corroded elbow
were used to analyze its corrosion behaviour. A series of experiments were conducted to identify the causes of the corrosion-erosion
phenomenon along the corroded elbow. The obtained results of the different zones of elbow are listed in this section.
In particular, our attempt in this study is to determine if one or more factor has helped in evolving and propagating corrosion in
the tested elbow. The inspection was made for three specimens taken from three different surfaces of elbow (part II) as shown in
Fig. 5. We have analyzed the three cutted specimens according to the friction of fluid flow in the internal surface of elbow. Fig. 5
shows also a photo-digital image that highlights the effect of corrosion on the internal surface of the elbow; it is clear that the surface
layer in which the liquid passes is corroded and surrounded by a rough layer as indicated by arrows named “A”, “B” and “D”. Zone
“A” is a proper surface which does not have signs of corrosion, while “B” is the area of where the fluid passes from and has a uniform
corrosion but without defects. Finally, “D” is the corroded zone where the flowing fluid attacks the indicated location in the image.

Table 1
Degradation of pipe elbow thickness (part I).
Thickness t0 t1 t2 t3 t4 t5 t6 t7

Value (mm) 3 3 2.3 2.55 2.8 2.6 3.1 3.45

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Table 2
the change of wall thickness of flange.
Thickness tb1 tb2 tb3 tb4 tb4 tb5 tb6

Value (mm) 26.95 26.90 19 22.85 22.75 25.75 26.85

Table 3
Chemical composition of DIN 17175 pipe steel (%) [13].
Grade C Si Mn P S

ST 35.8 0.17 max 0.10–0.35 0.40–0.80 0.040% max 0.040% max

Table 4
Mechanical properties of DIN 17175 (ST 35.8) pipe steel standard [13].
Tensile strength (MPa) Yeild strength (MPa) Elongation (% min) Pipe outside diameter (mm) Elbow bending (°)

360 to 480 235 25 140 90

Wall thickness (mm) Pressure inlet (bars) Pressure outlet (bar) The conductivity of Solution (ms/cm) pH of Solution
4 4 1 3.76 9.96

Fig. 5. Internal surface view of the analyzed specimens.

3.1. Optical microscope

Microscopic analyses were performed using a Carl Zeiss Axio Imager A1m microscope, coupled with a CANON camera model
Power shot A640. This optical microscope allows us to show the visualization of the specimens' surface colour, and their shape and
distribution. Figs. 6-8 provide a better imaging for the surface of specimens highlighted in Fig. 5.

3.2. Scanning Electron Microscopy (SEM)

The surface morphology and elemental compositions of different positions of corroded elbow specimens were studied by scanning
electron microscopy (SEM) measurements.

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Fig. 6. Optical microscopy at zone “A”.

Fig. 7. Optical microscopy at zone “B”.

Fig. 8. Optical microscopy at zone “D”.

The analysis of optical microscope and SEM results can indicate clearly the behaviour of the elbow's different materials under the
operating conditions of the pipe. The combined results of the two techniques can give an idea on the nature of the pipe's effluent that
is less corrosive to the pipe's material. From the images, it is clear that the surface of the elbow has degraded to different extents.
Figs. 6 and 9 show the images of the non-corroded zone “A”, while Figs. 7 and 10 depicted the status of the surface of the second
region “B” which might have a high degree of fluid-solid interaction that is responsible for the friction and corrosion phenomena
(brown colour) on the internal surface of steel. The dark brown colour also visible in zone “D” (Figs. 8 and 11) and indicates the
presence of cracks and serious corrosion-erosion problems on this part of the elbow. This zone has also a groove and pinhole due to
the attack of CO2-rich flowing fluid. In addition, the presence of small solid particles in the fluid is mainly responsible on the erosion
problem in the elbow which will be further addressed in the following section.

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Fig. 9. Top-surface SEM image of Region A.

Fig. 10. Top-surface SEM image of region B.

Fig. 11. Top-surface SEM image of Region D.

3.3. X-ray fluorescence (XRF) test

Micro X-ray fluorescence (XRF) is a vital non-destructive technique for the qualitative and quantitative elemental composition
analysis of solids [17]. The peak energy component of the XRF spectrum identifies the chemical elements present in the specimen,
while the height indicates the percentage of the element in the material.
The XRF investigation of the specimens was performed using a XGT 5000 model instrument and under operating conditions
consisted of 30 kV voltage and a current of 0.02 to 1.00 mA and incrementing by 0.02 mA.
Figs. 12-14 illustrate the XRF spectra of all specimens derived from the corroded inner layer which is directly in contact with the
steel carbon surface. From these spectra, a peak corresponding to Fe element can be observed. A peak for Ti is only observed in the
spectrum of region “A” but in a small concentration (Fig. 12). Furthermore, the varieties in the spectra of all zones indicate vividly
that the properties of elbow material and the degree of fluid-solid interaction were significantly influenced by the geometry of elbow
and valves as well as the operating conditions.

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Fig. 12. XRF spectrum of Region “A”.

Fig. 13. XRF spectrum of Region “B”.

Fig. 14. XRF spectrum of Region “D”.

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Fig. 15. XRD test for specimens “A” and “B”.

The XRF results of all specimens were calibrated and it was found that elements such as Si and Mn can be observed in the samples
but in a small concentration. It is possible that these elements that were in contact with the flowing fluid are causing mainly the
erosion-corrosion problem of the elbow pipe which leads eventually to the observed damage in the piping systems. As observed in the
XRF spectrum of the corroded layer in zone “D” (Fig. 14), the presence of many elements such as Si, Ca, S, Ti, Mn and Fe in this
corroded zone is an indication to the presence of sand particles in the fluid effluent.

3.4. X-ray diffraction (XRD)

XRD analysis was also conducted on the elbow specimens in order to discover the crystalline structures of the elbow's materials.
This technique is very informative in detecting the components of the corroded zones of metallic structures. The samples were
grinded into a finely ground powder in a cup (mortar grinder). Based on the reflected X-rays, the deformation of the sample was
detected by the sweep detector samples' intensity. Using APD 2000 XRD diffractometer model equipped with GD model Goniometer
for the meter, the corroded elbow specimens were characterized by recording the intensity of the diffraction lines as a function of the
deflection angle 2θ. In addition, Bragg's law is used to locate the directions of diffractions. The obtained results were analyzed using
WinDust32 software. “θ” is the half-deflection angle (half of the angle between the incident beam and the direction of the detector)
while “λ” is the wavelength of X-rays.
Several experiments were conducted in order to show the differences in the mechanical and chemical parameters properties of
zones including the structure of the corroded layer of elbow. Fig. 15 shows the obtained XRD diffractograms of the corroded zones
“A” and “B”. It is clearly observed that the crystal peaks of the hydrated phases in specimen “A” indicated that the corroded layers
have contained complex compounds such as hematite. The disappearance of these peaks can be also noted in the spectra of specimen
“B”. Moreover, a change in the structural composition of the corroded layer is manifested by the appearance of oxides containing iron
such as hematite Fe2O3.

4. Discussion

The microscopic results shown above support the existence of the chemical reactions resulted from the interaction between the
flowing fluid and the internal wall of elbow, and led to the observed corrosion phenomenon on the elbow under the operating
conditions. During the transport of liquid through the elbow, different concentrations of chemical additives are used to overcome the
instability of this mixture; still this is one of the main reasons that contribute to the decrease the wall thickness of the pipe, whereas
the solid particles stimulated the pipeline erosion-corrosion processes. As a result of the complex situation at the interaction zone, it
appears that the leak was caused by a localized hole. In spite of the several times repairing by welding, the fluid attack by valve
opening and the erosion-corrosion damage was repeated continue to appear again in the same zones surrounding the welding areas.
Due to the direct fluid-solid interaction caused by the opening of valve angle and its quick flow, very quickly were devoted towards to
form grooves on owing to the silicon particles taking into account the distinct morphology of elbow. The formation of a dark brown
colour coating layer on the surface of the elbow is direct proof on the evolution of corrosion process on the internal surface of
pipeline. It was noticed that there is a reduction in the thicknesses along the elbow especially in the interaction zone. The layer of
dark brown colour at a valve angle of 35° is main proof on forming the oxidation process (corrosion phenomenon) on the internal
surface of pipeline. According to the analysis, it is noted that the occurred defects on the pipe were caused by an inappropriate

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welding process which has also accelerated the corrosion process. The results indicated that the mechanical properties of elbow were
significantly influenced by the solution contents and additives materials. Among the advantages of corrosion is to form a ferrous layer
on the internal wall when exposed to aggressive chemical reactions which protects the steel from additional corrosion especially
under the aggressive operating conditions and the presence of silicon particles in the flowing fluid. However, it might lead also to a
serious corrosion issue if the layer was unable to form. Thus, carbon steel is a very fit to be used in piping systems carrying aggressive
solutions.
The reason for taking these tests into account was to identify the reasons and prohibit the elbow corrosion. This analysis was
necessary in order to find the fit solutions to protect the piping systems including more parameters such as improving the kind of
valves to reduce the interaction fluid-solid, improving the material quality to rise the lifetime, and the increase efficiency of geometry
and dimensions to reduce the pressure, and to diminish the erosion phenomenon, and to reduce the friction along the elbow. The iron
film is relatively fragile and can be eroded away or prevented it to be fully formed by turbulence or fluid flow attack. If this occurs,
the underlying metal rapidly corrodes until a new film is formed and becomes stable. The general corrosion attack appears on the
pipe elbow was most likely the result of corrosion caused by flowing fluid attack and turbulence. However, turbulence effects at
elbows, flanges, and other disruptions can destroy the film and lead to the accelerated corrosion.

5. Conclusions

The mechanical behaviour of the components of piping systems such as the elbow, was tested in this study by the analysis the
corroded layer in internal wall of elbow. To this effect, it was identified that the ferrous layer when exposed to aggressive chemical
reactions will protects the steel from additional corrosion; the layer was formed when the system showed the dark brown colour along
the corroded elbow due the fluid-solid interaction under the complex operating conditions and the presence of silicone particles. We
attempted here to identify the factors that can be controlled to prohibit the corrosion along the internal wall of elbow. In addition, the
presence of silicon and CO2 components in the flowing fluid enhances the erosion in the pipe elbow as well as the corrosion. This
study allowed us to identify the suitable solutions to develop the infrastructure of piping systems taking into consideration the
efficiency and orientation of the valves that will reduce the fluid-solid interaction, which will ultimately increase the service length of
the operating pipe. Moreover, the transport of the aggressive solution should be accompanied with much of consideration to increase
the efficiency of the adopted geometry and dimensions of the pipe that will reduces the pressure, decreases the erosion phenomenon,
and finally reduces the friction along the elbow.
Finally, the followings can be recommended to prevent the repetition of erosion-corrosion problems inside the elbow:

• Checking frequently the quality of the used membranes to prevent the sand particles to enter the water treatment units.
• Looking after the design of the pumping system and its depth in sea water.
• Replacing the welding curing methodology of defected parts with the composite patching methodology.
• Controlling the pH of MEA solution.
• Adding green inhibitors to MEA solution for decreasing its corrosivity to the steel elbow.
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