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    Erosion - Corrosion

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    Lakshman Tumpati
    Erosion-corrosion occurs when corrosion contributes to erosion by removing protective surface films or exposing the metal surface to further corrosion under combined erosion and corrosion. The rate of metal loss depends on factors like the velocity and properties of the impacting medium, and the hardness and corrosion resistance of the material. Common areas of damage include piping exposed to fluids/catalyst and equipment like heat exchangers. Prevention methods include increasing pipe diameters, surface treatments, and using more corrosion-resistant alloys. Inspection methods include visual examination and ultrasonic testing.

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    Erosion - Corrosion

    Uploaded by

    Lakshman Tumpati
    34 views18 pages
    Erosion-corrosion occurs when corrosion contributes to erosion by removing protective surface films or exposing the metal surface to further corrosion under combined erosion and corrosion. The rate of metal loss depends on factors like the velocity and properties of the impacting medium, and the hardness and corrosion resistance of the material. Common areas of damage include piping exposed to fluids/catalyst and equipment like heat exchangers. Prevention methods include increasing pipe diameters, surface treatments, and using more corrosion-resistant alloys. Inspection methods include visual examination and ultrasonic testing.

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    corrosion mechanisms

    Original Title

    Corrosion

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    Erosion-corrosion occurs when corrosion contributes to erosion by removing protective surface films or exposing the metal surface to further corrosion under combined erosion and corrosion. The rate of metal loss depends on factors like the velocity and properties of the impacting medium, and the hardness and corrosion resistance of the material. Common areas of damage include piping exposed to fluids/catalyst and equipment like heat exchangers. Prevention methods include increasing pipe diameters, surface treatments, and using more corrosion-resistant alloys. Inspection methods include visual examination and ultrasonic testing.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    34 views18 pages

    Erosion - Corrosion

    Uploaded by

    Lakshman Tumpati
    Erosion-corrosion occurs when corrosion contributes to erosion by removing protective surface films or exposing the metal surface to further corrosion under combined erosion and corrosion. The rate of metal loss depends on factors like the velocity and properties of the impacting medium, and the hardness and corrosion resistance of the material. Common areas of damage include piping exposed to fluids/catalyst and equipment like heat exchangers. Prevention methods include increasing pipe diameters, surface treatments, and using more corrosion-resistant alloys. Inspection methods include visual examination and ultrasonic testing.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 18

    Erosion - corrosion

    • Damage that occurs when corrosion contributes


    to erosion by removing protective films/scales or
    by exposing metal surface to further corrosion
    under combined action of erosion and corrosion.
    • Metals,alloys,refractories
    • Metal loss rates depend on velocity and
    concentration of impacting medium, impacting
    articles size and hardness, angle of impact,
    hardness and corrosion resistant of material
    subject to corrosion.
    • Softer alloys of CU,AL subject to metal loss under
    high velocity conditions
    • For each environment and metal condition,
    threshold velocity above which impacting
    medium produce metal loss
    • Metal loss depends on
    size,shape,density,hardness of impacting medium
    • Metal removed from surface as dissolved ions or
    solid corrosion products which are swept away
    from metal surface
    Affected Equipment
    • Equipment exposed to moving fluids/catalyst
    • Piping particularly at bends,elbows,pumps,blowers,heat
    exchanger tubing,propellers,impellers,turbine blades,nozzles
    • erosion by particles carried by liquid (slurry) like catalyst
    movement in FCC,coke handling equipment in fluidized bed
    cokers
    • Crude unit piping exposed to naphthenic acids,sulfur content
    Appearance
    • Erosion-corrosion seen by loss in thickness in
    form of pits,groove,rounded holes and valleys
    prevention
    • Increase pipe diameter to decrease velocity,
    streamlining bends to reduce
    impingement,increase wall thickness
    • increase substrate thickness (hard alloys),surface
    hardening treatments
    • Alter process environment to reduce corrosivity
    (deaeration)
    • Heat exchangers use impingement plates to
    minimize erosion
    • High Mo contain alloys to improve resistant to
    naphthenic acid corrosion
    Inspection
    • Visual examination,UT checks
    • IR scans to detect refractory loss on stream
    Erosion-corrosion: Mechanism
    • Cavitation,liquid impingemen erosion,fretting
    Corrosion under insulation (CUI)
    • Steel pipe-protective coating-insulation-
    weather barrier
    • Corrosion of piping,pressure vessels,structural
    components from water trapped under
    insulation
    • Carbon steel,low alloy steel,300 ss,duplex
    stainless steel
    • Affects- -12 c to 175 c for carbon and low alloy
    steel; 60c to 205c stainless steel
    • CUI increases with increase metal
    temperature, severe at 100 c 120 c where
    water vaporize and insulation stays wet longer
    • Insulation material which hold water not used
    • Equipment operates below water dewpoint
    condense water increase cui
    • Environments contain air contaminants as
    chlorides,so2 inc cui
    appearance
    • Carbon and low alloy steels – local
    pitting,localised loss in thickness
    • 300 SS subject to stress corrosion cracking,if
    chlorides are present, duplex ss less
    susceptible
    prevention
    • Use paints/coatings, maintain insulation
    barriers to prevent moisture enter
    • Flame sprayed Al coatings use on carbon
    steels- coating corrodes preferentially by
    gakvanic action and protects base metal
    • Al foil wrapped in SS pipes
    Chloride stress corrosion cracking
    (SCC)
    • Surface initiated cracks caused by envionmental
    cracking of 300 SS, Ni based alloy due to tensile
    stress,temperature,aqueous chloride environment.
    • Dissolved oxygen presence inc cracking
    • 300 SS – suspectible, duplex ss – more resistant
    • Inc temp,inc chloride – inc cracking
    • SCC occurs at pH above 2
    • Ni based alloys- highly resistant but not immune
    Affected eqipment
    • 300 ss piping,pressure vessel components,
    • Drains in hydro processing units,bellows and
    instrument tubing with hydrogen recycle
    streams affected
    • Cracking in boiler drain lines
    appearance
    • Cracks appear on surface
    • Fracture surface have brittle appearance
    prevention
    • Use resistant material for construction
    • When hydrotesting use low cl content water
    • Design should not allow stagnant regionwhere
    chloride can depoist
    Hydrochloric acid corrosion
    • Vapors containing water and hcl condense from
    overhead stream of distillation,fractionation
    tower,first water condense is highly acidic and
    promote high corrosion rates
    • Hcl concentration inc ,temp inc , inc
    corrosion,alloy composition
    • HCl is normally not corrosive but very corrosive
    where water is available to hcl acid
    • Carbon steel,low alloy steels excess corrosive
    when ph below 4.5
    • 300 ss not resistant to any hcl level
    Affected equipment
    • Crude unit,hydro processing units,catalytic
    reforming units
    Wet h2s damage (blistering)
    • Hydrogen blistering
    Form as surface bulges on ID,OD of
    pipe/pressure vessel,
    • Hydrogen induced cracking
    • Stress oriented hydrogen induced cracking
    • Sulfide stress cracking

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