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METAL OXIDE
REDUCTION
METAL
CORROSION
MECHANISM OF CORROSION
WHEN PUT IN AQUEOUS SOLUTON AT SOME LOCATIONS (KNOWN AS ANODE) METAL IONISES
ANODIC REACTION -M = Mn+ + ne ELECTRON RELEASED HAS TO BE USED TO SUSTAIN REACTION. THIS OCCURES AT ANOTHER POINT WHERE ELECTRON IS CONSUMED CATHODIC REACTION -2H+ + 2e = H2-Cu2+ + 2e = Cu O2 + 2H2O = 4(OH) RESULTS IN FLOW OF CURRENT FROM ANODE TO CATHODE ---- A MEASURE OF CORROSION RATE
DRIVING FORCE FOR FLOW OF CURRENT * DIFFERENCE IN POTENTIAL BETWEEN ANODE AND CATHODE * WHAT ARE THE FACTORS
* ALL METALS DEVELOP POTENTIAL SPECIFIC TO ENVIRONMENT VARYING FROM HIGH NEGATIVE TO HIGH POSITIVE * VARIATIONS IN CHEMICAL (OXYGEN & SALT CONCENTRATION) & MECHANICAL (STRESS, TEMPERATURE) ON METAL SURFACE
MORE NEGATIVE THE POTENTIAL HIGHER THE CORROSION (ANODIC) HIGHER THE POTENTIAL DIFFERENCE HIGHER IS CURRENT OR CORROSION
PASSIVATION IS DRASTIC DECREASE IN CORROSION CURRENT IN CRITICAL POTENTIAL RANGE DUE TO FORMATION OF PROTECTIVE OXIDE SCALE
FORMS OF CORROSION
UNIFORM CORROSION GALVANC CORROSION PITTING & CREVICE CORROSION INTERGRANULAR CORROSION IMPINGEMENT CORROSION DE ALLOYING STRESS CORROSION CRACKING HYDROGEN DAMAGE
ATMOSPHERIC
General Corrosion - This 40 year old sample of 8 in. schedule 80 pipe, while clearly containing deposits of iron oxide, shows very even wall loss and long remaining service life.
BOILING POINT CURVE SANICRO 28 904L (2RK65) SAF 2507 SAF 2205 316L 304L
GALVANIC CORROSION
TWO METALS WITH LARGE DIFFERENCE IN POTENTIAL IN ELECTRIC CONTACT ACTIVE METAL ACTS AS ANODE WITH RESPECT TO NOBLER METAL * EXAMPLES : Zn / Fe ; Fe / Ad. BRASS ; NAVAL BRASS / SS ; MONEL / Ti IN SUCH COMBINATIONS Zn , Fe , NAVAL BRASS & MONEL WILL BE ANODE AND CORRODE WHILE THE NOBELER METAL WILL BE PROTECTED DEGREE OF INCREASED CORROSION DEPENDS ON POTENTIAL DIFFERENCE; CATHODE TO ANODE RATIO; RESISTIVITY OF MEDIA
Galvanic Corrosion - A common problem area where carbon steel pipe is connected directly to either brass valves or copper pipe in a highly humid atmosphere
Example of material mix-up. A tube of type 304 (left) was unintentional welded to a tube of type 316 (right). When exposed to the process solution 304 gradually dissolved and the tube wall was heavily reduced.
PITTING CORROSION
LOCLISED ATTACK WITH NONE TO MILD GENERAL ATTACK DEPOLRISERS LIKE OXYGEN AND CHLORIDE MAINLY RESPONSIBLE FOR LOCAL CORROSION CELL OCCURS IN MOST METALS INCLUDING CARBON AND ALLOY STEELS
ATTACK UNDER DEPOSIT DUE TO OXYGEN RICH & OXYGEN DEFICIENT AREAS
Comparison of CPT- and CCT-values for some stainless steels (obtained by the modified ASTM G48 method).
CREVICE CORROSION
-INTENSE LOCALISED CORROSION WITHIN MICRON DIMENSION CREVICE FORMED BY OVERLAPPING THIN LAYER OF WATER CORRODES AND THEN FOLLOWED BY MIGRATION OF CHLORIDE ION AS IN PITTING. LOW PH RESULTS IN LOCALISED ATTACK -SOLID DEPOSITS AND BIOFILM DEPOSITS ALSO LEAD TO CREVICE ATTACK
crevice
INTERGRANULAR CORROSION
-CORROSION RESISTANCE OF STAINLESS STEELS IS DUE TO Cr-OXIDE FILM FORMED ON SURFACE. -DURING WELDING Cr-CARBIDE IS PRECIPITED AT GRAIN BOUNDARIES IN HAZ RESULTING IN Cr DEPLETED BAND ALONG GRAINS
-CORROSION THEN PROCEEDS ALONG GRAIN BOUNDARY -PREVENTED BY USING LOW CARBON OR ADDING STABILISERS LIKE Ti OR Cb (Nb)
WELD
HAZ ATTACK
PIPE BEND
EXCHANGER TUBE
U - BEND
FAILURE EXAMPLE
Corrosion of Steam Tracing Jump-Overs Due To Erosion Corrosion
Repeated failures were experienced in the jump-overs of low pressure steam tracing lines provided in piping conveying sour gas in a refinery.. The low radius carbon steel jump overs got punctured at the outer radius of jump-overs. Low pressure steam contains droplets of condensed water which normally have low pH. Impinging low pH water droplets resulted in erosion-corrosion. Use of SS 304 bends prevented this type of failure.
* STRESS
CORROSION CRACKING OCCURS BY COMBINED) CORROSIVE ENVIRONMENT ALLOY SPECIFIC EXAMPLES : Cu ALLOYS CRACK IN AMMONIA BUT NOT SS CARBON STEELS CRACK IN CAUSTIC BUT NOT Cu ALLOYS SS AND Al CRACK IN CHLORIDE BUT NOT CARBON STEEL OR Cu ALLOYS * CRACKING MODE IS INTER OR TRANS GRANULAR NORMALLY RELATED TO ALLOY AND ENVIRONMENT * TRANSGRANULAR CRACK SS IN CHLORIDE, CARBON STEEL IN CO+C02 INTERGRANULAR CRACK CARBON STEEL IN CAUSTIC AND Cu ALLOYS IN NH3
Organic and Inorganic Chlorides Acidic Hydrogen Sulfide, Caustic Sulfurous and Polythionic Acids
Caustic above 6000F (above 3150F) Hydrofluoric Acid Amines, Dilute Ammonia, Ammonium Hydroxide, Sulfur Dioxide
TRANS GRANULAR
CRACKING
DEALLOYING
DE ZINCIFICATION OF ADMIRALITY BRASS TUBE. FATIGUE CRACKS IN DEZINCIFIED SPOTS
EXAMPLES : -- SOLID COPPER / LIQUID ZINC -- SOLID COPPER / LIQUID MERCURY -- SOLID STAINLESS STEEL / LIQUID ZINC
Corrosion Under Insulation (CUI Corrosion) - Often identified only after the removal of pipe insulation for another purpose, water from rain and snow typically penetrates most exterior installations to cause wide ranging wall loss.
CUI Corrosion - Eexterior pipe corrosion due to moisture condensation can take the form of either deep and random pitting, or, as shown above - a generalized deterioration of the entire surface. Since iron oxide is approximately 25 times less dense that the original steel, it often suggests a much greater wall loss than actually exists. CUI is the greatest threat to smaller diameter piping..