Welcome to

Universiti Teknologi PETRONAS

2011 INSTITUTE OF TECHNOLOGY PETRONAS SDN BHD
All rights reserved. No part of this document may be reproduced, stored in a
retrieval system or transmitted in any form or by any means (electronic,
mechanical, photocopying, recording or otherwise) without the permission of
the copyright owner.
|Centre for Corrosion Research |Block I |

To be a partner of choice in
corrosion research.
www.utp.edu.my
By
Ir Dr Mokhtar Che Ismail
Copyright reserved
AP Ir Dr Mokhtar Che Ismail
B.E(Mechanical Eng) University of Newcastle,
Australia
M.Sc ( Materials Science and Eng) National
University of Singapore
PhD (Corrosion Engineering) , UMIST, England

9 years professional industrial experience
(INTEL & PETRONAS) and 14 years academic
experience.
Page 4
Understand the fundamentals of corrosion
COURSE OBJECTIVE
Explain thermodynamics and kinetics of
corrosion
Perform corrosion measurement
using standard procedures
|Centre for Corrosion Research |Block I |
Corrosion is a natural phenomenon and can be considered as
extractive metallurgy in reverse( Fontana).
Earth Mineral Ores Extraction/Refining Metal
(Fabrication) Components Corrosion Earth
Corrodere (Latin) means to chew away or to wear away.
The degradation of a material that occurs when it reacts with
environment.(Fontana)
Physicochemical interaction between a metal and its environment
which results in changes in properties of the metal and which
often lead to impairment of the function of the metal, the
environment, or the technical system of which these form a part :
ISO 8044-1986
Destruction of a metal by chemical or electrochemical reaction
with its environment. Herbert H. Uhlig in Corrosion Handbook
The deterioration of a material, usually a metal, that results
from a reaction with its environment. (NACE)
Corrosion is an irreversible interfacial reaction of a material
(metal, ceramic, polymer) with its environment which
results in consumption of the material or in dissolution into
the material of a component of the environment. IUPAC


Offshore 8" Pipeline
Corrosion
Pits
due to SRB
LP Riser
Onshore Pipeline Section
Lack of maintenance !!
Smart Flange
Severe corrosion at risers
R4
Lack of maintenance !!
Corrosion Under Insulation
Aboveground storage tank
Lack of maintenance !!
Emulsion line
Sample Background
Equip No: Equip Description:
Material: Part:
Plant: Unit:
Time to Failure: Date of Failure:
Photos
Phenomenon
Appearance
Environment
Remedy
4 Years April 2005

Under Deposit Corrosion.
Carbon Steel
Process Fluid: LPG
Working Pressure: 15.9 kg/cm
2
Working Temperature: 40
0
C
Pipe replacement with in kind material
Thin layer with dry and brown deposit and localized pitting
corrosion.
Cost in order of 4% of GNP in advanced countries. USA=
$100-200 billion.( recent data??)
The effect can be in many ways:
Appearance/Aesthetic factor: Bad impression low morale
to worker.
Maintenance and operating cost
Plant shutdowns
Contamination of products
Loss of product
Effect of safety and reliability

1950 H.H. Uhlig US Study: 2.1% of GNP
1970 T.P. Hoar UK Study: 3.5% of GNP
1974 Japan Study: 1.2% of GNP
1975 Battelle/NBS U.S. Study: 4.5% of GNP

Cost of Corrosion Previous Studies
Factors caused the collapse:
o Water caps over the fire-proofing concrete
of bad design letting water penetrate
between the steel beams and the concrete.
o Vertical cracks on the concrete let water in.
o Repairs had been done to the concrete, but
without good workmanship. The new
concrete has not adhered to the old
concrete, letting water in.
o Deluge system had been tested with salt
water, increasing the possibility of corrosion.

Root cause: bad and lazy maintenance system,
added to a bad administration and lack of
knowledge in inspection and maintenance services.
A proper maintenance and a suitable inspection
plan are major factors on the conditions of the
equipment. Inspection should be performed by
qualified personnel, to avoid the sad happening
which took place after a series of inspections that
approved the vessel conditions.


Some actions to be taken to avoid future accidents:
Water caps shall be designed, fabricated
and installed to ensure tightness and avoid
infiltration that will cause corrosion.
Fire protection shall be installed criteriously
to reduce the gap between the leg beams and
the concrete to a minimum.
Fire protection shall be of good quality and
regularly inspected.
Peep holes at the top of the legs shall be
seal welded before the water cap is installed.
Legs shall be inspected by qualified
companies and inspection reports shall be
verified and approved.
Pa
ge
23
Forms of Corrosion
General Corrosion Localised Corrosion
Environmentally Induced
Corrosion
Stress Corrosion Cracking
Mechanically Assisted
Corrosion
Metallurgical Influenced
Corrosion
Pitting
Atmospheric corrosion
1. When there is Anode
2. When there is Cathode
3. When there is electron path connecting anode and
cathode
4. When there is ionic path/electrolyte.
metal + oxidizing agent oxidized metal + reducing agent
For example, the corrosion of iron in the presence of hydrochloric
acid
Fe + 2 HCl (s) (aq) FeCl 2(aq) + H2(g)
Oxidation occurs corrodes
Produces electron (e-)
Produces cations ( positive-charged species)

Examples: Zn Zn
2+
+ 2e
-
Fe Fe
2+
+ 2e
-
All redox reactions consist of two partial reactions, also sometimes
called halfcell reactions: the partial oxidation reaction, also referred to
as the anodic partial reaction; and the partial reduction reaction or
cathodic partial reaction.

Reduction occurs.
Consumes electrons
Produces lower valency species

2H+ + 2e- H
2
Hydrogen evolution
O
2
+ 2H
2
O + 4e- 4OH- Oxygen reduction, neutral/basic
solution
O
2
+ 4H+ + 4e- 2H
2
O Acid solutions
Chemical reactions = elements are added or
removed from chemical species. No change in
valence
Electrochemical = chemical reactions + change in
valence

Example : Precipitation of iron hydroxide (Fe (OH)
2) is
pure chemical reaction

Fe
2+
+ 2 OH
-
--- Fe(OH)
2
Fe
2
O
3
H
2
O or hydrous ferrous oxide,









Fe
3
O
4
H
2
O or hydrated magnetite, also called ferrous ferrite
(Fe
2
O
3
FeO), is most often green but can be deep blue in the
presence of organic complexants.



Fe
3
O
4
or magnetite is black.

Failures come in
many different
forms!
Corrosion
management :
different
mechanisms for
inspection and
monitoring
Pa
ge
35
Method of Corrosion Protection
Corrosion Control
Electrochemical Process
Anodizing
Electrodeposition
Chemical Process
Chemical Conversion Coating
Electroless Deposition
Chemical Vapour Deposition
Physical Vapour Deposition
Surface Coating Inhibitor Material Selection
Cathodic
Anodic
The problems arising from short-sighted corrosion control
strategies have been particularly well articulated by Joe C.
Bowles (a former president of NACE International) in the
so-called corrosion cycle. Four phases were identified in
this cycle:
Phase 1 - Neglect: Corrosion control is ignored; this may
be "tempting" to (poor) management as corrosion
problems may not show up immediately. It is easy to be
lulled into a false sense of security.
Phase 2 - Panic: The previously hidden corrosion danger
becomes apparent, possibly with disastrous financial
consequences and safety hazards. It is not easy to combat
corrosion rationally and effectively in a state of panic.

Phase 3 - Learning Curve: In dealing with the serious corrosion
problems, effective corrosion control measures are eventually
introduced and failure rates are reduced to manageable levels.
Considerable effort (and time) may be required before effective
solutions are found, qualified and implemented.

Phase 4 - Unlearning Curve: Once the initial crisis is over, there
is a risk that corrosion control will be neglected again and that
hard lessons learnt in the past will be forgotten. This is when the
corrosion cycle starts all over again, with the neglect stage re-
establishing itself.

General bibliography
1. M. Fontana, Corrosion Engineering, 3rd edition, McGraw Hill
International Edition,New York, 1987, 556 pp.

2. H. H. Uhlig, R. W. Revie, Corrosion and Corrosion Control, 3rd
edition, JohnWiley, New York, 1985, 441 pp.

3. G. Wranglen, An Introduction to Corrosion and Protection,
Chapman and Hall,London, 1985, 288 pp.

4. Jones, Principles and Prevention of Corrosion, Prentice Hall