What is CORROSION ?

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 Only as Good as the Weak Link

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 1. The reaction of a solid with
its environment

2. the eating away of metal by

electrochemical action

3. rusting and pitting of

pipelines, tanks, vessels and
other metal structures

BROWN CORROSION SERVICES, INC.

 1. The reaction of a solid with
its environment

2. the eating away of metal by

electrochemical action

3. rusting and pitting of

pipelines, tanks, vessels and
other metal structures

BROWN CORROSION SERVICES, INC.

 An undesirable loss of
metal by environmental
attack

BROWN CORROSION SERVICES, INC.

 Metallic Oxides & Salts
Add Energy

Makes

Metals
Lose Energy

Makes

Metallic Oxides & Salts

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 What Causes Corrosion?

There are two main factors:

1. The nature of the metal.

2. The characteristics of the environment.

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 Five Main Causes
of Internal Corrosion

Oxygen
Carbon Dioxide (CO2)
Hydrogen Sulfide (H2S)
Chlorides (Salts)
Bacteria (MIC)

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BROWN CORROSION SERVICES, INC.
BROWN CORROSION SERVICES, INC.
BROWN CORROSION SERVICES, INC.
 Typical Oxygen Corrosion

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 CO2 Sweet Corrosion

Corrosion from the

presence of water with
dissolved CO2

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 CO2 Sweet Corrosion
Sweet Corrosion takes the form of deep
pitting.

Gas operations that are wet and oil wells that

have water are the most common areas for
CO2 corrosion.

Gas lift and gas injection areas are prone to

CO2 corrosion.

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 Typical CO2 Corrosion on Oilwell Tubing

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 Gas Well Tubing with Severe CO2 Corrosion

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 Severe CO2 Corrosion

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 Close-up of CO2 Pitting

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 Top-of-line CO2 Corrosion

Note wall thinning

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BROWN CORROSION SERVICES, INC.
 Sour well with
Sucker rod pump.
Note corrosion on
valve and that
sucker rod is FBE
coated for
corrosion control

BROWN CORROSION SERVICES, INC.

 Tube sheet with severe sour corrosion. This metal loss in
One Heating Season in Croatia.

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BROWN CORROSION SERVICES, INC.
 CO2 Corrosion
Section of Pressure Vessel wall showing crack

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 Paint bubbles due to Hydrogen Permeation

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 Hydrogen Patch on Acid Gas Line

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 Hydrogen Patch Operation

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 Chloride Corrosion

Corrosion from the

chlorides and water
both internal and
external

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 Flanges Offshore is Chloride Environment

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Pipe Clamp in Chloride Environment & Galvanic Corrosion

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 Helideck Guard Chloride Corrosion

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 Firewater Piping in Salt Environment

Plus Galvanic

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Firewater Line with Internal Corrosion (saltwater) & REPAIR?

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 Bacteria Corrosion
MIC
Microbiologically influenced Corrosion

Corrosion from the

results of bacteria
growing in the pipe or
soil surrounding the
pipe.

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 Internal MIC

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External MIC on Underground Storage Tank

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 MIC Corrosion

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 MIC at BOL & CO2 at TOL

Sometimes
more than one
mechanism

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 Bacteria Probe

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 Bacteria Probe

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BROWN CORROSION SERVICES, INC.
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 Inspection Techniques
1. Visual
2. Product analysis
3. Corrosion product analysis
4. Bacterial analysis
5. X-ray (radiographic)
6. SEM
7. Mag particle
8. Dye penetrant
9. Ultra sonic thickness
10. ILI
11. Caliper
12. Pit depth
13. Many more

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 Pit Depth Gauge

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 Performing Mag Particle Inspection

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Mag Particle
clearly showing
crack on weld

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Mag Particle defined area & length of crack on weld

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BROWN CORROSION SERVICES, INC.
BROWN CORROSION SERVICES, INC.
 The 7 Methods of Corrosion Control
All Methods fall into these categories

1. Coatings
2. Cathodic Protection
3. Filming Chemical Inhibition
4. Material Selection
5. Alteration of the Environment
6. Design & Alteration the Structure
7. Repair &/or Replace

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 Onshore

BROWN CORROSION SERVICES, INC.

 Offshore

BROWN CORROSION SERVICES, INC.

 Offshore

BROWN CORROSION SERVICES, INC.

 The 7 Methods of Corrosion Control
All Methods fall into these categories

1. Coatings
2. Cathodic Protection
3. Filming Chemical Inhibition
4. Material Selection
5. Alteration of the Environment
6. Design & Alteration the Structure
7. Repair &/or Replace

BROWN CORROSION SERVICES, INC.

 The 7 Methods of Corrosion Control

1. Coatings
2. Cathodic Protection
3. Filming Chemical Inhibition
4. Material Selection
5. Alteration of the Environment
6. Design & Alteration the Structure
7. Repair &/or Replace

BROWN CORROSION SERVICES, INC.

 Corrosion Control by Coatings

Coating depends upon three items

1.Product
2.Surface preparation
3.Application

If any of these is incorrect all fail !

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BROWN CORROSION SERVICES, INC.
 Good Coating

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 Good Coating

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 Good Coating

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 Good Coating

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 Good Coating Repair

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 Delayed Corrosion Control

Coating with
no surface
preparation
and
covering
problems!

BROWN CORROSION SERVICES, INC.

BROWN CORROSION SERVICES, INC.
 Corrosion Control by Coatings

Even the best coating can fail if it is damaged

1. During handling and shipping

2. During installation
3. After installation by damage
4. Sfter installation by third party

If usually does happen !

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 Corrosion Under Coating when not
Applied with proper surface preparation!

Coating flaked off

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BROWN CORROSION SERVICES, INC.
BROWN CORROSION SERVICES, INC.
 Well coated piping damaged during installation !

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 Newly coated spool onto failed coated piping

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Coated Re-Bar on truck. Note steel bands! Is coating Okay?

BROWN CORROSION SERVICES, INC.

 Good Coating by Bird Droppings may Cause Issues

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 Good Coating but Boat Colisions may Cause Issues

BROWN CORROSION SERVICES, INC.

 Good Coating
but laying of
pipe from spool
may cause
cracks or
damage to
coating.

BROWN CORROSION SERVICES, INC.

 Protection of Coating

BROWN CORROSION SERVICES, INC.

 The 7 Methods of Corrosion Control

1. Coatings
2. Cathodic Protection
3. Filming Chemical Inhibition
4. Material Selection
5. Alteration of the Environment
6. Design & Alteration the Structure
7. Repair &/or Replace

BROWN CORROSION SERVICES, INC.

 The 7 Methods of Corrosion Control

1. Coatings
2. Cathodic Protection
3. Filming Chemical Inhibition
4. Material Selection
5. Alteration of the Environment
6. Design & Alteration the Structure
7. Repair &/or Repalce

BROWN CORROSION SERVICES, INC.

BROWN CORROSION SERVICES, INC.
BROWN CORROSION SERVICES, INC.
BROWN CORROSION SERVICES, INC.
 Large Chemical Injection Skid

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 Multi Pump Chemical Injection

Pumps

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 Chemical Injection System
Remote Readout
Reservoir Level Gauge Transmitter

Pump

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 Chemical
Delivery
Chemical Line
Injection
Quill thru On-Off
Access Valve

Fitting Access
Fitting

Access
Fitting
Cover

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 Inhibitor Injection System

BROWN CORROSION SERVICES, INC.

 Inhibitor Injection System

BROWN CORROSION SERVICES, INC.

 Inhibitor Injection System
Options for Chemical Injection

Pump Fitting
- Volume - Retractable
- Pressure - Retrievable
- Non Retractable

Power Type of Dispercement

- Wind - Drip
- Solar - Quill
- Mains - Atomizer
- Battery
- Line flow

BROWN CORROSION SERVICES, INC.

 The 7 Methods of Corrosion Control

1. Coatings
2. Cathodic Protection
3. Filming Chemical Inhibition
4. Material Selection
5. Alteration of the Environment
6. Design & Alteration the Structure
7. Repair &/or Replace

BROWN CORROSION SERVICES, INC.

BROWN CORROSION SERVICES, INC.
BROWN CORROSION SERVICES, INC.
 Alteration of the Environment

Temperature Control Liquid Removal

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 The 7 Methods of Corrosion Control

1. Coatings
2. Cathodic Protection
3. Filming Chemical Inhibition
4. Material Selection
5. Alteration of the Environment
6. Design & Alteration the Structure
7. Repair &/or Replace

BROWN CORROSION SERVICES, INC.

 Improper Material Selection

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 Improper Material Selection

Bad Good

BROWN CORROSION SERVICES, INC.

 Improper Material Selection

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Proper Material Selection

Note change from metal

to fiberglass in this
offshore waterflood
application

BROWN CORROSION SERVICES, INC.

 Proper Material Selection

BROWN CORROSION SERVICES, INC.

 The 7 Methods of Corrosion Control

1. Coatings
2. Cathodic Protection
3. Filming Chemical Inhibition
4. Material Selection
5. Alteration of the Environment
6. Design & Alteration the Structure
7. Repair &/or Repalce

BROWN CORROSION SERVICES, INC.

BROWN CORROSION SERVICES, INC.
 Elbow Subject to Corrosion/Erosion

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 Elbow Replaced by Flow Tee or flow Cushion

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 Gas Pipeline on Pillows off Ground

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 Gathering Lines on Pillows

Pillows

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Cement Coated
Offshore
Pipeline

BROWN CORROSION SERVICES, INC.

 The 7 Methods of Corrosion Control

1. Coatings
2. Cathodic Protection
3. Filming Chemical Inhibition
4. Material Selection
5. Alteration of the Environment
6. Design & Alteration the Structure
7. Repair &/or Replace

BROWN CORROSION SERVICES, INC.

BROWN CORROSION SERVICES, INC.