General IMMR Table

Threat

Corrosion Under Insulation

(CUI)

Internal Corrosion

External Corrosion

Damaged Insulation
Porous Insulation Present
Moisture Ingress
External coating breakdown
Temperature
Chlorides

Vibration induced
Fatigue

Thermal Fatigue

Microbiologically Influenced
Corrosion (MIC)

Cavitation

Chemical Corrosion

CO2 Corrosion

Erosion/Corrosion

O2 Corrosion

Preferential Weld Corrosion

(PWC)

Under Deposit Corrosion

Inspection
External inspection for damaged lagging or rust stains
Visual inspection of substrate:
o Fitting of inspection ports
o Full or part lagging removal
NDT techniques through lagging:
o Radiography
o PEC (pulsed eddy current)

Monitoring

Maintenance

Repair
Pad welding
Lapped patch
Cut out and replace
Lagging reinstatement
Internal coatings

Routine inspection for damaged or

rust-stained lagging

Lagging maintenance to prevent

moiture ingress

UT, GVI, Pit Guage

Routine inspection

Coating Maintenance

Replace Spool

VI, UTS, RT (At metal interface)

Routine inspection

Maintenance of insulation (i.e.

insulation flange, shims)

N.A.

Reciprocating Machinery
Poor design (i.e. heavy valves on small bore piping)
CVI for vibration
Flow induced vibration (i.e. liquid hammer, liquid slugging in vapor lines)
MPI,PT or EC for cracking
Abnormal thermal expansion
Cyclic Stresses

Vibration Testing (accelerometers)

Rotating euipment maintenance

to minimise vibration

Stress
Exposure to Chlorides
Upset process conditions
Unanticipated condensation
CUI
Susceptible material

Chloride concentration monitoring

N.A.

Breakdown external coating (i.e UV degradation)

Environmental conditions (i.e salt spray, temperature)

A less noble metal/alloy in direct electrical contact with a more noble

Galvanic Corrosion (INT/EXT) metal
Dissimilar materials in electrical & aqueous contact

Chloride Stress Corrosion

Cracking (CSCC)

External Corrosion

Causes / Conditions

MPI, PT, EC

Cyclic stress due to temperature fluctuations

CVI, MPI and PT

Anaerobic Conditions (SRB)

Stagnant Flow
Low Flow
Suitable nutrients present
Microbial Infection

RT, UTS, INT

Fluid Pressure Drop

Flow Turbulance (collapsing bubbles)
Flow Velocity

INT (Valves control body d/s of orifice)

UT/RT d/s of flange & pipe

Metal Oxidation
Chemical reaction/reduction
Low pH of process chemicals
Thermal degradation of the chemical to form aggressive products
Insufficient atomisation
No injection quill
Failure to turn off chemical injection after shut-down

UT/RF d/s of Injection ports (as per API 570 section 5.3.1)

CO2 content
Operating Pressure
Temperature
Flow effects
Scaling
Lack of inhibitor (glycol or corrsion inhibitor)

UT, INT, RT

Presence of Solid Particles (i.e. sand, gas bubbles)

High Laminar Flow
Local Turbulance

UTS, RT & EC
Inspection locations (d/s of control valves, orifices, pump
discharges, piping configurations & any point of flow direction
change such as the inside and outside radii of elbows)

Dissolved Oxygen Content

Chlorides
Fluid Velocity
Temperature

UTS, RT, INT

Galvanic effects
Lack of inhibitor film at welds

TOFD, RT

Presence of Scale, Wax, Solids, Sand

UT, RT, INT

N.A.

N.A.

SRB Sampling

N.A.

Vibration monitoring
Accoustic monitoring Valve Testing

Valve Maintenance per AMOS

Control / Prevention Measures

Remove insulation where possible

Prevent moisture ingress
Protective coatings

Coatings & Linings

Shims under pipe supports
Insulation between materials (i.e
insulation flange, shims)
Design (materials selection)

Vibration dampening
Grind out and weld crack Pipe bracing
Replace spool
Design (i.e. monoflange block vs full
bore valves)

N.A.

Operation below critical temperatures

Materials selection
Coatings

Best prevented through design and

operation to minimise thermal stresses
Minimise localized temperature
excursions

Pad Welding of pits

Internal coatings

Biocide injection
Internal coating
Flushing

Replace damaged parts

Pad welding of damaged Valve selection & design
parts if possible

Monitor injection rate

Chemical injection equipment (i.e.

quills, pump, flowmeter)

Replace spool

Gas sampling for CO2 %

Corrosion (weight loss) Coupons
Corrosion Probes
Corrosion inhibitor monitoring

N.A.

Pad weld (vessel pitting)

Replace spool

Sand Monitoring Probes & Coupons

Accoustic monitors
Sand mass measurements from
separators

N.A.

Replace Spool

O2 content monitoring

N.A.

N.A.

N.A.

N.A.

Grind out and reweld

Replace spool

Thermography for deposits

N.A.

N.A.

Atomising quill
Chemical selection & test procedure
S/D procedure (to turn off injection)

Corrosion Inhibition
Internal coating
Sacrificial anodes (vessels)

Downhole screens
Sand separator
Design (i.e SD bends, cushion tees
etc)
Deoxygenation
Chemical treatment
Materials selection
Inhibitor selection/testing
Weld procedures
Filler material selection
Prevent deposit buildup (i.e. Sand
separator)
Scale Inhibition
Corosion Inhibition
Flushing / Sand sparging