CH371

HAIDER ALI
2015122
 What is Corrosion?
Corrosion is a natural process, which
converts a refined metal to a more
chemically-stable form, such as
its oxide, hydroxide, or sulfide. It is the
gradual destruction of materials
(usually metals) by chemical and/or
electrochemical reaction with their
environment.
 Types of Corrosion?
1. Uniform (general) corrosion
2. Galvanic (two–metal) corrosion
3. Thermogalvanic corrosion
4. Crevice corrosion (including deposit corrosion)
5. Pitting, pitting corrosion
6. Selective attack, selective leaching (de–alloying)
7. Intergranular corrosion (including exfoliation)
8. Erosion corrosion
9. Cavitation corrosion
10. Fretting corrosion
11. Stress corrosion cracking
12. Corrosion fatigue
• This is a uniform and general attack, in which the entire metal surface area
exposed to the corrosive environment is converted into its oxide form.
• It is the uniform thinning of a metal without any localized attack, corrosion does
not penetrate very deep inside.
• Traditionally, however it is not recognized as dangerous form of corrosion,
because:
• 1. Prediction of thickness reduction rate can by means of simple tests
corresponding corrosion allowance can be added taking into account strength
requiring and lifetime.
• 2. Available protection methods are usually so efficient that the corrosion rate is
reduced to an acceptable level.
• Atmospheric corrosion of a steel structure is also a common example of uniform
corrosion, which is manifested as a brown-color corrosion layer on the exposed
steel surface. This layer is a ferric hydroxide compound known as Rust.
• Zinc White Rust.
• Aluminum film formation.
1.Effect of pollutants
2.Humidity
3.Water Layer
RUST

• Effect of pollutants: Corrosion can proceed in a dry environment without any

moisture if trace of sulfur components or H2S or other pollutants are present in
the air or soil.

• The FeSO4 formed accelerates corrosion, once rusting has started, corrosion
cannot be stopped even after SO2 is removed.
 Mechanism
• A very thin layer of electrolyte is present.
• It is probably best demonstrated by putting a small drop of seawater
on a piece of steel.
• On a metal surface exposed to atmosphere, only a limited quantity of
water and dissolved ions are present, whereas the access to oxygen
present in the air is unlimited. (i.e. oxygen is in excess)
CATHODE

ANODE

DROP CENTRE
 Examples of Uniform Corrosion
• (1) Tarnishing of silver ware.
• (2) Tarnishing of electrical contacts.
• (3) Rusting of steels in open air.
• (4) Corrosion of offshore drilling platforms.
• (5) Corrosion of galvanized steel stairways.
• (6) Failure of distillation columns.
• (7) Corrosion of electronic components.
• (8) Corrosion of underground pipes (composite asphalt coated).
• (9) Corrosion of automobile bodies.
• (10) Corrosion of heat exchanger tubes.
• (11) Corrosion of structural steels.
SUI NORTHERN GAS PIPELINES LIMITED
Corrosion Control Department
Unprotected pipelines, whether buried in the ground, exposed to the
atmosphere, or submerged in water, are susceptible to corrosion.
Without proper maintenance, every pipeline system will eventually
deteriorate. Corrosion can weaken the structural integrity of a pipeline
and make it an unsafe vehicle for transporting potentially hazardous
materials.
SMS ( SALES METERING STATION )
• Currently SNGPL has not yet succeeded in preventing pipeline
corrosion which is cause by cooling effect on pipelines when pressure
is reduced. In summers it causes moisture on pipes while icing takes
place in winters.
WAYS TO PREVENT THIS CORROSION?
• Current Cathodic Protection (ICCP) systems
• Coating pipelines
1. Three-Layer PE (3LPE)/PP (3LPP)
2. Fusion Bonded Epoxy (FBE)
3. Coal Tar Enamel (CTE)
4. Asphalt Enamel and Polyurethane (PUR)
• Paint
TYPES OF SURVERYS CONDUCTED AT SNGPL
FOR PROPER MAINTENANCE

• ECDA (EXTERNAL CORROSION DIRECT ASSESSMENT)

• CIS(CLOSED INTERVAL SURVEY) Measuring the potential between a
pipe and Earth at regular intervals along the SNGPL pipeline.
• DCVG (DIRECT CURRENT VOLTAGE GRADIENT) By looking at the
direction of voltage gradients, the location of coating faults may be
identified
• PSP(PIPE TO SOIL POTENTIAL) The higher the value of pipe-to-soil
potential, the higher the magnitude of corrosion. -1.65V to -1.80V