Ir. Adi Ganda Putra, MT.

FT. UNJANI – Bandung

E-mail : adigandaputra@yahoo.com
Degradasi tersebut mengakibatkan :

 Logam menipis, berlubang, terjadi perambatan

retakan.
 Sifat mekanik berubah  kegagalan struktur
secara tiba-tiba
 salah satunya adalah
 Sifat fisik berubah
mengurangi efisiensi perpindahan panas.
 Penampilan menjadi lebih buruk.
KERUGIAN LANGSUNG:
 Biaya untuk mengganti material-material logam atau
alat-alat yang rusak akibat korosi
 Biaya pengerjaan untuk penggantian material-
material logam tersebut
 Biaya untuk pengendalian korosi
 Biaya tambahan untuk membuat konstruksi dengan
logam yang lebih tebal (over design)
KERUGIAN TIDAK LANGSUNG:
 Penghentian kerja / operasi pabrik / alat
 Penurunan Efisiensi
 Kehilangan produk berharga
 Pengotoran produk
 Mengurangi keselamatan kerja
 Pencemaran lingkungan
 Pengurangan cadangan sumber logam

BIAYA AKIBAT KOROSI BESAR

(3-5% GNP di USA)
 Mengurangi kerugian akibat korosi
 Meningkatkan keamanan dan keselamatan kerja
 Menghindari polusi

Masalah-masalah korosi meningkat dengan

meningkatnya agresivitas lingkungan dan
tumbuhnya industri baru.
A. KOROSI PADA TEMPERATUR RENDAH
 T < TDEW POINT (Temperatur padamana larutan aqueous
dapat mengembun)
 Umumnya korosinya berlangsung secara elektrokimia

2e + 2H+  H2
Asam Klorida
Korosi (H+ dan Cl-)
Fe  2e + Fe2+

e Katoda
Anoda
B. KOROSI PADA TEMPERATUR TINGGI
 T > TDEW POINT (T>374oC)
KOROSI BERLANGSUNG AKIBAT:
 Logam berinteraksi dengan lingkungan gas
 Logam berinteraksi dengan lelehan garam dalam
lingkungan gas
 Logam bereaksi dengan lelehan logam lain
 Khusus untuk korosi suhu tinggi ketahanan material
untuk digunakan pada suhu tinggi hanya bergantung
dari protektif tidaknya kerak oksida yang terbentuk

 Perlu diperhatikan bahwa kegagalan suatu

komponen alat / bejana / struktur logam umumnya
terjadi akibat korosi (> 60%). Faktor-faktor lain juga
harus diperhatikan dalam pemilihan logam.
 Corrosion
Resistance
Availability Cost

MATERIAL

Strength Appearance
Fabricability
 Electrochemical

Physical Corrosion Metallurgical

Chemical Resistance

Thermodynamic
 Umumnya terjadi secara elektrokimia
 Proses korosi berlangsung spontan / secara natural
 Korosi berlangsung saat logam terpapar (exposed)
dalam lingkungan aqueous
 harus ada beda potensial pada lokasi-lokasi di
permukaan logam (terdapat permukaan yang bersifat
lebih katodik dan terdapat permukaan yang lebih
anodik).
 Reaksi katodik harus dapat berlangsung.
 LOGAM LINGKUNGAN AQUEOUS

Katodik O2

O2 + 2 H2O + 4e  4OH-

Fe  Fe++ + 2e
Fe++ dilanjutkan dengan reaksi
samping
Anodik
Fe++ reaksi pembentukan karat
2Fe++ + 4OH-  2Fe(OH)2 
2Fe(OH)2 + H2O + 1/2 O2  2 Fe(OH)3
(karat)
Kondisi-kondisi yang menyebabkan terjadinya
perbedaan potensial (antarmuka) setempat pada
permukaan logam / struktur yang terpapar dalam
lingkungan aqueous
1. Beda logam
2. Beda konsentrasi spesi-spesi dalam lingkungan
di muka struktur logam
 Beda kadar oksigen terlarut (differential aeration cell)
 Beda konsentrasi garam terlarut
3. Beda temperatur pada permukaan struktur
4. Beda energi internal setempat pada lokasi-
lokasi di permukaan struktur
SEL ELEKTROKIMIA YANG TERBENTUK:
- macro cell
- micro cell
 Macro Cell Anoda
 Micro Cell

Katoda
 CORROSION

GENERAL CORROSION LOCALIZED CORROSION

Anodes and cathodes are evenly Anodes and cathodes are separated
distributed in space and time in space and/or time

Pitting Crevice Galvanic Cracking

Uniform Uneven but generally
Corrosion distributed corrosion

Macro-Corrosion Micro-Corrosion
Effects Effects

Galvanic Erosion Selective Stress Cracking

Dissolution

Crevice Pitting Exfoliation Fatigue

22
 Uniform Original surface

Unifrom corrosion is relatively rare. It occurs in acid medium (e.g. during

acid pickling to clean the steel) and in inhibited solutions. It is not usually
uniform at the micro-scale.

General
General corrosion is unevenly highly distributed corrosion and is
common in pipelines though it may be restricted to parts o the pipeline,
usually the 6 o’clock possition.

Blistering
Blistering is caused by hidrogen generation within the steel and occurs in
acidic condition (e.g. pickling) and sour service. The blisters from at
inclusions within the steel.
Pitting
leoladed Multiple Undercutting
Pitting corrosion is common in pipeline. Pits may be individual and deep
or in clusters and sometimes overlapping. Undercutting pits occur in sour
service where the sulphide films act as a cathodic surface.

Cracking
Sulphide Stress Chloride Stress
Cracking Cracking Internal hydrogen
Cracking Cracking is associated with high stress and may be intergranular or
wtransgranular. Hydrogen cracking is usually single unbranched cracking
which may be associated with blistering. Corrosion resistents alloys
show multiple braching cracking.
Erosion Corrosion
Flow
Erosion corrosion occurs because the flow friction is sufficient
to remove protective surface films. It is common is sweet
corrosion in pipelines. Metal loss, may appears as horsehoe
undercutting.

Erosion
Solid of liquid Flow Erosion by solids removes protective surface films allowing
corrosion to occur. The combination o erosion and corrosion
can be very destructive. Erosion is generally most severe at
areas of change in flow direction. It appears as a relatively
localised uniorm metal loss with a rough surface.

Slug of liquid Impingement attack occurs when slogs o liquid are carried at
in flow high velocity in the gas stream leading to removal of
Impingement
prospective films on the pipeline surface and enhanced
corrosion . It appears as a sequence of elongated undercut
areas of metal loss.

Crevice
Crevice corrosion occurs under bolt heads and gaskets but
can also occur under oxides or deposits. It is a particular
problem of corrosion resistant alloys especially stainless
steels.
Gasket
Intergranular
Intergranular corrosion is loss of metal along the boundaries of the metal grains usually
because there is a susceptible material in this region. Steel in sour service and zinc
sacrificial anodes at high temperature can suffer this from o attack

Galvanic HAZ Weld

Galvanic corrosion occurs at the junction o dissimilar metals where there is a potential
difference between the metals. One from found in pipelines is associated with the
welds.

Fatigue Fatigue is the failure of the metals by progressive cracking under cyclic loading.
Pipeline steels have a fatigue limit of about 50% tensile strength, below which the steel
does not suffer fatigue. In a corrosive enviroment (e.g. seawater) there is no fatigue
limit. Cathodic protection can restore the steel performance close to that in air. Fatigue
In air loading can occur on risers and at pipeline spans.
Fatigue
limit In a corrosive
environment
Total stress
Stress

Baseline static stress

Cycles
Cyclic imposed stress

Time
 Carbon dioxide HYDROCARBON

CO2 + H2O = H2CO3 = H+ + HCO3- H2

Ions Fe++

H H H = H2
Ferrous

Iron carbonate film Siderite

electrons PIPELINE STEEL

Corrosion Rate = 5.8 – 1710/T + 0.67 log 10 fCO2

Where T oK and fCO2, fugacity o carbon dioxide
 OIL
GAS

Corrosion calculated
GAS
at pipeline pressure
and pipeline temperature

MULTIPHASE

Corrosion calculated Corrosion calculated

at pipeline pressure at separator pressure
SEPARATOR
and pipeline temperature and pipeline temperature

CONDENSATE

Water discharge
OIL
Corrosion Rate (mm/year)

Cut off at maximum expected rate

De Waard Amelioration of corrosion

& Milliams at higher temperatures
Algorithm

Temperature (oC)
 FLUID FLOW

2 Aqueous layer Cross cestion

1 3 of attact
4

Pipeline wall

1. Isolated pitting resulting from a surface defect

2. At critical depth low eddies remove the protective iron carbonate film from sides o the pit
3. Corrosion of the pit face in the direction of flow:
~ 5 unit axially and two units circumferentially for each unit radially
4. Progressive corrosion along the bottom of the pipe
 K
(Fluid density) 0.5
VCRIT =
VCRIT1

Above VCRIT2
Agressivelly Bellow VCRIT2 CR  Re0.8
Corrosion Rate

Corrosive CR  Re0.2
Environment - VCRIT2
VCRIT2

Mildly corrosive
Environment – VCRIT2

Flow Rate
Cabon manganese steels K = 130 – 150
Duplex and stainless steels K = 250 – 300
 Stagnation
zone prevents
FLOW
fluid impact

Zones of
enhanced
corrosion
 Microdroplets Droplet Water Water pickup Water layers persist
of water coalesence drop out at high flowrate At lowrate

1 m/s rule of thumb

Water Environment Velocity

0.9 SG, 30 cp 0.85 SG, 5 cp

0.95 SG, 140 cp

0.8 SG, 0.9 cp

10 20 30 40
Internal Diameter (inch)
RANGKUMAN
1. Denny A. Jones “ Principle and Prevention
Corrosion”
2. Mars G. Fontana, “Corrosion Engineering”, Mc.Graw
Hill
3. Marcel Pourbaix, “ Atlas of Electrochemical
Equilibria “, NACE
4. Roberge, “ Hand Book of Corrosion Engineering, “
Mc Graw Hill
5. L.L. Sheir, “ Hand Book Corrosion Vol 2”