industrial corrosion and corrosion control technology

662 Pages·2009·4.96 MB·English

INDUSTRIAL CORROSION AND
CORROSION CONTROL TECHNOLOGY

H.M. Shalaby
A. Al-Hashem
M. Lowther
J. Al-Besharah
(Editors)

Published By
Kuwait Institute for Scientific Research
INDUSTRIAL CORROSION AND CORROSION CONTROL
TECHNOLOGY
1996
Sponsored by the Kuwait Institute for Scientific Research (KISR), the Kuwait
Foundation for the Advancement of Science (KFAS), the Kuwait National
Petroleum Company (KNPC), the Kuwait Oil Company (KOC), Ministry of
Electricity and Water (MEW), Kuwait University (KU), Ministry of Oil (MO),
the Gulf Cooperation Council-General Secretariat (GCC), Kuwait Chemical
Society (KCS), Organization of Arab Petroleum Exporting Countries (OAPEC),
and Petrochemical Industries Company (PIC).
INDUSTRIAL CORROSION AND CORROSION
CONTROL TECHNOLOY

Proceedings of the 2nd Arabian Corrosion Conference
Kuwait, October 12-15, 1996

Editors

H.M. Shalaby, A. Al-Hashem, M. Lowther and J. Al-Besharah

PUBLISHED BY KUWAIT INSTITUTE FOR SCIENTIFIC RESEARCH
P.O. BOX 24885, 13109 SAFAT, KUWAIT
Published by
Kuwait Institute for Scientific Research
P.O. Box 24885, 13109 Safat, Kuwait
Publication Number: KISR 4890

Copyright ® 1996 by Kuwait Institute for Scientific Research

The papers were reviewed for their technical contents. Editing was restricted to matters of
format, general organization and retyping. The editors assume no responsibility for the
accuracy, completeness or usefulness of the information disclosed in this book. Unauthorized
use might infringe on privately owned patents of publication right. Please contact the
individual authors for permission to reprint or otherwise use information from their papers

This book was printed in Kuwait

The 2nd Arabian Corrosion Conference
FOREWORD

The 2nd Arabian Corrosion Conference was held in the state of Kuwait during the period 12-
15 October, 1996 under the auspices of H.H. Sheikh Saad Al-Abdullah Al-Salem Al-Sabah,
Kuwait’s Crown Prince and Prime Minister. The present conference was scheduled to be
held in Kuwait during 27-30 April, 1991, however, it was postponed due to the events that
encompassed Kuwait and the Gulf region in 1990-1991.

The 1st Arabian Corrosion Conference was held in Kuwait during 4-8 February, 1984. It was
attended by over 300 scientists and engineers, representing 26 countries. The conference
proceedings were published in two volumes by Pergamon Press under the title “Corrosion:
Industrial Problems, Treatment and Control Techniques”. The conference provided a forum
for the exchange of ideas between scientists and engineers from the region with their
counterparts from the industrialized countries.

The patronage of the present conference, the organizing bodies, and the emphasis on
industrial corrosion and corrosion prevention reflect the keen interest of the countries in the
region in actively combating corrosion problems. This also reflect the recognition of the
economic impact resulting from the corrosion of materials.

Kuwait and the other Arab countries rely heavily on the utilization of metallic materials in
their oil-based industries. Seawater derived from the Arabian Gulf is used in water
desalination and as an industrial cooling media. The salinity of the Arabian Gulf seawater is
very high when compared to other seawater bodies. The Arabian Gulf countries are located in
an arid environmental zone where the temperature during the summer months could reach
50oC and the humidity during the autumn season could become 80% in some of the Gulf
states. All these factors contribute to the enhancement of the rate of corrosion of metals
and/or cause unpredictable service failures.

The program of the present conference includes a field visit to one of Kuwait’s modern
refineries and a trip to one of Kuwait’s oil fields. The success of the conference is perhaps
difficult to assess. However, the quality of the papers in this volume provides some
indication.

The Editors

v
PREFACE

The technical program of the present conference includes five plenary lectures and fifty three
scientific presentations from about twenty two countries. A number of honorary speakers,
carefully selected from high ranking officials and policy makers, were also invited to address
the conference. The honorary speakers are expected to provide an overview of the magnitude
of corrosion related problems in the Middle East as well as the avenues of linkage between
corrosion science and industrial applications. The conference papers were carefully selected
to include a blend of fundamental and applied research, and industrial experience. Such a
blend was thought to be essential for providing the participants from both industry and
academia with a chance to become familiar with the challenges facing each group and the
preventive actions to meet them. The papers were refereed in terms of scientific and
technical content and format in accordance with internationally accepted standards.

The papers in the proceedings are grouped in the following sections for quick reference:

• Plenary Lectures
• Oil Field Corrosion
• Corrosion in Refinery and Petrochemical Industries
• Seawater Corrosion
• Corrosion in the Building Industry
• Fundamental Aspects
• Corrosion Protection and Monitoring
• Corrosion Management
• Novel Techniques

The plenary papers are mostly reviews covering important topic related to the objectives of
the conference. The remaining papers cover various topics of major importance to corrosion
in general and particularly to the oil-based and desalination industries. A good number of
papers delt with corrosion protection and new techniques for corrosion monitoring.

The task of editing this volume was facilitated by the efforts of the International Advisory
Committee and the Scientific Committee for the conference who reviewed all the papers. The
editorial board gratefully acknowledge these efforts; the cooperation, time and effort of all
authors ; and the management of the Kuwait Institute for Scientific Research for allocating
the required resources to prepare the manuscript of this volume.

The Editors

vi
TABLE OF CONTENTS

Foreword............................................................................................................................................v
Preface...............................................................................................................................................vi
Organizing Committees......................................................................................................................xi
Acknowledgement.............................................................................................................................xii
PLENARY LECTURES
Corrosion Management
V. Ashworth........................................................................................................................................1
The Deterministic Prediction of Damage
D.D. Macdonald...............................................................................................................................17
Relevance of Laboratory Corrosion Tests in Corrosivity Assessment
and Materials Selection: Case Studies
R.D. Kane.........................................................................................................................................37
Corrosion of Condensers in Multi Stage Flash
Evaporation Distillers
A.M. Shams El Din...........................................................................................................................49
Correct Materials Selection for Desalination
-The Key To Plant Reliability
J.W. Oldfield....................................................................................................................................67
OIL FIELD CORROSION
Corrosivity Prediction for Co /H s Production Environments
2 2
S. Srinivasan and R.D. Kane.............................................................................................................89
Testing of Drilling Fluids Formulated From Tabuk Formation Clays
M.N.J. Al-Awad, A.S. Dahab and M.E. El-Dahshan........................................................................111
Preventing Sulfate Scale Deposition in Oil Production Facilities
C.J. Hinrichsen, M.J. McKinzie, S. He, J. Oddo, A.J. Gerbino, A.T. Kan, and M.B. Tomson...........127
Concerns Over the Selection of Biocides for Oil Fields and Power Plants:
A Laboratory Corrosion Assessment
J. Alhajji and M. Valliappan...........................................................................................................135
Evaluation of Microbially Influenced Corrosion Risks and Control Strategies
in Seawater and Produced Water Injection Systems, Kuwait
P.F. Sanders, M. Salman and K. Al-Muhanna.................................................................................149
Hydrogen Degradation of Steel - Diffusion and Deterioration
M. Farzam...................................................................................................................................................165
Control Strategies for Thermophilic Sulphate-Reducing Bacteria
P.F. Sanders, H.M. Lappin-Scott and C.J. Bass...............................................................................179
Corrosion Evaluation of Austenitic and Duplex Stainless Steels in Simulated
Hydrogen Sulphide Containing Petrochemical Environments
K. Saarinen and E. Hamalainen......................................................................................................191

vii
Damage of Pump Linkages and Tool Joints Caused by Crack Corrosion
A. Kinzel.........................................................................................................................................201
Analysis of Soils Possibility to Give Rise to Pipe Metal Stress Corrosion Cracking
V.G. Antonov and S.A. Loubenski....................................................................................................209
A Mysterious Downhole Corrosion Failure in an Oil Well
A. Husain and A. Hasan..................................................................................................................215
CORROSION IN REFINERY AND PETROCHEMICAL INDUSTRIES
Methodologies for Assessment of Crude Oil Corrosivity in Petroleum Refining
S. Tebbal and R.D. Kane.................................................................................................................225
New Nickel Alloys Solve Corrosion Problems of Various Industries
D.C. Agarwal and W.R. Herda....................................................................................................................233
Macro-Micro Segregation Bands (MMB) as a Main Factor Influencing
Steel Applicability for the Petroleum Industry
A. Mazur.........................................................................................................................................245
Fluid Catalytic Cracking Interstage and High-Pressure Cooler Corrosion
S.M. Halawani................................................................................................................................255
Assessment of Cracks in a High Pressure Multilayered Reactor
for its Fitness for Purpose
A.M. Askari, M.I. AL-Kandari and P.K. Mukhopadhyay.................................................................263
Polythionic Acid Stress Corrosion Cracking of Incoloy 800: Case Study
and Failure Analysis
M.S. Mostafa and S.A. Hajaj...........................................................................................................273
Corrosion of Tube Heaters in Refineries: Symptoms and Cures
A. Attou , A. Rais and H. Smamen...................................................................................................283
SEAWATER CORROSION
Super Duplex Grade UNS S32750 for Seawater Cooled Heat Exchangers
P.A. Olsson and M.B. Newman.......................................................................................................289
Evaluation of Aluminum Alloy 5083 Weldments to Stress Corrosion Cracking
in Seawater
A. Saatchi, M.A. Golozar and R. Mozafarinia.................................................................................301
Cavitation Corrosion Behavior of Some Cast Alloys in Seawater
A. Al-Hashem, P.G. Caceres and H.M. Shalaby..............................................................................311
Microbiologically Induced Corrosion of a Stainless Steel Pipe
H.H. Lee, M. Ali and K. Al-Omrani................................................................................................323
A Laboratory Study of Service Failure of Al-Brass Tubes in Arabian Gulf Seawater
H.M. Shalaby, W.T. Riad and V.K. Gouda......................................................................................329
CORROSION IN THE BUILDING INDUSTRY
Corrosion of Reinforced Concrete Structures and the Effects of the Service Environment
S. Al-Bahar and E.K. Attiogbe........................................................................................................341

Corrosion of Concrete in Seawater
viii