Corrosion in Oil Pipe Prepared by: Ali Agha Baghdad University/MSc. at Advanced Manufacturing Eng. Department Phone:

Outlines:  Introduction.  Risk of corrosion.  Cost of maintenance.  Methods to prevents the corrosion.

1.Introduction. Corrosion is the deterioration of materials by chemical interaction with their environment as shown in Fig (1). The term corrosion is sometimes also applied to the degradation of plastics, concrete and wood, but generally refers to metals. The most widely used metal is iron (usually as steel) and the following discussion is mainly related to its corrosion. Figure 1: Corroded anchor

The most common and important electrochemical reactions in the corrosion of iron are thus: Anodic reaction (corrosion) Cathodic reactions (simplified) In this latter case corrosion is usually accompanied by the formation of solid corrosion debris from the reaction between the anodic and cathodic products.

2. Risk of corrosion. Identification of hazards and assessing risks is fundamental for any management process. A hazard has the potential to cause harm or damage Risk is the combination of the severity of the effect (the consequences) and the likelihood of it happening (damage mode and probable frequency). Industrial risk assessment is a careful examination of potential hazards that may affect the operation of a business; these may be risks associated with the safety and integrity of physical assets, risks to the environment, financial risks from various decisions and also risks from corrosion or poor corrosion mitigation procedures. At its simplest it is a common sense approach that provides a means of checking what is often good existing practice. For example, in offshore installations produce hydro carbon fluids are flammable and are therefore a hazard. Some fluids also contain hydrogen sulphide, this toxic gas is present in the reservoir, either naturally because of the chemistry of the strata or can be the result of biological contamination from poor water injection. Such fluids are therefore hazardous with the potential to cause death and injury to personnel. Loss of containment can also result in damage to the environment.

3. Cost of corrosion maintenance. Over the past 22 years, the U.S. has suffered 52 major weather- related disasters—including hurricanes, tornadoes, tropical storms, floods, fires, droughts, and freezes—incurring total normalized losses of more than $380 billion1(averaging $17 billion annually). According to the current U.S. corrosion study, the direct cost of metallic corrosion is $276 billion on an annual basis. The study analyzed costs associated with each of these methods, as well as the cost of corrosion control services, research and development, and edu cation and training. It estimated that related total direct costs were $121 billion, or 1.38% of the U.S. GDP. The largest portion of this cost (88.3%) was attributed to organic coatings. These costs do not represent the total costs associated with corrosion control methods because they do not include labor and management related to costs in the U.S. could be saved if optimum corrosion management practices were employed. Weather Disasters, ” (Asheville, NC: National Climatic Data Center, National Oceanic and Atmospheric Administration, 2001). Direct Corrosion Costs: $276 billion (3.1% of U.S. GDP) 1998 U.S. GDP ($8.79 trillion)the development, design, and implementation of corrosion prevention systems—a major expense for the owner/operator.

4. Methods to prevents the corrosion. NRI’s Corrosion Protection Systems:  Syntho-Glass XT Syntho-Glass XT Applications:  Pipelines  Transmission and distribution pipelines  Oil and gas risers  Girth welds, elbows, tees and flanges on vessels  Process piping. Benefits:  Water activated polyurethane resin reduces composite preparation time by over 50%  Easy to apply underwater or in wet and rainy environments

 Thermo-Wrap Thermo-Wrap Applications:  Flare lines.  Steam piping.  Girth welds, elbows, tees.  Chemical processing lines.  Sites where temperature is expected to elevate. Benefits:  Ambient cured epoxy with high temperature rating  No heating or post-curing required.  Full factory support from NRI engineers to ensure that repairs are completed safely and efficiently.

 Syntho-Glass Syntho-Glass Applications:  Impact protection.  Emergency repair.  Corroded pipes.  Irregular pipe fittings.  Force mains and gravity lines.  Joint and tee repair.  Underwater repair and splash zone. Benefits:  Ready to use.  Activated by salt or fresh water.  Effective, time-saving.  No mixing and no mess.  Sets rock-hard in 30 minutes.

 Scar-Guard Scar-Guard Applications:  Provides mechanical protection to the pre-approved corrosion coating of your choice.  Welded field joints on pipelines (Horizontal directional drilling).  Boring.  Coating repair & protection. Benefits:  Quick setting.  Non-hazardous.  No field mixing or mess.  Water activated.  Smooth profile to reduce damage during pull through.

 Syntho-Glass 24 Syntho-Glass 24 Applications:  Impact protection  Emergency repair  Corroded pipes  Irregular pipe fittings  Force mains and gravity lines  Joint and tee repair  Underwater repair and splash zone Benefits:  Impact resistant  Energy absorbent  No mixing or mess  Water activated  Four layers of strength  No solvents  Can be applied underwater

 Composite Guard FP Composite Guard FP Applications:  Fire proofing system  Offshore platforms  Refineries  Chemical processing plants Benefits:  Instant fire resistance and protection  Lightweight  Impact resistant  Long term durability