Determining Corrosion Mechanisms in Failures Internal Corrosion Course 2017 February 21-23, 2017 Jane Nicole Brown & Jerry Brown BROWN CORROSION SERVICES, INC. 1 Period 2
Determining Corrosion
Mechanisms in Failures
Internal Corrosion Course
2017
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. 1
Period 2
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 2
2017 Underground Corrosion Short Course Internal - Period 2
As much as we try to prevent failures –
they do occur!
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 3
2017 Underground Corrosion Short Course
The Energy Sector – Down, Mid & Up Stream – Failures Tend to be Headline Grabbing!
Internal - Period 2
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 4
2017 Underground Corrosion Short Course Internal– Period 2
Platform Failure
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 5
2017 Underground Corrosion Short Course Internal– Period 2
Pipeline Failure San Bruno, CA
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 6
2017 Underground Corrosion Short Course Internal – Period 2
Pipeline Failure
Oklahoma
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 7
2017 Underground Corrosion Short Course Internal– Period 2
Pipeline Failure
Wyoming
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 8
2017 Underground Corrosion Short Course Internal – Period 2
Pipeline Failure Oklahoma
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 9
2017 Underground Corrosion Short Course Internal– Period #2
Wyoming
Third party failure
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 10
2017 Underground Corrosion Short Course Internal - Period 2
The Root Cause Analysis of a Failures
A Root Cause Analysis is a specialized type of incident
investigation process that is designed to find the lowest level
contributing causes to the failure.
The root is often a system of causes. There is rarely only one
root cause. The very basic understanding of cause and affect
is that every effect has causes (plural).
As an example an investigation determined that failed coating
contributed to a leak. The leak and coating are repaired and all
is well. Another leak occurs a few years later. It then turn out
that the main root cause was soil movement that damaged the
coating. In this case the investigators did not get to the root
cause of the coating failure thus leading to another failure.
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 11
2017 Underground Corrosion Short Course Internal - Period 2
The Root Cause of Failures can be attributed
to two categories: (often working together)
1. Mechanical
a. Earthquakes
b. Floods
c. Explosions
d. Crashes
e. Fires
f. Loads, pressures, stresses
g. Changes (Temperature, etc.)
h. Third party damage
2. Electrochemical
a. Corrosion
We will look at corrosion failures in the oil and gas industry in
this presentation and how to determine the actual mechanism
that caused the corrosion to occur.
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 12
2017 Underground Corrosion Short Course Internal - Period 2
Failures of metal pipes and vessels can occur from the inside
or the outside surfaces, and sometimes from both surfaces.
When this occurs the corrosion control measures (if any) did
not work as designed or were compromised in some way.
The Categories of Corrosion Control Measures are:
1. Material Selection
2. Design of the Structure
3. Coatings
4. Cathodic Protection
5. Alteration of the Environment
6. Inhibition
7. Repair and/or Replace
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 13
2017 Underground Corrosion Short Course Internal - Period 2
In the real world corrosion occurs when either the corrosion
control measures fail or the environment changes thus making
the corrosion control no longer able to control the corrosion.
The causes of corrosion are many and can be generally
divided into the following areas:
1. The chemical composition of the internal / external
environment.
2. The physical factors of the environment.
3. The physical factors of the structure.
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 14
2017 Underground Corrosion Short Course Internal - Period 2
The main things influencing internal corrosion in the oil and gas sector are:
a. H2O
b. H2S
c. CO2
d. Cl
e. O2
f. Bacteria
The main things influencing external corrosion in the oil and gas sector are:
a. H2O
b. Soil resistivity and pH
c. Cl
d. O2
e. Bacteria
It is important to know not only the present chemistry of the environment both
inside and outside of the pipe/vessel, but what was the environment from the
manufacture of the pipe through storage, delivery, installation, hydro testing,
start-up and condition over the life of the structure.
In many cases this data is not available. Even when it is available - is it accurate
and reliable - probably not!
1. The Chemical Composition of the Internal / External
Environment
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 15
2017 Underground Corrosion Short Course Internal - Period 2
2. The Physical Factors of the Environment.
A. Flow – no flow, velocity
B. pH
C. Solids in the flow
D. Depositions on the structure
E. Mixing of various products
F. Vibrations
G. Surfaces
H. Flow regimes
I. Pulsating flow
J. Mixing – or not – of gas, oil, water
K. Contamination
L. Subsidence, spanning, and earth movement
M. Wind, waves, storms, flooding, etc.
N. Third party damage
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 16
2017 Underground Corrosion Short Course Internal - Period 2
3. The Physical Factors of the Structure.
A. Pipe sizes
B. Change of direction – elbows
C. Dead legs
D. Material changes
E. Surfaces
F. Weld bumps
G. Heat affected areas
H. Pipe Flaws
I. Incorrect materials
J. Different stress levels
K. Erosion
L. Cracking
M. Stresses - unplanned
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 17
2017 Underground Corrosion Short Course Internal - Period 2
In all cases the following data is necessary:
A. Location
B. Weather
A. Temperature
B. Humidity
C. Other conditions
C. Date and time
D. Who was on duty
E. Any recent changes
F. Cell phone records
G. Coms records
H. Archived data
A. Operational
B. Logs
C. MOC’s
I. Original documents
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 18
2017 Underground Corrosion Short Course Internal - Period 2
When failures occur the failed section of pipe must be evaluated by a qualified metallurgical laboratory and overseen by a qualified Corrosion Engineer. As much data as possible must be obtained and the sections of pipe must be prepared for shipment with as little disturbance as possible and carefully protected from further damage or contamination. The flow direction and top of pipe should be marked on the cut-out section of pipe.
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 19
2017 Underground Corrosion Short Course Internal - Period 2
Sample Marking, Observation, & Recording
1. Top or ?
2. Flow Direction
3. Date & Time
4. Weather
5. GPS Coordinates
6. Who did it?
7. Etc.
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 20
2017 Underground Corrosion Short Course Internal - Period 2
Samples of the environment should be obtained – if at all possible.
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BROWN CORROSION SERVICES, INC. Page 21
2017 Underground Corrosion Short Course Internal - Period 2
Sampling of the Environment
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BROWN CORROSION SERVICES, INC. Page 22
2017 Underground Corrosion Short Course Internal - Period 2
Sampling of the Environment
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 23
2017 Underground Corrosion Short Course Internal - Period 2
Sampling of the Environment – Bugs
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BROWN CORROSION SERVICES, INC. Page 24
2017 Underground Corrosion Short Course Internal - Period 2
Solids Observation & Analysis
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 25
2017 Underground Corrosion Short Course Internal - Period 2
Water Analysis
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BROWN CORROSION SERVICES, INC. Page 26
2017 Underground Corrosion Short Course Internal - Period 2
Visual Observation & Photography
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 27
2017 Underground Corrosion Short Course Internal - Period 2
Photographic Observation & Recording
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 28
2017 Underground Corrosion Short Course Internal - Period 2
When You Get to the Laboratory
1. Record receipt and custody transfer information.2. Photograph and note as received.3. Unwrap carefully.4. Photograph and note opened samples.5. Take samples of any available products, label and contain.6. Plan sectioning and cutting if necessary.7. Section as required.8. Prepare samples for testing.9. Perform testing as per protocol.10. Record all data.11. Prepare report.12. Send report and store samples for sending back, storage or disposal.13. Issue report (draft or final per agreement).
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 29
2017 Underground Corrosion Short Course Internal - Period 2
Various Tests Can be Performed
Environment 1. Gas Analysis
2. Liquid Analysis
3. Solids Analysis
4. MIC Testing
5. pH and Resistivity
Structure 1. Material
2. Measurement
3. Depth
4. Deposition
5. Hardness
Four Main Areas of Analysis: 1. Chemical Analysis
2. Metallurgical Analysis
3. Microbial Analysis
4. Corrosion Testing.
Chemical Analytical Methods Include: XRD (X-Ray Diffraction), Ion
Chromatography, AAS (Atomic Absorption), DCP/ICP (Direct Current Plasma & Inductively
Coupled Plasma), Wet Chemistry, Gas / Mass Spectrometry, Scaling Index,
Conductivity, pH, SEM (Scanning Electron Microscopy), EDS (Energy Dispersive
Spectroscopy), TEM (Transmission Electron Microscopy), AES (Auger Electron Spectroscopy), SIMS
(Secondary Ion Mass Spectroscopy), FTIR (Fourier Transform Infrared Spectroscopy), ETC.
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 30
2017 Underground Corrosion Short Course Internal - Period 2
Lay out the failed portions so you get an understanding
of what went wrong and where. Then sampling of the
actual failed parts can be determined and cut into lab
size samples
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 31
2017 Underground Corrosion Short Course Internal - Period 2
Various Tests Can be Performed
Pit Depth
Thickness
Cracks
Weight
Hardness
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 32
2017 Underground Corrosion Short Course Internal - Period 2
Metallurgical Analytical Methods Include: Grain Size,
Inclusion Content & Distribution, Uniformity, Type, Phase Percentage,
Grade, Striations, Pitting, Distribution of Elements,
Metallurgical Analysis for Corrosion in used 3 Primary Ways: 1. Characterization of the Microstructure
2. Relationship of Microstructure to Corrosion
3. Size & Shape of Any Pits & Cracks
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 33
2017 Underground Corrosion Short Course Internal - Period 2
SEM & EDS Data
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BROWN CORROSION SERVICES, INC. Page 34
2017 Underground Corrosion Short Course Internal - Period 2
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BROWN CORROSION SERVICES, INC. Page 35
2017 Underground Corrosion Short Course Internal - Period 2
Bacteria Detected
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BROWN CORROSION SERVICES, INC. Page 36
2017 Underground Corrosion Short Course Internal - Period 2
Once all the testing is completed comparisons must be
made to include the material, properties of the material,
the environment (chemical and physical), the
operations, and any and all data available. With this,
and comparisons to other known failures, positive
conclusions can be drawn.
Typical conclusions might be:
1. Microbiological influenced corrosion.
2. CO2 induced corrosion.
3. Corrosion / Erosion.
4. Cracking corrosion due to H2S.
5. O2 corrosion.
6. Combinations of these and other factors.
7. Failure of the corrosion control used.
8. Third party damage.
9. Operating beyond design life.
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 37
2017 Underground Corrosion Short Course Internal - Period 2
Once the root cause analysis reveals the corrosion
mechanism that caused the corrosion in the first place
is determined, steps can be taken to create corrosion
control measures to prevent further corrosion failures.
Chemicals
Changes
Coatings Replacement Material Changes
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 38
2017 Underground Corrosion Short Course IInternal - Period 2
When all the testing, analysis, document gathering, research
is done the final REPORT must be written, checked,
approved and issued. The report should be complete
concise, clear and have all conclusions backed-up and
referenced.
1. Dates and names must be clear and concise.2. There must be an Executive Summary.3. There should be a clear Background regarding the failure.4. All details as to the failure must be included.5. All photos should be included.6. Conclusions must be made with back-up for each.7. References must be included.8. Recommendations must be included.9. All anachronisms must be spelled out.10. Proper and formal English must be used (spell-checked).11. The document must be signed.
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 39
2017 Underground Corrosion Short Course Internal - Period 2
Before you have a failure: Document everything.
Ensure compliance.
Keep up with technology.
Be an active NACE member.
Get involved in decision making in your company.
Be a good Steward of our world.
If you do have a failure: Put out the fire!
Document everything!
Determine the Root Cause of the failure!
Work to implement changes that will not allow future failures!
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 40
2017 Underground Corrosion Short Course Internal - Period 2
The general population, the politicians, the
progressives, and the media have little if any
understanding of the complexity of the assets we are
responsible for and the failures that do occur.
In addition, management often do not take corrosion
seriously, especially if a period of time has gone by
with no failures. Therefore, your corrosion control
budgets are cut - if not eliminated.
E & C & operation budgets are often cut not allowing
proper corrosion control to take place.
Offshore structures were designed for a 20 year life –
50 years ago & still in operating - aging infrastructure!
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 41
2017 Underground Corrosion Short Course Internal - Period 2
This is never the answer!
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 42
2017 Underground Corrosion Short Course Internal - Period 2
To understand why a Failure occurs we must determine the
root cause. If this is done thoroughly and accurately we can
then move forward to fix existing structures to remove these
causes and be sure future structures are designed without
the possibility of these known causes being present.
Unfortunately, we do not
always get to the root case,
and even if we do, time
moves on and we repeat the
mistakes leading to further
failures.
February 21-23, 2017 Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC. Page 43
2017 Underground Corrosion Short Course
"Those that fail to learn from history, are doomed to repeat it."
Winston Churchill
Internal - Period 2
February 21-23, 2017
Jane Nicole Brown & Jerry Brown
BROWN CORROSION SERVICES, INC.
Page 44
2017 Underground Corrosion Short Course Internal - Period 2
Questions ???
Thank your for this opportunity to present our views.