Corrosion threats handbook

Upstream oil and gas production plant

in association with
Issued under licence to BP employees only.
IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
Acknowledgements
The Institute wishes to record its appreciation of the work carried out by Dave Moore of Lloyd’s Register EMEA for compiling this document and for
input of expertise into its detail and content and members of the Corrosion Management Working Group who provided valuable expertise through
meeting attendance and correspondence.
The origins of this document and further details of the Work Group can be found in the associated publication: Guidance for corrosion management
in oil and gas production and processing which is referenced throughout this document.

Foreword
This publication was compiled to enhance the awareness of corrosion for a large cross section of personnel within the oil and gas industry. It was
produced in parallel to the main guideline publication, Guidance for corrosion management in oil and gas production and processing which was
prepared following consultation with a large cross section of UK offshore operators, specialist contractors and independent verification bodies who
have a role in the control of corrosion.
This document is for guidance only, and while every reasonable care has been taken to ensure the accuracy and relevance of its contents, the Energy
Institute, its sponsoring companies, the document writer and the Working Group members, shall not be liable to any person for any loss or damage
which may arise from the use of any of the information contained in any of its publications.
This handbook may be reviewed from time to time and it would be of considerable assistance for any future revision if users would send comments or
suggestions for improvements to:

The Technical Department

Energy Institute
61 New Cavendish Street
London W1G 7AR
e: [email protected]

Copyright © 2008 by the Energy Institute, London.

The Energy Institute is a professional membership body incorporated by Royal Charter 2003. Registered charity number 1097899, England.
All rights reserved. No part of this book may be reproduced by any means, or transmitted or translated into a machine language without the written permission of the publisher.
The information contained in this publication is provided as guidance only and while every reasonable care has been taken to ensure the accuracy of its contents, the Energy Institute cannot accept any
responsibility for any action taken, or not taken, on the basis of this information. The Energy Institute shall not be liable to any person for any loss or damage which may arise from the use of any of the
information contained in any of its publications. The above disclaimer is not intended to restrict or exclude liability for death or personal injury caused by own negligence.
ISBN 978 0 85293 496 8 Published by the Energy Institute
Further copies can be obtained from Portland Customer Services, Commerce Way, Whitehall Industrial Estate, Colchester CO2 8HP, UK. Tel: +44 (0) 1206 796 351 e: [email protected]
Electronic access to EI and IP publications is available via our website, www.energyinstpubs.org.uk. Documents can be purchased online as downloadable pdfs or on an annual subscription for single
users and companies. For more information, contact the EI Publishing Team. e: [email protected]
Issued under licence to BP employees only.
IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
Contents
page page
Introduction.................................................. 3 Degradation threats ................................... 12
Corrosion basics ............................................................................ 4 1. Carbon dioxide corrosion ................................................. 12
Controlling corrosion ................................................................... 4 2. Hydrogen sulphide corrosion ........................................... 13
The corrosion triangle...................................................................... 5 3. Oxygen corrosion .............................................................. 14
How to use this handbook .............................................................. 6 4. Microbially influenced and deadleg corrosion ............... 15
Abbreviations ................................................................................... 6 5. Galvanic corrosion ............................................................. 16
6. Weld corrosion .................................................................. 17
7. Grooving corrosion ........................................................... 18
System schematics / corrosion threats ....... 7 8. Crevice and flange face corrosion .................................... 19
Three phase and separation ........................................................ 7 9. External corrosion - coatings, fasteners and subsea ......... 20
Gas process ................................................................................... 8 10. Corrosion under insulation ............................................... 21
Seawater ....................................................................................... 9 11. Stress corrosion cracking................................................... 22
Cooling medium ........................................................................... 10 12 a. Erosion .............................................................................. 23
Heating medium .......................................................................... 10 12 b. Erosion corrosion............................................................... 24
Drainage system ........................................................................... 11 13. Fatigue and fretting.......................................................... 25
Diesel system ................................................................................ 12 14. Miscellaneous – embrittlement and acid corrosion ......... 26

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
Introduction
Oil and gas production facilities must continue to strive for, The majority of the corrosion threats apply to carbon steel, the
and improve, safety, environmental, production and cost most commonly used material for upstream oil and gas production
goals at a time when many UK plants are extending their systems, structures and components. Threats to other materials
period of operation beyond their original design life. Effective are identified.
management of corrosion of the structures and systems is a core
requirement to achieve those goals. The role of plant operation, This guide has been prepared to supplement the Energy Institute
maintenance, inspection and support personnel is, in turn, critical publication Guidance for corrosion management in oil and
in maintaining the integrity of their plant. The Energy Institute gas production and processing. Where appropriate, reference
has commissioned this guide as a concise reference tool to assist has been made to the relevant sections of Appendix B of that
these individuals by providing practical information to illustrate document, where more detailed information on managing each
the corrosion degradation mechanisms likely to affect upstream of the corrosion threats can be found.
oil and gas production systems, structures and components. The
The information in this guide should NOT be used to the exclusion
guide outlines the causes of the corrosion threats, shows typical
of established and applicable codes, standards and criteria; nor
locations for their occurrence and gives examples of how the
should the threats and their manifestation described in this
threats may be managed.
guide be seen as exhaustive. Please notify and consult with the
The guide is intended for use by plant engineers and personnel relevant technical engineering authority/discipline specialists for
with direct and indirect responsibility for the long-term integrity investigation of potential threats or actual degradation that may
of production facilities. It should assist system housekeeping and be observed.
more formal integrity audits. The guide should also be of value
The corrosion threats in this guide are presented either as specific
to practitioners of Integrity Management, especially those less
corrosion mechanisms, e.g. microbial corrosion, erosion corrosion;
familiar with corrosion issues specific to oil and gas production
or by location, e.g. external corrosion, corrosion under insulation.
plant.
In addition to the threats which are strictly corrosion, three other
The information should allow the user to: degradation processes are included in this handbook. They are:
s 5NDERSTAND THE KEY CORROSION THREATS BOTH INTERNAL AND erosion, fatigue and fretting. In practice, corrosion may be driven
external corrosion) by two or more mechanisms. Typically, the resultant corrosion rate
s 5NDERSTAND THE TYPICAL APPEARANCE OF THE MAIN THREATS is faster than would be anticipated from a single mechanism.
s 5NDERSTAND WHERE THE THREATS MAY OCCUR
s )DENTIFY THE CONDITIONS WHICH MAY GIVE RISE TO THREAT
s #ONSIDER ACTIONS TO MITIGATE THE THREAT

Corrosion threats guide 3

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
Corrosion basics
The metal used to fabricate process plant and structures is a
metastable material. Fundamental laws of thermodynamics
tell us that metals we use have the innate potential to
CONVERT TO A MORE STABLE LOWER ENERGY FORM
The rusting of steel is a well known example of the conversion
OF A METAL IRON INTO A MORE STABLE LOWER ENERGY STATE NON
METALLIC PRODUCT RUST  4HE CHANGE IN ENERGY OF THE SYSTEM
is the driving force for this process. It is no coincidence that
the corrosion products we observe on our facilities are the
same compounds as the original ores from which the metals
were extracted, for example, iron oxides, iron carbonates
and iron sulphides.

Controlling corrosion
It follows therefore that, without our intervention, the
metals from which facilities are fabricated will inevitably
return to the non-metallic compounds from which they
were extracted.
Recognising the indicators of degradation and
understanding the causes, forms the basis of the process by
which the threat of corrosion may be managed.

The fire triangle analogy OXYGEN FUEL

The majority of the corrosion reactions which occur in
upstream production facilities are aqueous oxidation
processes. As such they are analogous to combustion,
ANOTHER PROCESS BY WHICH A MATERIAL IS OXIDISED BY THE
oxygen in air) to a lower energy compound. The well known
Fire Triangle has an aqueous corrosion equivalent, which
may aid our understanding of corrosion and the methods
used to mitigate corrosion. ENERGY
Issued under licence to BP employees only.
IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with Corrosion threats guide 4
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
The corrosion triangle
In the same way that a fuel requires oxygen and energy to
combust, a metal requires water and a corrodent, for aqueous
corrosion to occur.
The water required for corrosion to occur may be atmospheric
MOISTURE OR SEA  RAIN WATER IN THE CASE OF EXTERNAL CORROSION
PRODUCED WATER IN THE CASE OF INTERNAL CORROSION OF HYDROCARBON
PROCESSING SYSTEMS OR SEAWATER IN THE CASE OF SEAWATER INJECTION
systems).
The corrodents are typically:
WATER CORRODENT
s /XYGEN ATMOSPHERIC CORROSION OF STEEL STRUCTURES
internal corrosion of water systems
s #ARBON DIOXIDE n CO PRODUCED WITH OIL AND GAS
s (YDROGEN SULPHIDE n PRODUCED FROM SOUR WELLS OR
by microbial action in production plant or water
systems
s !CIDS n EITHER CO PRODUCED IN PRODUCTION mUIDS OR
those used for well stimulation, or acidic production
chemicals

Corrosion control
METAL
The analogy with the fire triangle can be taken further in the
context of corrosion mitigation. A fire can be controlled by
removing any one of the three elements, e.g. a carbon dioxide
blanket to prevent oxygen access, or cooling with water to reduce
the energy. In the same way, corrosion may be controlled by
removing any one of the metal, water or corrodent components.
METAL + WATER + CORRODENT = CORROSION
Typical examples of these are:
s 2EPLACING STEEL WITH GLASS REINFORCED PLASTIC METAL + WATER + CORRODENT = NO CORROSION
pipework in seawater systems
s +EEPING INSULATION DRY TO PREVENT CORROSION UNDER
insulation
METAL + WATER + CORRODENT = NO CORROSION
s $EAERATING REMOVING OXYGEN FROM SEAWATER PRIOR
to downhole injection METAL + WATER + CORRODENT = NO CORROSION
s #OATING TO ISOLATE A METAL FROM WATER
The principle of removing at least one of the three necessary
components for corrosion lies behind most of the activities we
implement to control corrosion and is worth bearing in mind
when considering corrosion issues and mitigation measures.
Corrosion threats guide 5

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
How to use this handbook Abbreviations

The typical process and utility systems in upstream oil and gas The abbreviations used in
The abbreviations used to describe
the description section of the
production facilities are illustrated in the simplified process the threats are:
handbook are:
flow diagrams that follow. Typical corrosion threats for each General abbreviations Abbreviation Threat

of the systems are listed on each of the diagrams. Each threat CP Cathodic Protection Acid Acid Corrosion

is numbered, so that the number can be used to refer to the CRA Corrosion Resistant Alloy CO2 Carbon Dioxide Corrosion
Corrosion Under
description section of this guide. The description of each EI Energy Institute CUI
Insulation
European Federation of
threat shows typical examples of degradation morphologies EFC Crev Crevice Corrosion
Corrosion
and provides information on: the causes of the threats; how the HAZ Heat Affected Zone Eros Erosion

threat is manifested; which sections of the system are susceptible; Liquid Metal
LME Eros Corr Erosion Corrosion
Embrittlement
typical monitoring and inspection methods; and how the threat Magnetic Penetrant
MPI Ext Corr External Corrosion
Inspection
may be managed.
PW Produced Water F&F Fatigue and Fretting
More detailed information on these threats and their mitigation
QC Quality Control Galv Galvanic Corrosion
is given in the Energy Institute publication Guidance for corrosion
RBI Risk Based Inspection H2S Hydrogen Sulphide
management in oil and gas production and processing. Liquid Metal
SS Stainless Steel LME
Embrittlement
To differentiate between the main and less common threats
Ultrasonic Thickness Microbially Influenced
UT MIC
to each section of the plant, the major threats are highlighted Measurement Corrosion
WP Working Party O2 Oxygen Corrosion
in red.
SCC Stress Corrosion Cracking

Issued under licence to BP employees only. Corrosion threats guide 6

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 Degradation threats to the oil process and produced water systems
Internal threats: topsides External threats: topsides
Water-wet hydrocarbon fluids
Ext Corr / CUI / F&F
CO2 / H2S / O2 / MIC / Galv / Weld / Groove
Crev / SCC / Eros / Eros Corr / Acid

RD 3TAGE
 0HASE &LUIDS ND 3TAGE
ST 3TAGE 3EPARATION
3EPARATOR 3EPARATOR #OALESCER

#$ 3YSTEM

-ETERING
(YDROCYCLONES
Internal threats: downhole
CO2 / H2S / MIC / Galv / Weld / Groove / Crev
/ SCC / Eros / Eros Corr / Ext Corr / Acid %XPORT
0UMPING
External threats: downhole
Ext Corr / F&F $EGASSER#&5

# Threat Abbr’n # Threat Abbr’n

1. Carbon Dioxide Corrosion CO2 9. External Corrosion Ext Corr 0IPELINE
$ISPOSAL
2. Hydrogen Sulphide Corrosion H2S 10. Corrosion under Insulation CUI
3. Oxygen Corrosion O2 11. Stress Corrosion Cracking SCC
4. Microbially Influenced Corrosion MIC 12a. Erosion Eros
5. Galvanic Corrosion Galv 12b. Erosion Corrosion Eros Corr
Main threats are shown in red
6. Weld Corrosion Weld 13. Fatigue and Fretting F&F See Description section (pages 12-26) for
7. Grooving Corrosion Groove 14a. Misc. – Liquid Metal Embrittlement LME information on the threats.
8. Crevice Corrosion Crev 14b. Misc. – Acid Corrosion Acid

Corrosion threats guide 7

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 Degradation threats to the gas process system
Wet gas Dry gas Wet gas Dry gas Total system
Internal threats No internal Internal threats No internal External threats
CO2 / H2S / O2 / MIC / Galv /Crev / threats CO2 / H2S / O2 / MIC / Galv
Eros Corr / Acid /Crev / Eros Corr / Acid
threats Ext Corr/CUI/F&F

./4%
  OR  STAGES OF
COMPRESSION PRIOR TO
DEHYDRATION 'LYCOL
2EGEN

&ROM
3EPARATION
$RY 'AS
ABOVE DEW 'LYCOL
POINT #ONTACTOR
-ETERING
4O 4O
3EPARATION 4O 3EPARATION
3EPARATION
Internal threats
Glycol regen.
CO2 / Acid
7ET 'AS NORMALLY NO FLOW &UEL 'AS %XPORT
#ONDITIONING

# Threat Abbr’n # Threat Abbr’n

1. Carbon Dioxide Corrosion CO2 9. External Corrosion Ext Corr
2. Hydrogen Sulphide Corrosion H2S 10. Corrosion under Insulation CUI
3. Oxygen Corrosion O2 11. Stress Corrosion Cracking SCC &UEL 'AS
4. Microbially Influenced Corrosion MIC 12a. Erosion Eros $ISTRIBUTION
5. Galvanic Corrosion Galv 12b. Erosion Corrosion Eros Corr
6. Weld Corrosion Weld
Main threats are shown in red
13. Fatigue and Fretting F&F
7. Grooving Corrosion Groove 14a. Misc. – Liquid Metal Embrittlement LME See Description section (pages 12-26) for
8. Crevice Corrosion Crev 14b. Misc. – Acid Corrosion Acid information on the threats.

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
Corrosion threats guide 8
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 Degradation threats to the seawater system
Internal threats External threats
O2 / MIC / Galv / Weld / Ext Corr / CUI / F&F
Groove / Crev / Eros Corr

&IREWATER
3YSTEM 6ACUUM
0UMPS
&INE
&ILTRATION $EAERATOR
#OARSE OPTIONAL
&ILTRATION 5TILITY
5SERS
(EAT
%XCHANGERS

"OOSTER (IGH
0UMPS 0RESSURE
0UMPS

3EAWATER
,IFT 0UMPS

)NJECTION
# Threat Abbr’n # Threat Abbr’n
7ELLS
1. Carbon Dioxide Corrosion CO2 9. External Corrosion Ext Corr
2. Hydrogen Sulphide Corrosion H2S 10. Corrosion under Insulation CUI
3. Oxygen Corrosion O2 11. Stress Corrosion Cracking SCC
4. Microbially Influenced Corrosion MIC 12a. Erosion Eros
5. Galvanic Corrosion Galv 12b. Erosion Corrosion Eros Corr
Main threats are shown in red
6. Weld Corrosion Weld 13. Fatigue and Fretting F&F See Description section (pages 12-26) for
7. Grooving Corrosion Groove 14a. Misc. – Liquid Metal Embrittlement LME information on the threats.
8. Crevice Corrosion Crev 14b. Misc. – Acid Corrosion Acid

Corrosion threats guide 9

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 Degradation threats to the cooling and heating medium systems
Cooling medium system Heating medium system

%XPANSION %XPANSION
Internal threats 6ESSEL 6ESSEL
O2 / MIC / Galv / Weld / Crev Internal threats
O2 / MIC / Galv / Weld / Crev

0ROCESS 0ROCESS
#OOLERS $UMP (EATERS
#- (EAT #OOLER (EAT
External threats -AKE 5P EXCHANGERS EXCHANGERS External threats
Ext Corr / CUI / F&F Ext Corr / CUI / F&F

37

#OOLING -EDIUM
3EAWATER (EAT 7ASTE (EAT
%XCHANGER 2ECOVERY
Internal threats #IRCULATION 5NITS
0UMPS #IRCULATION
Recirc pumps 0UMPS Internal threats
Eros Corr 37 Recirc pumps
Eros Corr
4URBINE
%XHAUST

# Threat Abbr’n # Threat Abbr’n

1. Carbon Dioxide Corrosion CO2 9. External Corrosion Ext Corr
2. Hydrogen Sulphide Corrosion H 2S 10. Corrosion under Insulation CUI
3. Oxygen Corrosion O2 11. Stress Corrosion Cracking SCC
4. Microbially Influenced Corrosion MIC 12a. Erosion Eros
5. Galvanic Corrosion Galv 12b. Erosion Corrosion Eros Corr
Main threats are shown in red
6. Weld Corrosion Weld 13. Fatigue and Fretting F&F See Description section (pages 12-26) for
7. Grooving Corrosion Groove 14a. Misc. – Liquid Metal Embrittlement LME information on the threats.
8. Crevice Corrosion Crev 14b. Misc. – Acid Corrosion Acid

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with Corrosion threats guide 10
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 Degradation threats to the diesel and drainage systems
&ROM 0RESSURISED
Diesel system (YDROCARBON 3OURCES External threats
Closed drains system
Internal threats All drainage systems
Ext Corr / CUI / F&F
O2 / MIC / Weld / Crev 4O
&LARE
3EPARATION
Internal threats
3ETTLING 3ERVICE
#$ CO2 / O2 / MIC /
"ULK &LASH $RUM Weld / Crev
3TORAGE

7ATER

/PEN (AZARDOUS $RAINS

7ATER
Hazardous open drains system
"UNKERING $IESEL 5SERS 4O
3EPARATION
/(
$RAINS Internal threats
&ILTRATION O2 / MIC /
0OWER 4ANK
 7ATER Weld / Crev
'ENERATION
#OALESCENCE

7ATER TO
$ISPOSAL
External threats 3AFE /PEN $RAINS
Safe open drains system
Ext Corr / CUI / F&F 6ENT

# Threat Abbr’n # Threat Abbr’n Internal threats

3AFE /PEN
O2 / MIC /
9. External Corrosion Ext Corr $RAINS 4ANK
1. Carbon Dioxide Corrosion CO2 Weld / Crev
2. Hydrogen Sulphide Corrosion H2S 10. Corrosion under Insulation CUI
3. Oxygen Corrosion O2 11. Stress Corrosion Cracking SCC 7ATER TO
$ISPOSAL
4. Microbially Influenced Corrosion MIC 12a. Erosion Eros
5. Galvanic Corrosion Galv 12b. Erosion Corrosion Eros Corr
6. Weld Corrosion Weld 13. Fatigue and Fretting F&F Main threats are shown in red
7. Grooving Corrosion Groove 14a. Misc. – Liquid Metal Embrittlement LME
8. Crevice Corrosion Crev
See Description section (pages 12-26) for
14b. Misc. – Acid Corrosion Acid
information on the threats.
Corrosion threats guide 11

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #1 – CARBON DIOXIDE (CO2) CORROSION

INSPECTION /
CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS MANAGEMENT
MONITORING METHODS

– Dissolved carbon –All water-wetted n !LL WATER CONTAINING – Process parameter – Corrosion resistant
dioxide, produces locations in hydrocarbon hydrocarbon processing monitoring, e.g. alloy
carbonic acid systems systems temperature, – Chemical inhibition
– Inadequate n 0IPEWORK STRAIGHTS  pressure, dew point – See EI Guidance
corrosion inhibition o’clock)/bends/tees/ – UT Document. Appdx B,
reducers – Radiography Sections 1,6 and 13.
– Welds, heat affected – Corrosion probes/
zone and downstream of coupons
welds – Intelligent pigging
of pipelines

DEGRADATION
MORPHOLOGY

General corrosion Localised corrosion Preferential weld corrosion

mOW INmUENCED LOW mOW

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with Corrosion threats guide 12
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #2 - HYDROGEN SULPHIDE (H2S) CORROSION

INSPECTION /
CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS MANAGEMENT
MONITORING METHODS

– Hydrogen sulphide – Pitting – typically at – All water-wetted – Process parameter – Materials to

and water 6 o’clock locations in sour monitoring, e.g. ISO15156
– Stress cracking - hydrocarbon service temperature, – Chemical inhibition/
3ULPHIDE 3TRESS AND n 3USCEPTIBLE MATERIALS IE pressure, dew point H2S scavenging
Hydrogen Induced not meeting ISO 15156 – UT – Avoid rolled plate
Cracking) especially at criteria) – Radiography product
locations of high stress, – Dye penetrant n +EEP DRY INTERNALLY
applied or residual, e.g. INSPECTION CRACKING – See EI Guidance
welds, bends, welded on – Eddy current document Appdx B,
trunnions INSPECTION CRACKING Section 2
– Blistering of carbon steel
pipework and vessels

DEGRADATION
MORPHOLOGY

Localised corrosion Sulphide stress cracking - Hydrogen blistering

Branched cracking

Corrosion threats guide 13

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #3 - OXYGEN (O2) CORROSION

INSPECTION /
CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS MANAGEMENT
MONITORING METHODS

– Oxygen in an aqueous – All aerated water- – Water injection: – Process parameter – Oxygen removal
phase wetted locations pipework, vessels, pumps monitoring, e.g. $EAERATION OXYGEN
– Oxygen ingress e.g. at – Pipework – straights, and flowlines oxygen scavenger scavenging)
leaks bends, welds – Seawater system residual, flow rate – Leak prevention
– Under dosing – Vessels – Firewater system – UT AVOID OXYGEN
oxyscavenger – Exacerbated by deposits – Open drains – Radiography ingress)
– Inadequate UNDER DEPOSIT CORROSION – Heating and cooling – Corrosion probes / – Monitor oxygen
performance of medium coupons – See EI Guidance
mechanical deaeration document Appdx B,
7ATER INJECTION Sections 3, 6 and 7
systems)

DEGRADATION
MORPHOLOGY

General oxygen corrosion Oxygen corrosion at welds Oxygen corrosion at the inlet of a
deaerator tower

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with Corrosion threats guide 14
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #4 – MICROBIALLY INFLUENCED CORROSION (MIC) AND DEADLEG CORROSION

INSPECTION /
CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS MANAGEMENT
MONITORING METHODS

– Primarily sulphate – Water containing – Water injection – Microbial and – Biocide

reducing bacteria organic nutrient and – Produced water sulphide sampling – Circulation
– Stagnant sulphate treatment and and trending – Deadleg register
DEOXYGENATED – Deadlegs – permanent or re-injection – UT – Remove dead legs if
environments operational – Firewater – Radiography possible
– Mothballed plant – Drains – Biostuds / sidestream – Drain deadlegs
– Under deposits – Seawater monitoring frequently
– Occasionally in – – Risk based inspection
hydrocarbon processing – See EI Guidance
systems, e.g. vessel trim, document Appdx B,
recovered oil lines Section 4

DEGRADATION
MORPHOLOGY

Microbially initiated erosion

MIC pits in carbon steel MIC in a carbon steel deadleg corrosion of Cunifer
 COPPER NICKEL

Corrosion threats guide 15

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #5 – GALVANIC CORROSION

INSPECTION /
CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS MANAGEMENT
MONITORING METHODS

– Dissimilar metals in a – All plant, especially at: – Seawater systems are – UT – Materials selection
corrosive electrolyte – Welds particularly susceptible – Radiography – Weld consumable
–Incorrect weld n 3CREWED lTTINGS SMALL – Water injection selection/weld
metallurgy anode / large cathode – Hydrocarbon systems procedures
–Defects in noble metal combination) – Drains – Gasket selection
coatings – Some types of gasket – Electroless nickel plated – Use insulating gasket
pipework and vessels sets/ insulating spool
– Noble metallic coatings,
– Corrosion resistant alloy WHERE APPROPRIATE
e.g. nickel plated carbon
clad carbon steel vessels – Sacrificial spool /
carbon steel
– Under insulation coat cathode / CP
– Dissimilar metals in – See EI Guidance
pumps document Appdx B,
Section 5

DEGRADATION
MORPHOLOGY

Galvanic corrosion of cupro-nickel in a

Galvanic corrosion of carbon steel firewater system which incorporated both Galvanic corrosion of nickel plated
in contact with Cunifer CuNi and duplex stainless steel spools carbon steel

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with Corrosion threats guide 16
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #6 – WELD CORROSION

CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS INSPECTION / MANAGEMENT

MONITORING METHODS

– Microstructural and/ – Pipelines/flowlines – All systems where CO2 – UT – Weld consumable

or compositional – Pipework O2 and erosion corrosion – Radiography selection
difference between occurs. – On-line monitoring, – Control welding
the weld and its – Systems subjected to e.g. using welded quality
parent metal, resulting acetic acid injection probes – Use of corrosion
in a galvanic effect. inhibitor
– Poor weld quality – See EI Guidance
– Poor weld document Appdx B,
morphology, e.g. weld Section 6
root protruding out

DEGRADATION
MORPHOLOGY

Corrosion at weld heat affected Weld corrosion Corrosion at weld heat affected
zone zone

Corrosion threats guide 17

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #7 - GROOVING CORROSION

INSPECTION /
CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS MANAGEMENT
MONITORING METHODS

– Synergy of two – Centred on the 6 o’clock – Water injection pipework – Monitor parameters – Mitigate primary
or more corrosion position of horizontal / and pipelines influencing primary MECHANISMS #/2,
mechanisms , i.e. near horizontal pipelines – Production fluid mechanisms O2, MIC, erosion)
erosion, oxygen, pipework and pipelines. – Intelligent pigging – Materials selection
carbon dioxide, – See EI Guidance
microbial and H2S document Appdx B,
corrosion Section 3

DEGRADATION
MORPHOLOGY

Grooving corrosion of a water Grooving corrosion of a water Grooving corrosion of a water

injection pipeline injection pipeline injection pipeline

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with Corrosion threats guide 18
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #8 – CREVICE CORROSION AND FLANGE FACE CORROSION

INSPECTION /
CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS MANAGEMENT
MONITORING METHODS

– Differential – Flange/gasket – All systems, carbon – Difficult for flanges – Materials selection, e.g. gaskets,
concentration cell interfaces steel and stainless – Visual inspection, instrument tubing materials
– Under clamps on steel. Especially especially during – Weld overlay flange faces with
instrument tubing seawater systems maintenance corrosion resistant alloy
– Bolt/flange interfaces OXYGEN CONTAINING n 4EMPORARY PRESERVATIVES WAX
grease) on fasteners and tube
clamps
– Inhibitor impregnated clamps for
instrument tubing
– Inspection - planned and
opportunistic
– See EI Guidance document
Appndx B, Section 8

DEGRADATION
MORPHOLOGY

Crevice corrosion of a flange/ Crevice corrosion of instrument Crevice corrosion of bolting

gasket interface tubing under clamps

Corrosion threats guide 19

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #9 – EXTERNAL CORROSION: (A) COATINGS, (B) FASTENERS AND (C) SUBSEA

INSPECTION /
CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS MANAGEMENT
MONITORING METHODS

– Coatings degradation/ – Field applied coatings – All coated topsides – Visual inspection – Fabric maintenance
DAMAGE EG LACK OF especially susceptible pipework, vessels – Subsea - video – Materials selection,
fabric maintenance) to degradation – Structures inspection by ROV e.g. galvanised
– Inadequate surface – Carbon steel bolting / – Bolting and fittings – CP potential bolting
preparation prior to fasteners – Gratings and walkways monitoring and – Coat hot stainless
coating – Subsea structures and SURVEY 3UBSEA steels
– Pitting corrosion of
– Deposit build-up on components – Avoid deposit build-
stainless steel
pipework / vessels up
– Stress corrosion
– Incorrect materials – Cathodic protection
cracking of stainless
selection, e.g. carbon 3UBSEA
steel
steel bolting on stainless – Risk based inspection
flanges – See EI Guidance
document Appdx B,
– Inadequate cathodic
Sections 9, 14 and 15
PROTECTION 3UBSEA

DEGRADATION
MORPHOLOGY

Coating degradation Corroded bolting, e.g. carbon Deposit build-up leading to

steel bolting in stainless steel under-deposit corrosion
equipment

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with Corrosion threats guide 20
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #10 – CORROSION UNDER INSULATION

INSPECTION /
CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS MANAGEMENT
MONITORING METHODS

– Wet insulation – CUI tends to be at 6 o’clock – Insulated pipework – Visual inspection – Avoid insulation
location on pipework / vessels and vessels across all – Strip and search where possible
– Damaged or missing
/ attachments; but can occur systems – Real time radiography – Effective coatings
Cladding
at any orientation – Heat traced – Thermography for and maintenance of
– Degraded seals on components wet insulation coatings
sheet metal – Higher probability and rate
– Pulsed eddy current – Fabric maintenance
cladding of corrosion on warm / hot – RBI
– Missing or damaged pipework – See EI Guidance
coating ª# TO ª# FOR CARBON STEEL document Appdx B,
– Chloride pitting and cracking Sections 10 and 14
of stainless steels – See also: EFC WP15
Corrosion Under
Insulation Guidelines

DEGRADATION
MORPHOLOGY

#ORROSION UNDER INSULATION CARBON Damaged cladding #5) WITH TELLTALE STAINING 6ESSEL 
steel pipework) o’clock location)

Corrosion threats guide 21

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #11 –STRESS CORROSION CRACKING (SCC)

INSPECTION /
CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS MANAGEMENT
MONITORING METHODS

– Chlorides in oxygenated – Internally and externally – Hot topsides stainless – Process parameter – Paint/thermally
environment acting on n 3TAINLESS STEEL 3## steel pipework and monitoring, e.g. sprayed aluminium
susceptible materials – Duplex stainless steel vessels temperature, – Materials selection
– May occur as an internal – High strength carbon – Subsea cathodically chloride – Follow weld
mechanism in absence steel protected duplex concentration procedures and QC
of oxygen at high stainless steel, e.g. – Eddy current – Temperature control
chloride levels and high manifolds, pipelines – Dye penetrant n #0 DESIGN SUBSEA
– Especially areas of stress n /VERPROTECTED #0 HIGH – UT – Diode control of CP
temperature
concentration, e.g. welds strength carbon steel – Radiography – See EI Guidance
– Impact of CP of duplex
or high residual stress 3UBSEA – Visual document Appdx B,
33 SUBSEA (YDROGEN
Induced Stress Cracking) Section 11
n $RY METHANOL TITANIUM
n !MINES CARBON STEEL IN
scrubbing systems)

DEGRADATION
MORPHOLOGY

External SCC of a duplex SS vessel SCC of a 316L SS pipework

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with Corrosion threats guide 22
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #12a - EROSION

INSPECTION /
CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS MANAGEMENT
MONITORING METHODS

– High fluid flow rates – Solids-containing fluids – Any system exposed to – Monitor process – Flow control
– Sand/solids/proppant – Pipework – straights, sand / solids production, parameters, e.g. flow – Sand management
n 3AND WASHING EG bends, welds especially: rate, solids prod’n – Well management
separators) – Vessels - Risers, rate – Erosion resistant
– Valves - Valves, – UT materials, facings
- 1st stage, test/ – Radiography and coatings
– Flow obstructions, e.g.
clean-up separators – Acoustic probes – Increase pipe
thermowells
- Produced water – Intrusive erosion diameter and/or
system probes bend radius
– Corrosion resistant – See EI Guidance
coupons document Appdx B,
Section12

DEGRADATION
MORPHOLOGY

Orifice plate erosion – High flow Erosion at a bend Eroded valve cage
rates and solids

Corrosion threats guide 23

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #12b - EROSION (flow affected) CORROSION

INSPECTION /
CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS MANAGEMENT
MONITORING METHODS

– Combination of flow – All water-wetted – All systems especially: – Monitor process – Flow control
AND CORRODENT EG locations - Three phase systems parameters, e.g. – Sand management
carbon dioxide or –Especially locations – Produced water factors affecting – Well management
oxygen) of flow disruption / – Seawater / water primary mechanisms, – Erosion resistant
acceleration injection flow rate materials, facings
– Pipework – straights, – UT and coatings
bends, tees, welds, – Radiography – Increase pipe
valves, downstream of – Corrosion monitoring diameter and/or
pumps bend radius
– Vessels, especially – See EI Guidance
document Appdx B,
nozzles, areas of
impingement Section12

DEGRADATION
MORPHOLOGY

Erosion corrrosion of carbon steel Errosion corrosion of cunifer Erosion corrosion of stainless steel
#OPPER NICKEL ALLOY

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
Corrosion threats guide 24
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #13 – FATIGUE AND FRETTING

INSPECTION /
CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS MANAGEMENT
MONITORING METHODS

– Inadequately supported – Small bore – All systems, especially at: – Visual inspection – Stress analysis
pipework PIPEWORK &ATIGUE - Pipe supports – Radiography – Review and modify
– Slug flow in pipework or – CRA pipework - Through wall – Vibration supports
vessels TENDS TO BE THINNER penetrations monitoring – Hydrodynamic
– Strong vibration sources, e.g. wall than carbon - Heat exchangers, modelling
reciprocating compressors STEEL n &ATIGUE baffles / tube – Risk based inspection
– Flexing of structures, – Fretting, e.g. pipe supports – Vibration monitoring
e.g. FPSO tanks and deck supports, deck /wall – Adhere to Energy
supports Institute Avoidance
penetrations, heat
– Acoustic resonance in gas exchanger pipe of vibration induced
systems fatigue failure
supports/baffles
– Inadequate chemical guidelines
injection quill design
– Thermal cycling

DEGRADATION
MORPHOLOGY

Fatigue crack of structural web Fretting pipework at a deck Fatigue fracture of small bore
penetration tubing

Corrosion threats guide 25

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
 THREAT #14 – MISCELLANEOUS: (a) ACID CORROSION (b) EMBRITTLEMENT

INSPECTION /
CAUSES OCCURRENCE SUSCEPTIBLE SYSTEMS MANAGEMENT
MONITORING METHODS

– Co-produced organic – Acidic Corrosion – Acidic corrosion – Acidic corrosion – Acidic corrosion
acids, e.g. acetic acid -All water-wetted locations - Hydrocarbon - UT - Corrosion resistant
– Glycol decomposition production - Radiography alloy
0IPEWORK STRAIGHTS 
products systems, including - Corrosion probes - Chemical inhibition
o’clock)/bends/tees/
– Well acidisation and gas systems, /coupons – LME
reducers
returns glycol regen., – LME - Remove mercury
- Welds, HAZ and
- PW system - Dye penetrant/ - Materials’ selection
– Acidic production downstream welds
– Liquid Metal MPI – Production chemical
chemicals, e.g. scale – Liquid Metal Embrittlement Embrittlement corrosion
inhibitor, acetic acid,
- Copper alloys in the -Hydrocarbon - Correct use of
oxygen scavenger
presence of co-produced production injection quills
– Co-produced mercury mercury. - Switch off injection
systems, including
,IQUID -ETAL while plant is not
- Aluminium in the presence gas systems
%MBRITTLEMENT ,-% in use
of co-produced mercury

DEGRADATION
MORPHOLOGY

Corrosion by acidic production Corrosion caused by acetic acid ,-% OF BRASS 4UNGUM TUBING BY
CHEMICAL 3CALE INHIBITOR used to treat high naphthenic acid mercury
crude oil
Issued under licence to BP employees only.
IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with Corrosion threats guide 26
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100
energy Institute This publication has been produced as a result of
61 New Cavendish Street work carried out within the Technical Team of the
London W1G 7AR, UK Energy Institute (EI), funded by the EI’s Technical
Partners. The EI’s Technical Work Programme
t: +44 (0) 20 7467 7157 provides industry with cost effective, value adding
f: +44 (0) 20 7255 1472 knowledge on key current and future issues
e: [email protected] affecting those operating in the energy sector,
www.energyinst.org both in the UK and beyond.

registered Charity number 1097899

ISBN 978 0 85293 496 8

Issued under licence to BP employees only.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: [email protected] t: +44 (0)207 467 7100