Corrosion Forms IV

Flow-Induced Corrosion
ME 472
Dr. Zuhair M. Gasem
ME, KFUPM

Corrosion Forms

Dr. Z. Gasem
ME 472-062
KFUPM

Uniform

Corrosion
Localized Corrosion

Galvanic
Pitting
Crevice
IG and Weld decay
Erosion and corrosion

Localized Corrosion

Dr. Z. Gasem
ME 472-062
KFUPM

Causes

of Localized Corrosion

Electrolyte Variables

Variation in concentration:
o
o
o

Oxygen (differential aeration cell)

Chloride
H+ (variation in pH)

Flow rate
o

Relative movement b/w a corrosive fluid and a metal

surface

Material Variables

Segregation of impurity atoms

Inclusions in SS
Sensitization of grain boundaries

Localized Corrosion

Dr. Z. Gasem
ME 472-062
KFUPM

High flow rate of electrolyte may:

1.

2.
3.

high velocity electrolyte may remove deposited

corrosion products and keeps the metal surface
clean and therefore the metal becomes more active
which increases corrosion rate (see Nernsts
equation).
mechanically remove protective oxides.
increase oxygen transport and supply to the metal
surface:

4.

increases the rate of dissolution of active metal

enhances passivating passive-metals

increase ions supply to the metal surface

Flow-Induced Corrosion

Dr. Z. Gasem
ME 472-062
KFUPM

Three

forms of corrosion related to flow of

electrolyte:

Erosion-corrosion
Impingement
Cavitation

Dr. Z. Gasem
ME 472-062
KFUPM

Erosion

Erosion: solid
particles in the fluid
cause abrasive wear
of the material and
cause metal loss.
Erosion is mainly
mechanical effect.
Occurs in metals in
contact with highvelocity fluid carrying
solid particles.

Flow

Erosion or abrasive wear:

hard-velocity particles in
contact with metal surface

Erosion

Dr. Z. Gasem
ME 472-062
KFUPM

Example: erosion in
steel tube-inserts in
fire-tube boiler (the
heat source is inside
the tubes and the
water to be heated is
outside).

Fluid: hot flue gasses

containing ashes
2 months in service

fire-tube boiler

Erosion-Corrosion

Dr. Z. Gasem
ME 472-062
KFUPM

Erosion-Corrosion: occurs in metal surfaces in contact with high

velocity flow electrolyte:
Electrolyte with solid particles:

solid particles may remove metal mechanically

Electrolyte without solid particles:

In turbulent flow, hydrodynamic shear forces may remove oxide

and allow metal to corrode more quickly

In petroleum refineries, pipe wall thickness may decrease

as high as 3 mm/yr due to erosion-corrosion

Dr. Z. Gasem
ME 472-062
KFUPM

Erosion-Corrosion

Erosion-Corrosion: increase in
the rate of material loss due to
combined action of corrosion
and fluid flow.
Occurs in metals in contact
with fast flowing corrosive
liquids or gasses with or
without abrasive particles.
Example: steel feed water
pump spacer

spiral grooves indicating flow

pattern
4.5 months
Steam with oxygen at 252 C

Dr. Z. Gasem
ME 472-062
KFUPM

Erosion-Corrosion

Example: carbon steel

switch levers of two water
supply-pumps in power
station:

High flow turbulence due

to the lever
Time in service = 1 yr
Note the cladded stainless
steel is not showing E-C
SS is more resistant than
carbon steel against E-C

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Dr. Z. Gasem
ME 472-062
KFUPM

Erosion-Corrosion

Any part in contact with a

moving corrosive fluid is
subject to E-C:

Piping systems specially at

elbows, tees, and bends
where there is a change in
flow direction or increase
in turbulence.
Pumps, valves, heat
exchanger tubes, nozzles,
impellers, and turbine
blades (high temp E-C)
At any surface
discontinuities causing flow
turbulence.

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Dr. Z. Gasem
ME 472-062
KFUPM

Erosion-Corrosion

EC appears as grooves,
elongated pits, and
rounded holes which
indicate the flow pattern.
EC failures usually occur
in short time periods (few
months)

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Dr. Z. Gasem
ME 472-062
KFUPM

Erosion-Corrosion
Turbulent flow

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Dr. Z. Gasem
ME 472-062
KFUPM

Turbulent Flow

Most EC problems occur in

turbulent flow.
Tubes in heat exchangers
suffer E-C at the first few
inches at the inlet end.
Turbulence is created at flow
restrictions.
Laminar flow does not cause EC.
Flow damage is often increased
in two phase flows:
particles mixed in fluids
liquid droplets in gas
streams (gas wells and
steam return lines)
gas bubbles in liquid
streams (oil/gas wells)

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Dr. Z. Gasem
ME 472-062
KFUPM

Turbulent Flow

Turbulent flow in a pipe is defined by a Reynolds Number of >3,000.

Re = vd/ ( = viscosity, v = velocity, d = pipe diameter, = fluid
density)
Turbulent flow means that the fluid is highly mixed by eddy motion.
The transfer processes between the bulk fluid and the wall take place
across a thin boundary layer of stagnant fluid attached to the wall.
With turbulent flow the boundary layer is continuously penetrated by
eddies or vortices which increase:
Mass transfer
Heat transfer
Energy transfer

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Dr. Z. Gasem
ME 472-062
KFUPM

Effect of Velocity

Factors influencing E-C:

Adherence of surface
protective films or corrosion
product films
Fluid velocity: E-C increases
with velocity especially if the
flow is turbulent
Limiting or breakaway
velocity: max fluid velocity
before breaking the
protective surface film
Higher velocity increases
supply of oxygen, chloride,
and other ions to the metal
surface
Higher velocity prevents
deposits and concentration
cells (no pitting or crevice).

In general:
Corrosion rate (velocity)0.5-2

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Dr. Z. Gasem
ME 472-062
KFUPM

Effect of Velocity

17

Dr. Z. Gasem
ME 472-062
KFUPM

Critical velocities in seawater

18

Dr. Z. Gasem
ME 472-062
KFUPM

A 22 in (56 cm) line pipe for oil

and gas in the North sea:

Example of EC in Oil Pipe

75-80 C , 60-80 bar, Flow

velocity 4-5 m/s
3-years in service

Deep pits observed (as deep as

6.5 mm).
The pipe section was removed
and replaced.
Recommendation: reduce flow
rate (velocity) and add
corrosion inhibitor.

19

Dr. Z. Gasem
ME 472-062
KFUPM

Erosion-Corrosion

Metals attacked:
Passive metals (Al,
SS) protective films
are damaged by the
mechanical effects
and corrosion attack
will be rapid.
Soft metals (copper,
lead, low carbon
steel) damaged or
worn mechanically

20

Prevention of E-C

Dr. Z. Gasem
ME 472-062
KFUPM

Use higher E-C resistant alloys (SS vs. carbon steel)

In Design

Alteration of the environment:

Increase pipe diameter to reduce flow velocity and enhance

laminar flow
Increase thickness at bends and tees
Remove flow discontinuities
Avoid impingement flow (inlet at middle of tanks instead near
the wall)
filters to remove abrasive particles
Add inhibitors

Coatings
CP

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Dr. Z. Gasem
ME 472-062
KFUPM

Design Practice to reduce EC

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Dr. Z. Gasem
ME 472-062
KFUPM

Case study (Eng. Fail. Anal., 2002, PP 673)

One of the two engines in an F5F combat aircraft went out

during flight and forced
emergency landing. The failed
engine was disassembled and
inspected to find the root cause
of failure.
The main fuel pump (MFP) is
self-lubricating, consisted of
two elements driven by the
same drive shaft:

a boost stage: is an impeller

screw type pump designed to
increase the inlet fuel
pressure up to 65 psi.
a high pressure stage: is a
positive displacement gear
pump to increase boost pump
discharge pressure to 950
1250 psi.

MFP
Boost stage

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Dr. Z. Gasem
ME 472-062
KFUPM

Case study

A positive displacement
gear pump supply
constant flow rate
(Wikipedia).

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Dr. Z. Gasem
ME 472-062
KFUPM

The boost element of the main

fuel pump was rubbed and
chipped off.
Mechanical damage caused by
erosion.
The impeller was made of Al
casting (soft material).
The fuel filters were clogged
by foreign objects.
The clogging and large
clearance in the boost pump
reduced the fuel pressure
suddenly and could not supply
sufficient fuel to the engine.

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Dr. Z. Gasem
ME 472-062
KFUPM

Case study

What caused the impeller to

erode?
The filter was examined in
the electron microscope and
metal chips were found
ranging in size up to 0.2
mm.
The metal chips were found
to be stainless steel (harder
than Al)
Where these hard particles
came from?

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Dr. Z. Gasem
ME 472-062
KFUPM

Case study

The fuel manifold was

made out of SS.
Erosion attack at the bend
of the fuel manifold was
observed.
Severe erosion was
observed near the internal
welding bead.
Bend and internal weld
beads acted as flow
restrictions and increased
fuel flow turbulence.
Soln:

Improve welding to avoid

internal welding bead.

Bend in the fuel manifold

27

Impingement Attack

Dr. Z. Gasem
ME 472-062
KFUPM

Impingement: localized EC caused by impinging

flow (fluid flow is normal
to metal surface).
Usually in two phase flow:

Vapor-liquid
Liquid-solid

Occurs in pumps
impellers, valves, heat
exchangers tubes, turbine
blades, elbow, tees in
tubes.

Carbon steel spectacle flange in 2

MPa saturated steam with
condensate droplets (vapor-liquid)

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Dr. Z. Gasem
ME 472-062
KFUPM

Impingement

Corrosion rate
increased by the
impact of particles
normal to the metal
surface.
Liquid-solid 2-phase
flow.

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Dr. Z. Gasem
ME 472-062
KFUPM

Impingement Attack

Example of impingement:
Steam turbine blade (carbon steel)

Vapor-liquid flow

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Dr. Z. Gasem
ME 472-062
KFUPM

Impingement Attack

Occurs during startup

of steam turbines in
the low-pressure
turbine inlet.
Sudden temperature
changes in the boiler
break up the oxide
films in the steel
tubes.

Solid-vapor flow

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Dr. Z. Gasem
ME 472-062
KFUPM

Impingement Attack Control

selection of resistant materials

Separate different flowing phases

filtering out unwanted solids

installing water traps in steam lines

installation of wear plates and baffles in tanks

and vessels, and design for replacement
sections.

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Dr. Z. Gasem
ME 472-062
KFUPM

Cavitation

Cavitation: a mechanical damage caused by

collapsing vapor bubbles in flowing fluids due
to pressure variation.
Occurs in pump impellers and ship propellers
at large pressure change
At a given temperature, a fluid can exist as a
liquid and a vapor at a specific pressure called
the vapor pressure.
Cavitation occurs when the absolute pressure
at a point in the flow decreases below the
vapor pressure of the fluid.

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Dr. Z. Gasem
ME 472-062
KFUPM

Cavitation

34

High velocity flow leads to pressure falling below

zero at points of high-velocity flow
Vapour bubbles form in these low pressure
regions
When the pressure increases again, the vapour
bubbles collapse creating intense shockwave that
damages the protective film and locally deforms
the surface.
This causes a local hammering action and
mechanical damage of surfaces.

Cavitation

Dr. Z. Gasem
ME 472-062
KFUPM

Mechanisms:

Bubbles formation in an
area of low pressure
Bubbles move to higher
pressure areas
Bubble collapse ejecting
water droplets at 100 to
500 m/s removing the
protective films
Increased corrosion at
bare surfaces
Repeat the cycle

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Dr. Z. Gasem
ME 472-062
KFUPM

Example of cavitation

36

Cavitation in propellers of a high-speed

passenger ship.

Cavitation at
the inlet side of
the pump
impeller (cast
iron) in 5 yrs

Dr. Z. Gasem
ME 472-062
KFUPM

Cavitation at Flow Restrictions

Local pressure drops at

restrictions or expansions (
pumps and T-sections) can
cause cavitation where vapor
bubbles form in the flowing
liquid.
Pressure drops can be caused
by blocked filter upstream of
the pump (figure)
The local and intense
concentration of collapsing
vapor bubbles damages the
protective films and attack
metallic substrates.

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Dr. Z. Gasem
ME 472-062
KFUPM

Prevention of Cavitation

38

Improve design to minimize large hydrodynamic pressure

differences.
Use harder and more corrosion resistant alloys:
use hard metals, alloys containing high levels of nickel,
chrome, cobalt and tungsten (work hardenable surfaces are
more resistant)
For some pump impellers use a soft rubber coating / plastic
that absorbs the cavitation energy
Specify smooth finish at critical metal surfaces
Clogging of upstream filters can cause high pressure
differences in pumps.
Coating interior of pipes with resilient materials such as rubber
to absorb cavitation energy