Materials - Effects and

Economic Impact of
Corrosion -
What is meant by Corrosion Allowance?
By knowing the expected general corrosion rate and the anticipated plant or service life of a

part, the designer can calculate the extra thickness required for corrosion resistance of the

process equipment being designed.

After determining a wall thickness that meets mechanical requirements, such as pressure,

temperature and weight of equipment, an extra thickness called "corrosion allowance" is

added to the wall thickness to comensate for the metal expected to be lost over the life of

the equipment. Then, because the penetration depth cab very, a corrosion allowance is

assigned a safety factor of two.

Example:

A tank wall required a 5 mm wall thickness for mechanical considerations. The designer has

determined that the corrosion rate will be 0.4 mm/yr and the expected life of the tank will

be 10yr. The total corrosion allowance is the corrosion rate per year (0.4 mm x 10 yr = 4

mm).

The corrosion allowance is doubled to 8 mm as a safety consideration.

Calculation of Corrosion Allowance

Corrosion allowance is not only determined by the designer, but also and especially by a

state or local agency. The latter often have years of experience with local conditions and

especially the weather conditions in a relevant area.

Humidity, temperature, rain, wind, impurities and metal wet times have an effect on the

corrosion rate. Corrosion occurs when the relative humidity of the air is 70 to 80%.

Corrosion reaction is possible generally when the temperature is above 0C and the relative

humidity is over 80% (the surface is wet). Air impurities that dissolve in condensed water or

rain water may accelerate corrosion. Settling of dust and dirt on the metal surface

accelerates atmospheric corrosion.

Corrosion rates are expressed in terms of mm per year of surface wastage and are used to

provide a corrosion allowance in the design thickness of equipment such as vessels and

pipework.

Operators will often use data based on historical experience from plant operations to aid

them in determining appropriate corrosion allowances. Alternatively corrosion charts are

widely available that give corrosion rates for many combinations of materials of construction

and process fluids and normally a range of values will be provided for various process

temperatures.

In some instances, particularly where there is a mixture of chemicals present, appropriate

data may not exist and corrosion tests may be necessary in order to determine the

suitability of equipment. Operators should be able to demonstrate the use of corrosion

allowances in equipment specification and design. The sources of data used should be

traceable.

As far as I know, there is no corrosion allowance exactly specified in ASME B31.3. Corrosion

allowances are normally established by the end user and are somewhat based on personal

preferences and industry tradition. 1.5 mm for piping is a common standard, but you are

free to set a corrosion allowances you wish, unless a state or local agency has adopted and

superceded B31.3. To specify the pipe, add the corrosion allowance to the minimum design

thickness and select a pipe schedule that is equal to or greater than the minimum +

corrosion allowance.

Below are two tables with guidelines for corrosion allowance.

Note 1: For pipes passing through tanks, an additional corrosion allowance is to be

considered in order to account for the external corrosion.

Note 2: The corrosion allowance of pipes efficiently protected against corrosion may be
reduced by no more than 50%.

Note 3: When the corrosion resistance of alloy steels is adequately demonstrated, the
corrosion allowance may be disregarded.
Corrosion allowance for steel pipes mm
Superheated steam 0.3
Saturated steam 0.8
Steam coils in cargo tanks and liquid fuel tanks 2.0
Feed water for boilers in open circuit systems 1.5
Feed water for boilers in closed circuit systems 0.5
Blow-down systems for boilers 1.5
Compressed air 1.0
Hydraulic oil 0.3
Lubricating oil 0.3
Fuel oil 1.0
Thermal oil 1.0
Fresh water 0.8
Sea water 3.0
Refrigerants referred to in Section 13 0.3
Cargo systems for oil tankers 2.0
Cargo systems for ships carrying liquefied gases 0.3

Note 1: The corrosion allowance for other materials will be specially considered by the

Society. Where their resistance to corrosion is adequately demonstrated, the corrosion

allowance may be disregarded.

Note 2: In cases of media with high corrosive action, a higher corrosion allowance may
be required by the Society.

Corrosion allowance for non-ferrous metal pipes mm

Copper 0,8
Brass 0,8
Copper-tin alloys 0,8
Copper-nickel alloys with less than 10% of Ni 0,8
Copper-nickel alloys with at least 10% of Ni 0,5
Aluminium and aluminium alloys 0,5

Interesting articles

Corrosion Allowance general

The corrosion allowance is a measure which is used in the maintenance applications.

A corrosion allowance of 3.0 mm means that e.g. a wall thickness without any problem may

be decrease with 3.0 mm.

Mind you, that does not mean than the minimum wall thickness is achieved and the object

has reached its end of life.

Example: a piece of equipment has a wall thickness of 10 mm with a corrosion allowance of

3.0 mm. With a wall thickness of 7.0 mm action is required because the specified corrosion

allowance is completely consumed.

Some attention points when the corrosion allowance almost of completely is consumed.

What is the corrosion rate. Is it linear or progressive occurred.

What was the wall thickness during construction.

Are there baseline measurements are available.

Are the process conditions changed.

Is there erosion occurred in combination with corrosion.

Can we get the next inspection period.

What is the structural wall thickness that is needed.

Should we make a recalculation.

Wall thickness monitoring during process (Preventive control).

Must the equipment to be replaced at the next shut-down.

Must be the same material used for eventual replacement.

The wall thickness measurements are reliable.

Paint-and temperature can affect the measurement results.

Is the decline occurred internal or external, or a combination of both.

Can equipement remain in use or should it be taken out of service.

etc. etc.