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Lesson 11 Corrosion

The document provides information on corrosion calculations and examples. It discusses calculating metal loss, corrosion rate, remaining corrosion allowance, and retirement date for different courses on a tower. It then provides additional examples and explanations for calculating long term and short term corrosion rates, and using those rates to determine remaining life. Finally, it discusses criteria for evaluating minimum thickness when there is corrosion, including averaging thickness over a length, limits on pit size and spacing, and calculations for corroded welds.

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147 views10 pages

Lesson 11 Corrosion

The document provides information on corrosion calculations and examples. It discusses calculating metal loss, corrosion rate, remaining corrosion allowance, and retirement date for different courses on a tower. It then provides additional examples and explanations for calculating long term and short term corrosion rates, and using those rates to determine remaining life. Finally, it discusses criteria for evaluating minimum thickness when there is corrosion, including averaging thickness over a length, limits on pit size and spacing, and calculations for corroded welds.

Uploaded by

MAT-LION
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Lesson 11

Corrosion Calculations
Corrosion Example Problems
A 60 foot tower consisting of four (4) shell courses was found to have varying corrosion
rates in each course. Minimum wall thickness readings were taken after 4 years and 6
months of service. All original wall thicknesses included a 1/8" corrosion allowance.
The top course's original thickness was .3125". The present thickness is .3000". The
second course downward had an original thickness of .375".
During the inspection it was found to have a minimum wall thickness of .349". The third
course was measured at .440" its original thickness was .500". The bottom course had
an original thickness of .625" and measured to be .595".
Determine the metal loss for the top course, the corrosion rate for the second course,
the corrosion allowance remaining in the third course, the retirement date for the
bottom course
Solution
Solution A:
TOP COURSE:
Metal loss equals the previous
thickness minus the present
thickness.

Previous .3125"
Present

-.3000"

.0125" Metal Loss


SECOND COURSE:
Corrosion rate equals metal loss per given unit of time.
Previous .3750
Present - .3490"
.0260"

Metal Loss =

= .006"/ Per Year

THIRD COURSE:
Remaining Corrosion Allowance equals the actual thickness minus the required
thickness.
Original Thickness
Original C. A.

.500"
-.125"

Required Wall Thickness

.375"

Actual Wall Thickness

.440"

Required Wall

-.375"

Remaining C.A.

.065

BOTTOM COURSE
Remaining life equals the remaining corrosion allowance divided by the corrosion rate.
1. Required Thickness
Original Thickness

.625"

Original C. A.
Required Thickness

-.125"
.500

2.Remaining Corrosion Allowance


Actual Wall Thickness .595
Required Thickness -.500"
Remaining Corr. Allow .095
3.Corrosion Rate
Original Thickness

.625"

Present Thickness

-.595

Metal Loss
Metal Loss

.030"
.030

= Corrosion Rate = .0067"/Yr.

Time 4.5 Years


4. Remaining Life
Corrosion Allowance.095

= 14.2 Yrs. Remaining Life

Corrosion Rate .0067"/Yr.

Corrosion Just Milling Around


In the previous examples we calculated using decimal fractions of an inch such as .
006. However questions on the exam often have the format of Mils or thousandths of
and inch. So if you are not familiar with this terminology here are some examples.
.1 = 1/10th of an inch
.01 = 1/100th of an inch
.001 = 1/000th of an inch or 1 Mil. this is what is used.
Take our example above .006 this translates to 6 Mils.
.0067 translates to 6.7 Mils.
Class Quiz Just Milling Around
1. Convert the following decimal fractions into Mils.
.195

= _____ Mils

. 023 = _____ Mils


.009

= _____ Mils.

.0011 =______Mils.
2. Calculate or previous Remaining Life problem using Mils.

Corrosion Allowance.095

= 14.2 Yrs. Remaining Life

Corrosion Rate .0067"/Yr.

Solution Just Milling Around


Converting the following decimal fractions into Mils.
.195 = 195 Mils
.023 = 23 Mils
.009 = 9 Mils.
.0011 = 1.1 Mils.
Corrosion Allowance 95 Mils

= 14.2 Yrs. Rem. Life

Corrosion Rate 6.7 Mils/Yr.

Time A year has 12 parts


The next issue is how do you handle the odd months in a year. Its all good when it has
been an even number of years. However what about 2 years and 5 months?
Five months is 5/12th of a year. 5/12 = .416 years rounded to 3 places. Of course 6
months is then 6/12 or .5 years.
Example: Based on 4.416 years and a metal loss of 50 Mils we have;
Metal Loss 50 Mils

= Corrosion Rate = 11.3 Mils/Yr.

Time 4.416 Years


Class Quiz Time
A vessel shell course was replaced in October of 1980. The initial or, baseline thickness
was .505. The most recent actual thickness measured was .485 in January 1991. What
is the corrosion rate, based in Mils per year in January of 1991.

Solution
.505(t-initial) - .485(t-actual) = .020 = 20 Mils
Oct.1990 Oct.1980 = 10 years plus November, December of 1990 and January of
1991 so; 10 yrs. 3 Mos.
10 - 3/12th (3/12 = .250) = 10.25 years
Therefore;
Metal Loss 20 Mils

= Corrosion Rate = 1.95 Mils/Yr.

Time 10.25 Years

Can there be two Corrosion Rates?

Yes, in the API 510 there are, the Long Term and Short Term. Here is the Long Term.
From API 510 6.4 page 6-3
The long term (L.T.) corrosion rate shall be calculated from the following formula:

Corrosion rate (L.T.) =

Corrosion Example Problems


The short term (S.T.) corrosion rate shall be calculated from the following formula:

t previous - t actual
time (years) between t previous and t actual

Corrosion rate (S.T.) =

tinitial = the thickness, in inches(millimeters), at the same location as t actual measured


at the initial installation or at the commencement of a new corrosion rate environment.
tprevious = the thickness, in inches(millimeters), at the same location as t actual measured
during a previous inspection.
Long-term and short-term corrosion rates should be compared to as part of the data
assessment. The authorized inspector, in consultation with a corrosion specialist, shall
select the corrosion rate that best reflects the current process.
Example:
A vessel shell had a second set of ultrasonic thickness measurements after 1 year of
service, the original baseline wall thickness was 0.500, and the second set revealed
that the shell was now at 0.489. Five years later a third set of wall readings were taken
and the shell was measured to be 0.459.
What value should be used in the Remaining Life calculations? Comparing short term to
long term corrosion we find the following values. Normally the most aggressive will be
used and in this case it will be the Long Term Corrosion Rate.

0.500- 0.459
6 years
L.T. =

= 6.8 Mils/ year

0.489 - 0.459
5 years
S.T. =

= 6 Mils/ year

The remaining life of the vessel shall be calculated from the following formula:
t actual - t required
corrosion rate

Remaining life (years ) =

(6.4)

tactual = the actual minimum thickness, in inches determined at the time of inspection
for a given location or component.
trequired = the required thickness in inches at the same location or component as the t
actual measurement computed by the design formulas (e.g. , pressure and structural)
before corrosion allowance and manufacturers.
Example: Determine Remaining life of the vessel shell course in the example above. T
required thickness of the shell course is 0.388 (known as t minimum). Compare S.T. and
L.T. corrosion rates as follows:
S.T. rate = 0.006 or 6 Mils a year
L.T. rate = 0.0068 or 6.8 Mils a year
Therefore we will use the most aggressive corrosion rate found to be the Long Term
Rate.
Remaining life (years)
What would be the maximum length of time before the next inspection?
ANS: the Remaining Life or 10 years whichever is less.
Therefore: 17.79/2 = 8.895 years

What would be the maximum length of time before the next inspection? From: API 510
page 6-2

6.4 Internal An On-Stream Inspection


The period between internal or on-stream inspections shall not exceed one half the
estimated remaining life of the vessel based on corrosion rate or 10 years, whichever is
less. In cases where the remaining safe operating life is estimated to be less than 4
years, the inspection interval may be the full remaining safe operating life up to a
maximum of 2 years.
ANS: the Remaining Life or 10 years whichever is less.

Therefore: 17.79/2 = 8.895 years

Example 5.7 Page 5-3Corrosion


(a) (the second a) For a corroded area of considerable size in which the
Circumferential Stress Govern, the least thickness along the most critical element of
the area may be averaged over a length not exceeding the following:
1. For vessels with the inside diameters less than or equal to 60 inches one half the
vessel diameter or 20 inches whichever is less.
2. For vessels with the inside diameters greater than 60 inches one third the vessel
diameter or 40 inches whichever is less.

Corrosion and Minimum Thickness Evaluation 5.7


For a corroded area of considerable size in which the Circumferential Stress Govern,
the least thickness along the most critical element of the area may be averaged over a
length not exceeding the following:
1. For vessels with the inside diameters less than or equal to 60 inches one half the
vessel diameter or 20 inches whichever is less.
2. For vessels with the inside diameters greater than 60 inches one third the vessel
diameter or 40 inches whichever is less.

Corrosion and Minimum Thickness Evaluation

When the area contains an opening the distance on either side of the opening within
which the thicknesses are averaged shall not extend beyond the limits of the
reinforcement as defined in the ASME Code

See Fig. UG-37 and refer to reinforcement calculations for determining the extra metal
in the shell.
For Limits:

d ( t tr) or 2(t + tn) ( t tr)


Use the Larger

Corrosion and Minimum Thickness Evaluation


Widely scattered pits may be ignored as long as the following are true:

1. The remaining thickness below the pit is greater than one-half the required
thickness. (1/2 t required)
1.0 0.125 = 0.875 the required thickness
Therefore no pit equal to 0.875/2 = 0.4375 or greater!
Pit #3 0.402 < 0.4375 Acceptable.

2. The total area of the pits does not exceed 7 square inches (45 sq. centimeters) within
any 8 inch (20 centimeter) diameter circle.
We will assume the pits to be circles and use the formula Pi x Radius Squared to
determine the area of each pit.
Pit # One
Pit # Two

3.141 x (0.170/2)

= 0.085

3.141 x (0.330/2) 2 = 0.165

= 0.0855 sq. in.

Pit # Three 3.141 x (0.250/2)

= 0.125

Pit # Four

= 0.1185

3.141 x (0.377/2)

= 0.0226 sq. in.

= 0.0490 sq. in.


2

= 0.1116 sq. in.

Total: 0.2678 sq. in. less than 7 sq. inches Acceptable!

3. The sum of their dimensions along any straight line within the circle does not exceed
2 inches
Straight line for pits 1-3-4
#1.

0.170

#3.

0.250

#4.

0.377

Total 0.797 < 2 inches Acceptable


When the surface at a weld with a joint factor other than 1.0 as well as the surfaces
remote from the weld is corroded, an independent calculation using the appropriate
weld joint factor must be made to determine if thickness at the weld or remote from the
weld governs the allowable working pressure.
For this calculation the surface at a weld includes 1 inch on either side of the weld,
(measured from the toe of the weld), or twice the minimum thickness on either side of
the weld, whichever is greater.

When measuring the corroded thickness of ellipsoidal and torispherical heads the
governing thickness may be as follows:
1. The thickness of the knuckle region with the head rating calculated by the
appropriate head formula.
2. The thickness of the central portion of the dished region in which case the dished
region may be considered to be a spherical segment whose allowable pressure is
calculated by the Code formula for spherical shells.
3. For calculating the spherical portion using the spherical formula the following applies
to find the spherical radius L:
a. L = the OD of the Torispherical head
b. L = the ID of the shell times 90% for 2 to 1 Ellipsoidal heads See 5.7
second e.

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