Mapping Corrosion Activities Of Various Concentration Of Acidic Solution In A Pipe Using Ultrasonic Testing.

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Nama Penyelia II : ……….

MAPPING CORROSION ACTIVITIES OF VARIOUS CONCENTRATION OF ACIDIC SOLUTION IN A PIPE USING ULTRASONIC TESTING

FARAHILDA BINTI MASEKAM

Laporan ini dikemukakan sebagai

memenuhi sebahagian daripada syarat penganugerahan Ijazah Sarjana Muda Kejuruteraan Mekanikal (Struktur dan Bahan)

Fakulti Kejuruteraan Mekanikal Universiti Teknikal Malaysia Melaka

“I hereby declare that I have read this thesis and in my opinion this thesis is sufficient in terms of scope and quality for the award of the degree of Bachelor Mechanical

Engineering (Structure & Material)”

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ABSTRACT

Conventional method of inspecting the thickness of pipe due to corrosion is using Ultrasonic Testing Thickness Measurements (UTTM). This experiment is to study the corrosion activities in a pipe with using different concentration of acidic. Hydrochloric acid is used as a medium to create corrosion in internal wall of pipe. The hydrochloric acid is a strong acid, since it is fully dissociated in water where is a strong inorganic acid that is used in many industrial processes. The different of concentration of hydrochloric acid in water, 30%, 50% and 70% are used for this experiment. The different concentration of acidic used shown distinguishes of corrosion activities on the internal wall of pipe. The thickness of pipe wall is measured with an Ultrasonic Testing Thickness Measurement method. The results of corrosion activities are presented in C-scan presentation resulted from A-C-scan readings obtained from Ultrasonic Testing Thickness Measurement method. The C-scan result displays are created using the MATLAB Programming.

ABSTRAK

Ujian Pengukuran Ketebalan Ultrasonik (UTTM) merupakan kaedah yang paling sesuai untuk memeriksa dan menguji ketebalan paip yang disebabkan oleh kakisan. Eksperimen ini dijalankan bertujuan untuk mempelajari dan mengetahui aktiviti kakisan pada paip dengan menggunakan kepekatan asid yang berbeza. Asid hidroklorik digunakan sebagai medium untuk membentuk kakisaan pada permukaan dalam paip. Asid ini bersifat kuat dan meluas digunakan di pelbagai proses perindustrian. Pada eksperimen ini sebanyak tiga jenis kepekatan asid yang berbeza digunakan iaitu 30%, 50% dan 70% kepekatan. Perbezaan kepekatan asid yang digunakan menunjukkna perbezaan aktiviti kakisan pada bahagian dalam dinding paip. Ketebalan dinding paip akan diukur dengan menggunakan kaedah Ujian Pengukuran Ketebalan Ultrasonik (UTTM). Keputusan aktiviti kakisan akan dipaparkan dalam paparan C-scan yang ditukar daripada paparan A-scan yang diperolehi daripada Ujian pengukuran Ketebalan Ultrasonik dengan menggunakan perisian MATLAB.

CONTENTS

CHAPTER TITLE PAGE

PENGAKUAN

ACKNOWLEDGEMENT

ABSTRACT

ABSTRAK

CONTENTS

LIST OF TABLE

LIST OF FIGURE

LIST OF SYMBOL

LIST OF APPENDIX

CHAPTER 1 INTRODUCTION 19

1.1 Project 19 1.2 Problem Statement 19 1.3 Objectives 22 1.4 Scope of Study 22

CHAPTER 2 LITERATURE REVIEW 23

2.1 Corrosion in Pipelines 23 2.2 Types of Corrosion 25 2.3 Ultrasonic Testing Thickness 25

2.4 Comparison of Previous Researching 26

CHAPTER 3 METHODOLOGY 30

3.1 Introduction 30 3.2 Specimen 32

3.2.1 Type of Specimen 32 3.2.2 Preparation of Specimen 33 3.2.3 Grid Line 35

3.3 Acidic Solution 36 3.3.1 Type of Acidic 36 3.3.2 Concentration of Acidic 38 3.3.3 Volume of Acidic Used 39

3.4 Ultrasonic Testing and Data Recording 39 3.4.1 A-Scan Data 41 3.4.2 C-Scan Data Presentation 42

3.5 Programming and Data Display 42

CHAPTER 4 RESULTS AND DISCUSSIONS 44

4.1 MATLAB Programming 44 4.2 Result of 30% Concentration of 46 Hydrochloric Acid

4.3 Result of 50% Concentration of 53 Hydrochloric Acid

4.4 Result of 70% Concentration of 60 Hydrochloric Acid

4.5 Result Comparison Between Three 66 Various Concentration of Acidic

4.6 Advantages of C-scan Display 68 4.7 Factors Influenced the Corrosion Activities 70

CHAPTER 5 CONCLUSION 71

CHAPTER 6 RECOMMENDATION 73

REFERENCES 74

LIST OF TABLE

NO. TITLE PAGES

1 Properties of Hydrochloric Acid 37 (Source: http://en.wikipedia.org/wiki/Hydrochloric_acid)

2 Physical Properties of Hydrochloric Acid with Different 38 Concentration

LIST OF FIGURE

NO. TITLE PAGES

1.0 Internal Corrosion on Pipeline 21 (Source: http://www.corrview.com/service_03.htm)

3.1 Project Flow Diagram 31

3.2 Both of End of Pipe Will Welding With Two Lids and Hole 33 to Insert Acidic on Specimen

3.3 Welding Area on Specimen 34

3.4 Dimension of Specimen 34

3.5 Specimen of Experiment 35

3.6 Grid Line on Layout Pipe Surface 35

3.7 Grid Line on a Pipe Surface 36

3.8 Calibration Block K1 (right) and Calibration Block K2 (left) 40

(Source: Sonix, Inc. “The ABC’s of Ultrasonics Power Point Presentation”)

3.10 Color Range of Pipe Wall Thickness 43

4.0 Example of C-scan Result Display 46

4.1 First Reading Display Result for 30% Concentration of 46 Hydrochloric Acid

4.2 Second Reading Display Result for 30% Concentration of 47 Hydrochloric Acid

4.3 Third Reading Display Result for 30% Concentration of 47 Hydrochloric Acid

4.4 Forth Reading Display Result for 30% Concentration of 48 Hydrochloric Acid

4.5 Fifth Reading Display Result for 30% Concentration of 49 Hydrochloric Acid

4.6 Sixth Reading Display Result for 30% Concentration of 50 Hydrochloric Acid

4.7 Seventh Reading Display Result for 30% Concentration of 50 Hydrochloric Acid

4.8 Eighth Reading Display Result for 30% Concentration of 51 Hydrochloric Acid

4.9 Ninth Reading Display Result for 30% Concentration of 51 Hydrochloric Acid

4.10 Tenth Reading Display Result for 30% Concentration of 52 Hydrochloric Acid

4.11 First Reading Display Result for 50% Concentration of 53 Hydrochloric Acid

4.12 Second Reading Display Result for 50% Concentration of 54 Hydrochloric Acid

4.13 Third Reading Display Result for 50% Concentration of 54 Hydrochloric Acid

4.14 Forth Reading Display Result for 50% Concentration of 55 Hydrochloric Acid

4.15 Fifth Reading Display Result for 50% Concentration of 56 Hydrochloric Acid

4.16 Sixth Reading Display Result for 50% Concentration of 57 Hydrochloric Acid

4.17 Seventh Reading Display Result for 50% Concentration of 57 Hydrochloric Acid

4.18 Eighth Reading Display Result for 50% Concentration of 58 Hydrochloric Acid

Hydrochloric Acid

4.20 Tenth Reading Display Result for 50% Concentration of 59 Hydrochloric Acid

4.21 First Reading Display Result for 70% Concentration of 60 Hydrochloric Acid

4.22 Second Reading Display Result for 70% Concentration of 61 Hydrochloric Acid

4.23 Third Reading Display Result for 70% Concentration of 61 Hydrochloric Acid

4.24 Forth Reading Display Result for 70% Concentration of 62 Hydrochloric Acid

4.25 Fifth Reading Display Result for 70% Concentration of 63 Hydrochloric Acid

4.26 Sixth Reading Display Result for 70% Concentration of 63 Hydrochloric Acid

4.27 Seventh Reading Display Result for 70% Concentration of 64 Hydrochloric Acid

4.28 Eighth Reading Display Result for 70% Concentration of 65 Hydrochloric Acid

4.29 Ninth Reading Display Result for 70% Concentration of 65 Hydrochloric Acid

4.30 Tenth Reading Display Result for 70% Concentration of 66 Hydrochloric Acid

LIST OF SYMBOLS

h = height, m r = Radius, m V = Volume, m3

LIST OF APPENDIX

NO. TITLE PAGES

A Gantt Chart of PSM I and PSM II 76 B(i) Week 1 Data Reading Initial Thickness of Pipeline Model 78 for 30% Concentration of Hydrochloric Acid

B(ii) Week 2 Data Reading Thickness of Pipeline Model 79 for 30% Concentration of Hydrochloric Acid

B(iii) Week 3 Data Reading Thickness of Pipeline Model 80 for 30% Concentration of Hydrochloric Acid

B(iv) Week 4 Data Reading Thickness of Pipeline Model 81 for 30% Concentration of Hydrochloric Acid

B(v) Week 5 Data Reading Thickness of Pipeline Model 82 for 30% Concentration of Hydrochloric Acid

B(vi) Week 6 Data Reading Thickness of Pipeline Model 83 for 30% Concentration of Hydrochloric Acid

B(vii) Week 7 Data Reading Thickness of Pipeline Model 84 for 30% Concentration of Hydrochloric Acid

B(viii) Week 8 Data Reading Thickness of Pipeline Model 85 for 30% Concentration of Hydrochloric Acid

B(ix) Week 9 Data Reading Thickness of Pipeline Model 86 for 30% Concentration of Hydrochloric Acid

B(x) Week 10 Data Reading Thickness of Pipeline Model 87 for 30% Concentration of Hydrochloric Acid

C(i) Week 1 Data Reading Initial Thickness of Pipeline Model 88 for 50% Concentration of Hydrochloric Acid

C(ii) Week 2 Data Reading Thickness of Pipeline Model 89 for 50% Concentration of Hydrochloric Acid

C(iii) Week 3 Data Reading Thickness of Pipeline Model 90 for 50% Concentration of Hydrochloric Acid

C(iv) Week 4 Data Reading Thickness of Pipeline Model 91 for 50% Concentration of Hydrochloric Acid

C(v) Week 5 Data Reading Thickness of Pipeline Model 92 for 50% Concentration of Hydrochloric Acid

C(vi) Week 6 Data Reading Thickness of Pipeline Model 93 for 50% Concentration of Hydrochloric Acid

C(vii) Week 7 Data Reading Thickness of Pipeline Model 94 for 50% Concentration of Hydrochloric Acid

for 50% Concentration of Hydrochloric Acid

C(ix) Week 9 Data Reading Thickness of Pipeline Model 96 for 50% Concentration of Hydrochloric Acid

C(x) Week 10 Data Reading Thickness of Pipeline Model 97 for 50% Concentration of Hydrochloric Acid

D(i) Week 1 Data Reading Initial Thickness of Pipeline Model 98 for 70% Concentration of Hydrochloric Acid

D(ii) Week 2 Data Reading Thickness of Pipeline Model 99 for 70% Concentration of Hydrochloric Acid

D(iii) Week 3 Data Reading Thickness of Pipeline Model 100 for 70% Concentration of Hydrochloric Acid

D(iv) Week 4 Data Reading Thickness of Pipeline Model 101 for 70% Concentration of Hydrochloric Acid

D(v) Week 5 Data Reading Thickness of Pipeline Model 102 for 70% Concentration of Hydrochloric Acid

D(vi) Week 6 Data Reading Thickness of Pipeline Model 103 for 70% Concentration of Hydrochloric Acid

D(vii) Week 7 Data Reading Thickness of Pipeline Model 104 for 70% Concentration of Hydrochloric Acid

D(viii) Week 8 Data Reading Thickness of Pipeline Model 105 for 70% Concentration of Hydrochloric Acid

D(ix) Week 9 Data Reading Thickness of Pipeline Model 106 for 70% Concentration of hydrochloric Acid

D(x) Week 10 Data Reading Thickness of Pipeline Model 107 for 70% Concentration of hydrochloric Acid

CHAPTER 1

INTRODUCTION

1.1 Project

The purpose of this project is to conduct experiment to study the corrosion activities in a pipe using various concentration of acidic solution using Ultrasonic Testing Thickness Measurement (UTTM) method, and to produce a program that models a C-scan presentation of the corrosion activities in the pipe from A-scan presentation obtained from UTTM. The study and data collection of this project will be held at the Universiti Teknikal Malaysia Melaka (UTeM).

1.2 Problem Statement

Corrosion in pipelines is a problem long faced since long time ago. Industrial sector fields grow older and move to more challenging and often aggressive environments, the difficulties presented by corrosion are multiplying. Some pipelines deteriorate slowly, and certain cases pipeline life has been reliably targeted at 70 years or more. Other pipelines have been built which have exhausted their life after 1 year operation. (Nestleroth, 2006).

According to Kucera (1988), CO2 and H2S gases, in combination with water,

define most of the corrosion problems in oil and gas production. Other problems include microbiological activity and the solids accumulation. The mechanisms of CO2 corrosion

are generally well defined. However, the reality inside a pipeline becomes complicated when CO2 acts in combination with H2S, deposited solids, and other environments. H2S

can be highly corrosive, but can, in some cases, form a protective sulfide scale that prevents corrosion. Microorganisms can attach to pipe walls and cause corrosion damage.

On the latest researching by A. Cosham, P. Hopkins, K.A. Macdonald (2007), corrosion can be classified into one of three general categories. There are internal corrosion caused by the produced fluids and gases, external corrosion caused by exposure to groundwater or seawater, and atmospheric corrosion caused by salt spray and weathering offshore. Of these, internal corrosion is the most costly since internal mitigation methods cannot be easily maintained and inspected. Pitting corrosion along the bottom of the pipeline is the primary corrosion mechanism leading to failures in gas pipelines. The common features of this mechanism are:

a. The presence of water containing any of the following; carbon dioxide (CO2),

bacteria, oxygen (O2), or solids;

b. Pipelines carrying higher levels of free-water production with no means of water removal, i.e. well site separation or dehydration;

c. The presence of fluid traps where water and solids can accumulate;

d. Vapor phase corrosion is a less common mechanism that has also led to failures. Although not specifically addressed in this recommended practice, many of the preventative measures described in this document will also mitigate this mechanism.

Figure 1.0: Internal Corrosion on Pipeline (Source: http://www.corrview.com/service_03.htm)

On April 2006, in Alaska they had a case about the corrosion in pipelines. On 2nd March 2006 until April 2006 was determined that 201,000 gallons of oil had spread over almost 2 acres of tundra. The leaky pipeline remains out of service while field workers check out corrosion problems. The corrosion on pipelines was detected by the pipeline leak-detection system sound warnings on four straight days in the week leading up to last month’s record North Slope oil spill. They found that the 34 inches pipeline that leaked had circumstances that made leak detection become difficult, which including a relatively high level of sediment moving through the pipe along with the oil. They also found the fluctuations in the volume of oil sent was down to the line from a processing plant can mask a potential leaks. Then the corrosion was blamed for causing an almond-sized hole through which the oil escaped. (Wesley Loy, Anchorage Daily News, April 20, 2006).

1.3 Objectives

The objectives of this study are:

a. To study the corrosion activities in internal pipe using various concentration of acidic solution.

b. To measure the wall pipe thickness due to corrosion using Ultrasonic Testing Thickness Measurements (UTTM).

c. To produce a program that models a C-scan presentation of the corrosion activities in the pipe from A-scan presentation obtained from UTTM using MATLAB Programming.

1.4 Scope of Study

This study is focused on the internal corrosion in pipelines, where the corrosion is the main problem since a long time ago. This experiment is to study the corrosion activities in a pipe with using a different concentration of acid. Then, the thickness of pipe will be measure with using the Ultrasonic Testing, where every different concentration of acid affects the different corrosion rate. The acid that is used on this experiment is a hydrochloric acid (HCl), and the various concentration of acid that will be used is 30%, 50% and 70% concentration per volume. For one specimen, there have 108 points of thickness need to be measured. The thickness reading taken is doing by weekly from week one until week ten. The results of corrosion activities will be present as a program that models a C-scan from A-scan presentation obtained from Ultrasonic Testing Thickness Measurement (UTTM) method. MATLAB Programming is using to create a C-scan result display.

CHAPTER 2

LITERATURE REVIEW

2.1 Corrosion in Pipelines

According to A. Cosham, P. Hopkins, K.A. Macdonald (2007), corrosion is an electrochemical process where it is a time dependent mechanism and depends on the local environment within or adjacent to the pipeline. Corrosion usually appears as either general corrosion or localizes (pitting) corrosion. There are many different types of corrosion, including galvanic corrosion, microbiologically induced corrosion, alternate current (AC) corrosion, differential soils, differential aeration and cracking. Corrosion causes metal loss. It can occur on the internal or external surfaces of the pipe, in the base material, the seam weld, the girth weld, and/or the associated heat affected zone (HAZ).

According to Bolt R and Owen RW (1999), the internal and external corrosion are together one of the major causes of pipeline failures. Data for onshore gas transmission pipelines in Western Europe for the period from 1970 to 1997 indicates that 17% of all incidents resulting in a loss of gas were due to corrosion.

On the latest researching by Eiber , Miele and Wilson (2002), incident data from the Office of Pipeline Safety in the USA for the year 2001 attributes 29% of incidents in liquid pipelines, and 19% of incidents in gas pipelines due to corrosion. Corrosion in a

D(x) Week 10 Data Reading Thickness of Pipeline Model 107 for 70% Concentration of hydrochloric Acid

CHAPTER 1

INTRODUCTION

1.1 Project

The purpose of this project is to conduct experiment to study the corrosion activities in a pipe using various concentration of acidic solution using Ultrasonic Testing Thickness Measurement (UTTM) method, and to produce a program that models a C-scan presentation of the corrosion activities in the pipe from A-scan presentation obtained from UTTM. The study and data collection of this project will be held at the Universiti Teknikal Malaysia Melaka (UTeM).

1.2 Problem Statement

Corrosion in pipelines is a problem long faced since long time ago. Industrial sector fields grow older and move to more challenging and often aggressive environments, the difficulties presented by corrosion are multiplying. Some pipelines deteriorate slowly, and certain cases pipeline life has been reliably targeted at 70 years or more. Other pipelines have been built which have exhausted their life after 1 year operation. (Nestleroth, 2006).

are generally well defined. However, the reality inside a pipeline becomes complicated when CO2 acts in combination with H2S, deposited solids, and other environments. H2S can be highly corrosive, but can, in some cases, form a protective sulfide scale that prevents corrosion. Microorganisms can attach to pipe walls and cause corrosion damage.

On the latest researching by A. Cosham, P. Hopkins, K.A. Macdonald (2007), corrosion can be classified into one of three general categories. There are internal corrosion caused by the produced fluids and gases, external corrosion caused by exposure to groundwater or seawater, and atmospheric corrosion caused by salt spray and weathering offshore. Of these, internal corrosion is the most costly since internal mitigation methods cannot be easily maintained and inspected. Pitting corrosion along the bottom of the pipeline is the primary corrosion mechanism leading to failures in gas pipelines. The common features of this mechanism are:

a. The presence of water containing any of the following; carbon dioxide (CO2), bacteria, oxygen (O2), or solids;

b. Pipelines carrying higher levels of free-water production with no means of water removal, i.e. well site separation or dehydration;

c. The presence of fluid traps where water and solids can accumulate;

d. Vapor phase corrosion is a less common mechanism that has also led to failures. Although not specifically addressed in this recommended practice, many of the preventative measures described in this document will also mitigate this mechanism.

Figure 1.0: Internal Corrosion on Pipeline (Source: http://www.corrview.com/service_03.htm)

On April 2006, in Alaska they had a case about the corrosion in pipelines. On 2nd March 2006 until April 2006 was determined that 201,000 gallons of oil had spread over almost 2 acres of tundra. The leaky pipeline remains out of service while field workers check out corrosion problems. The corrosion on pipelines was detected by the pipeline leak-detection system sound warnings on four straight days in the week leading up to last month’s record North Slope oil spill. They found that the 34 inches pipeline that leaked had circumstances that made leak detection become difficult, which including a relatively high level of sediment moving through the pipe along with the oil. They also found the fluctuations in the volume of oil sent was down to the line from a processing plant can mask a potential leaks. Then the corrosion was blamed for causing an almond-sized hole through which the oil escaped. (Wesley Loy, Anchorage Daily News, April 20, 2006).

a. To study the corrosion activities in internal pipe using various concentration of acidic solution.

b. To measure the wall pipe thickness due to corrosion using Ultrasonic Testing Thickness Measurements (UTTM).

c. To produce a program that models a C-scan presentation of the corrosion activities in the pipe from A-scan presentation obtained from UTTM using MATLAB Programming.

1.4 Scope of Study

This study is focused on the internal corrosion in pipelines, where the corrosion is the main problem since a long time ago. This experiment is to study the corrosion activities in a pipe with using a different concentration of acid. Then, the thickness of pipe will be measure with using the Ultrasonic Testing, where every different concentration of acid affects the different corrosion rate. The acid that is used on this experiment is a hydrochloric acid (HCl), and the various concentration of acid that will be used is 30%, 50% and 70% concentration per volume. For one specimen, there have 108 points of thickness need to be measured. The thickness reading taken is doing by weekly from week one until week ten. The results of corrosion activities will be present as a program that models a C-scan from A-scan presentation obtained from Ultrasonic Testing Thickness Measurement (UTTM) method. MATLAB Programming is using to create a C-scan result display.

CHAPTER 2

LITERATURE REVIEW

2.1 Corrosion in Pipelines

According to A. Cosham, P. Hopkins, K.A. Macdonald (2007), corrosion is an electrochemical process where it is a time dependent mechanism and depends on the local environment within or adjacent to the pipeline. Corrosion usually appears as either general corrosion or localizes (pitting) corrosion. There are many different types of corrosion, including galvanic corrosion, microbiologically induced corrosion, alternate current (AC) corrosion, differential soils, differential aeration and cracking. Corrosion causes metal loss. It can occur on the internal or external surfaces of the pipe, in the base material, the seam weld, the girth weld, and/or the associated heat affected zone (HAZ).

According to Bolt R and Owen RW (1999), the internal and external corrosion are together one of the major causes of pipeline failures. Data for onshore gas transmission pipelines in Western Europe for the period from 1970 to 1997 indicates that 17% of all incidents resulting in a loss of gas were due to corrosion.

On the latest researching by Eiber , Miele and Wilson (2002), incident data from the Office of Pipeline Safety in the USA for the year 2001 attributes 29% of incidents in liquid pipelines, and 19% of incidents in gas pipelines due to corrosion. Corrosion in a