Corrosion Allowance Introduction Corrosion allowance in the industry refers to the additional thickness of a pipe or other equipment that is added to account for the expected corrosion during its intended Design/ Service life. Corrosion is a natural process that occurs when metal is exposed to a corrosive environment such as water, acids, and chemicals, Etc.. Corrosion can cause the metal to deteriorate and weaken, which can lead to leaks, equipment failures, and safety hazards. Corrosion allowance is widely popular by its acronym CA. To prevent corrosion-related failures, piping systems are designed with a corrosion allowance, which is typically a small additional thickness added to the pipe wall or Equipment. The corrosion allowance is based on the expected corrosion rate of the material in the specific service environment and the expected service life of the piping system. The corrosion allowance is typically specified by the Corrosion & Piping design engineer in the piping material class and is based on industry standards and codes. The additional thickness of the pipe ensures that even if corrosion does occur, the pipe will still have sufficient wall thickness to maintain its strength and integrity, and the expected service life will not be compromised. The corrosion allowance is an important factor in ensuring the reliability and safety of piping systems.
2 By: Muhammad Usman Asghar
Factors Affecting Corrosion Allowance The corrosion allowance in piping systems typically depends on several factors, including:
Material: The type of material used for the piping system, such as carbon steel, stainless steel, or other alloys, can impact the corrosion rate and thus the necessary corrosion allowance.
Service environment: The corrosiveness of the service environment, such as exposure to saltwater, acids, or chemicals, can impact the corrosion rate and determine the necessary corrosion allowance.
Operating temperature and pressure: Higher operating temperatures and pressures can increase the corrosion rate and thus require A higher corrosion allowance.
Flow rate and velocity: The flow rate and velocity of the fluid through the piping system can impact the corrosion rate and determine the necessary corrosion allowance.
Design/ Service life: The expected service life of the piping system can also impact the corrosion allowance, as a longer service life may require a higher corrosion allowance to account for potential corrosion over time.
These factors are typically evaluated by the Piping Engineer in consultation with Corrosion & Process engineer and used to determine the appropriate corrosion allowance for the specific piping system. The corrosion allowance is an important consideration in ensuring the reliability and safety of the piping system over its expected service life. 3 By: Muhammad Usman Asghar Corrosion Allowance for Steel The corrosion allowance for steel in piping systems depends on several factors, including the type of steel, the service environment, the operating conditions, and the expected service life. The corrosion allowance for steel is typically specified by industry standards and codes, such as ASME B31.3, which provide guidelines for the design and construction of process piping systems. According to ASME B31.3, the minimum corrosion allowance for carbon steel piping in typical process applications is 1.6 mm (1/16 inch). However, the actual corrosion allowance required may vary depending on the specific service conditions and is typically determined by the piping design engineer with the help of the process engineer. For more corrosive service environments, such as those involving saltwater or acidic solutions, a higher corrosion allowance may be required. Additionally, the expected service life of the piping system may also impact the necessary corrosion allowance. It is important to note that the corrosion allowance is intended to provide a margin of safety for the piping system and should be carefully considered in the design and construction of the system. The corrosion allowance is an important factor in ensuring the reliability and safety of piping systems over their expected service life. Usually, the corrosion allowance for stainless steel, DSS, and PE/Roto-lined carbon steel pipes are considered zero. However, in certain conditions, SS or DSS material can have corrosion allowance. Clause 8.2 of ISO 21457 provides commonly used corrosion allowance values for pipes. As per that standard, the usual corrosion allowance values are: • 1.0 mm to 1.5 mm for non-corrosive service • 3.0 mm for mildly corrosive service • 6.0 mm for severely corrosive service.
4 By: Muhammad Usman Asghar
How to calculate the corrosion allowance Calculating the corrosion allowance involves considering factors that can affect the rate of corrosion and adding a margin of safety to the original thickness of the piping. The corrosion allowance is typically specified during the design phase of a piping system to ensure its longevity and safety. • Understand the Corrosion Environment: Assess the environmental conditions that the piping system will be exposed to, such as the type of fluid being transported, temperature, humidity, pH, presence of contaminants, and other corrosive agents. • Identify the Material’s Corrosion Resistance: Different materials exhibit varying degrees of corrosion resistance. Select a material that is suitable for the specific corrosive environment and consider its corrosion rate data. • Determine the Design Life: Decide on the desired design life for the piping system. This is the intended service life for the pipe before any significant replacement or repair is required. • Select the Corrosion Allowance Value: The corrosion allowance is typically expressed in millimeters (mm) or inches (in). The specific value chosen depends on the severity of the corrosion environment, the material’s corrosion rate, and the desired design life.
5 By: Muhammad Usman Asghar
How to calculate the corrosion allowance Normally the following formula is used to calculate the corrosion allowance: Corrosion Allowance = (Corrosion Rate × Design Life), CA = CR x DL Add the Corrosion Allowance to the Original Wall Thickness: Once you have calculated the corrosion allowance, add this value to the original wall thickness of the piping material to obtain the final required wall thickness. Final Wall Thickness = Original Wall Thickness + Corrosion Allowance
The corrosion allowance ensures that even if corrosion occurs over the piping system’s intended Design/ Service life, there will be enough material remaining to maintain structural integrity and prevent leaks or failures. Design Life (DL): Normally 20 years for Equipment, 10 years for piping, or Per Client’s requirements Corrosion Rate (CR) Estimation CR = mils per year (mpy) or millimeters per year (mm/yr) Corrosion Allowance (CA) CA = 1/16”, 1/8”, 3/16” or 1/4”= 1.6 mm, 3.2 mm, 4.8 mm or 6.4 mm Maximum CA = 1/4” or 6.4 mm Note: Upgrade material if required CA is > ¼” or 6.4 mm 6 By: Muhammad Usman Asghar Thank You! References https://www.sciencedirect.com/topics/engineering/corrosion-allowance https://engineeringserviceslp.com/wp-content/uploads/2020/12/CORR-ALLOWANCE.pdf
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