Corrosion Allowance

Sarbendu Paul
WHAT IS 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.
Page 1 of 3
Sarbendu Paul
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

Corrosion allowance for steel pipes
Superheated steam
Saturated steam
Steam coils in cargo tanks and liquid fuel tanks
Feed water for boilers in open circuit systems
Feed water for boilers in closed circuit systems
Blow-down systems for boilers
Compressed air
Hydraulic oil
Lubricating oil
Fuel oil
Thermal oil
Fresh water
Sea water
Refrigerants referred to in Section 13
Cargo systems for oil tankers
Cargo systems for ships carrying liquefied gases
mm
0.3
0.8
2.0
1.5
0.5
1.5
1.0
0.3
0.3
1.0
1.0
0.8
3.0
0.3
2.0
0.3
Notes:
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 non-ferrous metal pipes
Copper
Brass
Copper-tin alloys
Copper-nickel alloys with less than 10% of Ni
Copper-nickel alloys with at least 10% of Ni
Aluminium and aluminium alloys
mm
0,8
0,8
0,8
0,8
0,5
0,5
Notes:
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.
Page 2 of 3
Sarbendu Paul
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 equipment remain in use or should it be taken out of service.
Page 3 of 3

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Sarbendu Paul

WHAT IS CORROSION ALLOWANCE?

CALCULATION OF CORROSION ALLOWANCE

BELOW ARE TWO TABLES WITH GUIDELINES FOR CORROSION ALLOWANCE

CORROSION ALLOWANCE GENERAL

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