FACTORS INFLUENCING ACCELERATED CORROSION OF CARGO OIL TANKS
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ABSTRACT
This study was conducted to critically investigate the factors driving rapid corrosion of cargo oil tanks, with Cheron Oil and Gas Company as a case study. To accomplish this goal, three research questions and one research hypothesis were developed to drive the investigation.
The data was examined using basic percentages and tables to answer research questions, and the Chi-square statistical technique was utilized to test the study hypothesis with Statistical Package for Social Sciences (SPSS) software. A structured questionnaire was utilized as the primary data gathering tool for Cheron Oil and Gas Company respondents. Following a thorough review of the data, the following findings were discovered: there are factors causing accelerated corrosion of cargo oil tanks in Nigeria.
The study concluded with the following recommendations: the composition and moisture content of inert gas should be examined to determine its influence on the corrosion rate as well as methods for decreasing the corrosive constituents of the gas; an effort should be made to determine if some crudes are more susceptible to creating accelerated corrosion than others; and the effectiveness of coal tar and pure epoxy coatings should be evaluated in an environment that includes microbial influenced corrosion.
TABLE OF CONTENTS
Cover page
Title page
Certification
Dedication
Acknowledgments
Abstract
Table of contents
Chapter One: Introduction
1.1 Background of the Study
1.2 Statement of the Problem
1.3 Objectives of the Study
1.4 Research Questions
1.5 Research Hypothesis
1.6 Significance of the Study
1.7 Scope of the Study
1.8 Limitation of the Study
Chapter Two: Review of Related Literature
2.1 Introduction
2.2 Single Hull Tankers
2.3 Shore Tanks
2.4 Types of Corrosion
2.5 Potential Causes of Accelerated Corrosion
2.6 Associated Risk
Chapter Three: Research Methodology
3.1 Introduction
3.2 Research Design
3.3 Area of the Study
3.4 Population of the Study
3.5 Sample Size and Sampling Techniques
3.6 Sources of Data
3.7 Method of Data Collection
3.8 Method of Data Analysis
Chapter Four: Presentation, Analysis and Interpretation of Data
4.1 Introduction
4.2 Presentation and Analysis of Data
4.3 Testing of Hypotheses
4.4 Discussion of Findings
Chapter Five: Summary, Conclusion and Recommendations
5.1 Introduction
5.2 Summary
5.3 Conclusion
5.4 Recommendations
References
Appendices
CHAPTER ONE
INTRODUCTION
1.1 Background to the Study
Operating oil tankers in the severe maritime environment always results in cargo tank structure corrosion. According to Towers (2010), the interior structure of cargo tanks, which are frequently uncoated, is subjected to corrosive gasses, seawater, crude oil, and oil products. Over time, the corrosion causes the material thickness and, thus, the structure’s strength to decrease. Design guidelines from the Classification Society usually include a corrosion allowance based on a specific level or quantity of corrosion. Should corrosion proceed at an accelerated rate greater than that allowed for in the design of the cargo tank structures and be allowed to continue unchecked, then a structural failure with consequent oil spillage, explosion or loss of the ship could be the result (OCIMF, 1997).
Individual tankers usually exhibit a unique, but controllable corrosion pattern. However, recent experiences of OCIMF members have indicated problems in new single and double hull tonnage from excessive pitting corrosion of up to 2.0 mm per year in the un-coated bottom plating in cargo tanks due, inter alia, to microbial induced corrosion processes. In addition accelerated general corrosion up to 0.24mm per year has been found in vapour spaces. This type of wastage and the increased rate of corrosion, which is much greater than that which would be normally expected, gives cause for serious concern.
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Recognizing the potentially serious impact of marine incidents, the Oil Companies International Marine Forum (OCIMF), has carried out an investigation into the factors which may be influencing accelerated cargo tank corrosion (Prince, 2010). The results of this investigation and areas for further study are presented in this paper. Also included are practicable long and short term mitigating and remedial actions which may be considered as appropriate to reduce the rate of corrosion in the cargo tanks of oil tankers (OCIMF, 1997).
1.2 Statement of the Problem
The normal corrosion rate of uncoated cargo tank deck plating is 0.10 mm or less per year. However, annual wastage rates as high as 0.16mm to 0.24mm have been reported on ships less than 3 years old. This accelerated corrosion rate, which is approximately 2 to 3 times that which would normally be anticipated, is sometimes accompanied by accelerated general corrosion of the vapour space steelwork. In addition to accelerated general corrosion, there has also been an increase in the incidence and severity of pitting corrosion in cargo tank bottom plating. In one specific instance a 150,000dwt tanker is reported as having an average pit depth of between 2.0mm & 3.0mm with a maximum pit depth of 4.0mm. This after only 2 years in service (DeCola and Fletcher, 2006).
In addition to the more conventional corrosion mechanisms, a possible contributory cause of accelerated corrosion has been microbial attack from bacteria in the cargo oil. It would appear that, as crude oil is often loaded at temperatures higher than ambient air and sea temperatures, during the loaded passage the temperature of the cargo tank structure is being maintained at higher levels than normal due to the insulating effect of the double hull spaces.
Higher tank temperatures, coupled with residual water in the cargo tank can:
i) offer favourable conditions for SRB anaerobic bacteria to proliferate, and;
ii) activate the formation of corrosive cells on the surface of the inner bottom.
1.3 Objectives of the Study
1. To determine the factors influencing accelerated corrosion of cargo oil tanks in Nigeria.
2. To examine the various types of corrosion of oil tanks in Nigeria.
3. To determine the potential causes of accelerated corrosion of oil tanks in Nigeria.
4. To make useful recommendations based on the research findings.
1.4 Research Questions
The following research questions were stated to guide this study:
1. Are there any factors influencing accelerated corrosion of cargo oil tanks in Nigeria?
2. What are the various types of corrosion of oil tanks in Nigeria?
3. Are there any potential causes of accelerated corrosion of oil tanks in Nigeria?
1.5 Research Hypothesis
In order to achieve the above stated objectives, the following research hypothesis were formulated to guide this study:
H0: There are no factors influencing accelerated corrosion of cargo oil tanks in Nigeria.
H1: There are factors influencing accelerated corrosion of cargo oil tanks in Nigeria.
1.6 Significance of the Study
This study will be significance to the following:
1 Management Experts and Policy Makers: It would enable management experts and policy makers in the formulation and implementation of policies internally; it will benefit the management and staff as well as the shareholders of the offshore operations. Through this study, managers will be informed of various motivational factors that are helpful in obtaining improved work performance by the employees.
2 The Staff: The staff of Cheron Oil and Gas Company will stand to benefit by availing them the opportunity for training on offshore cargo lifting operations.
3. The Government: The findings of this study will be beneficial to government in its policy formulation and review of existing laws, regulations and bye laws for achieving maximum efficiency in maritime sector in Nigeria. The staff of Cheron Oil and Gas Company is interested to improved work performance of her employees as a way of enhancing productivity. Thus it would attain growth through improving the workers motivational factors of efficiency.
4. Future Researchers: It will help the future researchers and students of higher learning who may wish to carry out research on the similar topic.
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