K. Elayaperumal, V. S. Raja

Corrosion Failures (eBook, PDF)

Theory, Case Studies, and Solutions

• Format: PDF

Produktbeschreibung

Provides corrosion basics in a lucid manner to students and working professionals and over 80 corrosion-failure analysis case studies * Correlates Failure Analysis with Corrosion Science * Exclusively provides corrosion-related failure analysis case histories in one place in a convenient format * One-stop shop for both science and real time occurrence of the phenomenon of corrosion * Full coverage of all MOC, Materials of Construction, used for process equipments * Simple but Lucid presentation of Failure Analysis procedure

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Produktdetails

• Verlag: John Wiley & Sons
• Seitenzahl: 256
• Erscheinungstermin: 27. April 2015
• Englisch
• ISBN-13: 9781119043119
• Artikelnr.: 42832221

Autorenporträt

K. Elayaperumal has close to 50 years of experience in Corrosion and Metallurgical Analysis. Since 1979 he has been a Corrosion & Metallurgical Consultant extending advisory Consultancy Services in the areas of Corrosion Prevention, Materials Selection, Failure Analysis, Water treatment etc. as related to Process Industry. He is the recipient of the National Metallurgist Award instituted by Ministry of Iron and Steel, Government of India, for contribution in Corrosion Prevention and Failure Analysis and also the Life Time Achievement Award from NACE International India Chapter. V. S. Raja is currently a professor in the Department of Metallurgical Engineering and Materials Science at the Indian Institute of Technology Bombay, Mumbai, India. He has guided about 20 doctoral and 100 master's students in Corrosion and has been a Consultant to over 50 industries; has over 120 publications in various peer reviewed journals & books and also delivered over 100 plenary, keynote and invited talks in conferences. He is a recipient of Meritorious award by NACE international India Section and Excellence in Teaching award by IIT Bombay and a Fellow of NACE International and Indian Institute of Metals.

Inhaltsangabe

About the Authors xiii Foreword xv Preface xvii 1 Introduction 1 1.1 The
Phenomenon of Corrosion 1 1.2 Importance of Corrosion 2 1.2.1 Cost of
Corrosion: Direct and Indirect 2 1.3 The Purpose and Format of the Book 6
References 7 2 Thermodynamics and Kinetics of Electrochemical Corrosion 9
2.1 Introduction 9 2.2 Thermodynamics 10 2.2.1 Corrosion Reactions and
Gibbs Free Energy Change 10 2.2.2 Electrochemical Nature of Corrosion 11
2.2.3 Summary 16 2.3 Kinetics of Corrosion 17 2.3.1 Description of a
Corrosion System 18 2.3.2 Predicting Corrosion 19 2.3.3 Passivity 21 2.3.4
Summary 22 2.4 Corrosion Evaluation and Monitoring 23 2.4.1 Electrochemical
Techniques 24 2.4.2 Non-electrochemical Techniques 26 References 27 3 Forms
of Corrosion 29 3.1 Introduction 29 3.2 Uniform Corrosion 30 3.3 Galvanic
Corrosion 31 3.3.1 Factors Affecting Galvanic Corrosion 31 3.3.2
Controlling Galvanic Corrosion 34 3.4 Pitting Corrosion 35 3.4.1 Pitting
Process and Pitting Morphology 35 3.4.2 Factors Affecting Pitting Corrosion
35 3.4.3 Controlling Pitting Corrosion 38 3.5 Differential
Aeration-Assisted Corrosion (Crevice Under Deposit and Water-Line
Corrosion) 39 3.5.1 Characteristics of Differential Aeration Corrosion 39
3.5.2 Factors Affecting Differential Aeration Corrosion 40 3.5.3
Differential Aeration Corrosion Control 41 3.6 Intergranular Corrosion 41
3.6.1 IGC of Stainless Steels 41 3.6.2 Weld Decay of Stainless Steels 45
3.7 Selective Dissolution/Selective Attack 47 3.7.1 Characteristics of
Selective Dissolution 47 3.7.2 Dezincification 47 3.7.3 Graphitic Corrosion
49 3.8 Flow-Assisted/Erosion/Cavitation Corrosion 50 3.8.1 Flow-Assisted
Corrosion (FAC) 50 3.8.2 Erosion Corrosion 51 3.8.3 Cavitation Damage 55
3.9 Stress Corrosion Cracking 55 3.9.1 Characteristics of SCC 56 3.9.2
Effect of SCC on Mechanical Properties 57 3.9.3 Factors Affecting SCC 59
3.9.4 Controlling SCC 63 3.10 Hydrogen Damage 63 3.10.1 Low Temperature
Hydrogen-Induced Cracking 63 3.10.2 High Temperature Hydrogen
Damage/Decarburization 67 3.11 Stray Current Corrosion 68 3.12 High
Temperature Corrosion 70 3.12.1 Oxidation 70 3.12.2 Sulfidation 71 3.12.3
Hot Corrosion 71 3.12.4 Chloridation 71 3.12.5 Carburization/Metal Dusting
72 References 72 4 Materials of Construction for Chemical Process
Industries 75 4.1 Introduction 75 4.2 Cast Irons 76 4.3 Carbon Steels 78
4.3.1 Corrosion 79 4.3.2 Stress Corrosion Cracking Including Hydrogen
Cracking and Sulfide Stress Cracking 80 4.3.3 Caustic Stress Corrosion
Cracking 81 4.3.4 Favorable and Unfavorable Points in Using Carbon Steel as
MOC 82 4.4 Low Alloy Steels 82 4.5 Stainless Steels 86 4.5.1
Ferritic/Martensitic Stainless Steels 87 4.5.2 Austenitic Stainless Steels
88 4.5.3 Super Austenitic Stainless Steels 92 4.5.4 Duplex Stainless Steels
94 4.6 Nickel Base Alloys 96 4.7 Copper Base Alloys 96 4.8 Titanium 99 4.9
Aluminum Alloys 100 4.10 Nonmetallic Materials 102 4.11 Ceramics/Inorganic
Oxide Glasses 103 4.12 Organic Polymers/Plastics 103 4.13 Materials
Selection for Corrosion Prevention in Hydrocarbon Service 104 4.13.1
Materials Selection as per NACE MR0175 107 References 109 5 Failure
Analysis Procedure with Reference to Corrosion Failures 111 5.1
Introduction 111 5.2 Purpose of Failure Analysis Investigations 112 5.3
Failure Analysis Steps 112 5.3.1 Site Visit 112 5.3.2 Tests on the Samples
114 5.3.3 Analysis Interpretation and Diagnosis of the Failure 116 5.4
Failure Analysis Report: Contents and Preparation 117 References 118 6 Case
Studies 119 6.1 Preamble 119 Classification of Case Studies 120 General 123
1 Bromine Preheater in a Pharmaceutical Fine Chemical Plant 124 2
Structurals in a White Clay Manufacturing Plant 125 3 Sea Water Cooler
Tubes in an Oil Refinery 126 4 Package Boiler Tube in an Organic Chemical
Plant 127 5 Shell of a Packed Column for Ammonia and Water Contact in an
Ammonia Processing Plant 128 6 Instrumentation Tube in an Offshore Platform
of an Oil and Gas Plant 129 7 Plate Type Heat Exchanger/Cooler in a
Sulfuric Acid Plant 130 8 Dissimilar Stainless Steel Weld in an Organic
Chemical Plant 131 9 Digestor Preheater in a Pulp and Paper Plant 132 10
Esterification Column in an Organic Chemical Plant 133 11 Half Pipe Limpet
Coil of a Stirred Reactor in an Organic Chemical Plant 134 12 Firewater
Lines Buried Underground in an Organic Chemical Plant 135 13 Alcohol
Superheater in a PVC Manufacturing Petrochemical Plant 136 14 Package
Boiler Tubes in an Alcohol Distillery Plant 137 15 Reducers in a Reformer
Tube in an Ammonia Plant of a Fertilizer Industry 138 16 Pressure Safety
Valve (PSV) Fitting on Instrumentation Tubes in an Off-shore Platform in an
Oil and Gas Company 139 17 Water Drum (Mud Drum) Shell in a Coal-Fired
Steam Boiler 140 18 Tubes in a Kettle Re-boiler of an Amine Plant 141 19
Evaporator Tubes in an Organic Chemical Plant 142 20 Top Tube Sheet Vent
Equalizer Weld Zone of a Gas Cooler in a Petrochemical Plant 143 21 Bottom
Row Tubes in a Kettle Re-boiler of an Organic Chemical Plant 144 22 Cages
for Filter Bags in an Inorganic Chemical Plant 145 23 High Temperature
Generator (HTG) Tubes of Vapor Absorption Chiller of an Air-Conditioning
and Refrigeration Unit 146 24 Gasket Seat in a Shell and Tube Condenser in
a Petrochemical Plant 147 25 Acid Gas CO2 Cooler Condenser in Ammonia Plant
of a Fertilizer Unit 148 26 Naphtha Coolers in a Fertilizer Plant 149 27 U
Type Jet Dyeing Machine in a Textile Dyeing Unit 150 28 Acetic Acid
Manufacturing Unit in a Petrochemical Plant 151 29 Large Stainless Steel
Pipeline in a Urea Plant of a Fertilizer Unit 152 30 Heat Recovery System
of a PVC Unit in a Petrochemical Plant 153 31 EDC Furnace Coil of a PVC
Plant in a Petrochemical Unit 155 32 Internals of a Stirred Reactor
Processing Ortho Phosphoric Acid 157 33 Salt Evaporator 158 34
Cooler/Condenser Tubes of an Absorption Chiller Machine of an
Airconditioning Plant 159 35 Nitro Mass Cooler in an Organic Chemical Plant
161 36 Fertilizer Industry Ammonia Plant Natural Gas Feed Preheater Coil
162 37 Petrochemical Unit. PVC Plant. Radiant Coils of the EDC Pyrolysis
Furnace 164 38 Exhaust Gas Boiler in a Sugar Mill 166 39 Domestic Storage
Water Heater 167 40 Stirred Reactor in a Rubber Chemical Plant 168 41
Stainless Steel Tubes During Long Storage in Packed Condition 169 42
Fertilizer Plant. Ammonia Units. Secondary Waste Heat Boiler Tubes 170 43
Hospital Hydroclave for Treating Wastes 172 44 Petrochemical Plant.
Phosgene Absorption Column Internals 174 45 Fertilizer Unit Ammonia Plant
Start-Up Preheater Outlet Line 176 46 Petrochemical Plant Underground
Fire-Water Pipelines 177 47 Monel Clad Evaporator in a Pure Water Plant 178
48 Loop Steamer Machine in a Textile Dyeing Unit 179 49 Rubber Chemicals
Plant: Leakage in Process Pipelines 180 50 Clay Drier in a Clay
manufacturing Plant 181 51 Hydrogen Sulfide Processing Plant 182 52 Textile
Bleaching Vessel in a Dyeing Industry 184 53 Condenser of an Absorption
Chilling Machine in an Air-Conditioning Plant 185 54 Petrochemical Complex:
Lube Oil Cooler Tubes of Captive Gas Turbine Power Plant 187 55
Petrochemical Plant: Plate Heat Exchanger (PHE) Exchanging Heat Between
Spent Caustic and Vent Gas in a Cracker Plant 188 56 Inorganic Chemical
Plant: Distillation Pots 189 57 Starch Industry: Economizer Tubes of High
Pressure Captive Boilers 190 58 Rubber Chemical Plant-Crump Slurry Tank 191
59 Petrochemical Plant: Gas Cracker Unit Dilute Steam Kettle Re-boiler 193
60 Textile Dyeing Unit: Jet Dyeing Machine Shell 194 61 Oil Refinery: 12
Inch Dia. Overhead Pipeline 195 62 Fertilizer Plant: CO2 Compressor
Inter-stage Cooler 196 63 Oil Refinery: Flash Crude Heater Shell Cover
Drain Nozzle 198 64 Oil Refinery: Light Cycle Oil Steam Generator 199 65
Organic Chemical Plant: High Pressure Autoclave in R&D Laboratory 200 66
Fertilizer Industry: Captive Power Plant: Economizer Tube 202 67 Inorganic
Chemicals Plant: Reactor Shell 203 68 Reactor for an Organic Chemical Plant
204 69 Fertilizer Unit. Ammonia Plant. Primary Waste Heat Boiler 205 70
Pulp and Paper Plant. TL Vertical Screen Inlet Line of the Paper Section
207 71 Fertilizer Plant. Underground Sections of Cooling Water and Fire
Hydrant Water Pipe Lines 208 72 Thermal Power Plant. Condenser Cooling Sea
Water In-take Line. Butter Fly Valve 210 73 Petrochemical Plant. Pressure
Transmitter Sensors 211 74 Organic Chemicals Plant: Coolers and Condensors
212 75 Organic Chemicals Plant: Alcohol Vaporizer 214 76 Organic Chemicals
Plant. Thermowells 215 77 Fertilizer Unit. Ammonia Plant. Gas to Gas Heat
Exchanger 216 78 Oil Refinery. Sulfolane Recovery Column Reboiler 217 79
Oil Refinery. Hydrocarbon vapor-liquid heat exchanger 218 80 Chlor-Alkali
Plant Stainless Steel Laboratory Reactor 219 Index 221