Corrosion Failures E-Book

K. Elayaperumal

• Herausgeber: John Wiley & Sons
• Kategorie: Wissenschaft und neue Technologien
• Serie: Wiley Series in Corrosion
• Sprache: Englisch

Seitenzahl: 294

Veröffentlichungsjahr: 2015

Beschreibung

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

Leseprobe

WILEY SERIES IN CORROSION

R. Winston Revie, Series Editor

Corrosion Inspection and Monitoring • Pierre R. Roberge

Corrosion Resistance of Aluminum and Magnesium Alloys: Understanding, Performance, and Testing • Edward Ghali

Microbiologically Influenced Corrosion • Brenda J. Little and Jason S. Lee

Corrosion Resistance of Aluminum and Magnesium Alloys • Edward Ghali

Metallurgy and Corrosion Control in Oil and Gas Production • Robert Heidersbach

Green Corrosion Inhibitors: Theory and Practice • V. S. Sastri

Heterogenous Electode Processes and Localized Corrosion • Yongjun Tan

Stress Corrosion Cracking of Pipelines • Y Frank Cheng

Challenges in Corrosion: Costs, Causes, Consequences and Control • V. S. Sastri

Corrosion Failures: Theory, Case Studies, and Solutions • K. Elayaperumal and V. S. Raja

CORROSION FAILURES

Theory, Case Studies, and Solutions

K. ELAYAPERUMAL

Corrosion and Metallurgical Consultant, 3034, Sobha Amethyst, Kannamangala, Bangalore 560 067 India

V.S. RAJA

Professor, Dept. of Metallurgical Engineering and Materials Science, Indian Institute of Technology Bombay, Powai, Mumbai, India

Copyright © 2015 by John Wiley & Sons, Inc. All rights reserved

Published by John Wiley & Sons, Inc., Hoboken, New Jersey

Published simultaneously in Canada

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Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages.

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Library of Congress Cataloging-in-Publication Data:

Elayaperumal, K. (Kailasanathan), 1937- Raja, V.S (Vngaranahalli Srinivasan),1958-

     Corrosion failures: theory, case studies, and solutions/K. Elayaperumal, V.S. Raja.

       pages cm

     Includes bibliographical references and index.

     ISBN 978-0-470-45564-7 (cloth)

     1. Corrosion and anti-corrosives. 2. Metals- Stress corrosion cracking. I. Title.

     TA418.74.E42 2015

     620.1′1223–dc23

               2015000046

Cover image courtesy of V.S. Raja

Table of Contents

Cover

Wiley Series in Corrosion

Title Page

Copyright

About the Authors

Foreword

Preface

Chapter 1 Introduction

1.1 The Phenomenon of Corrosion

1.2 Importance of Corrosion

1.3 The Purpose and Format of the Book

References

Chapter 2 Thermodynamics and Kinetics of Electrochemical Corrosion

2.1 Introduction

2.2 Thermodynamics

2.3 Kinetics of Corrosion

2.4 Corrosion Evaluation and Monitoring

References

Chapter 3 Forms of Corrosion

3.1 Introduction

3.2 Uniform Corrosion

3.3 Galvanic Corrosion

3.4 Pitting Corrosion

3.5 Differential Aeration-Assisted Corrosion (Crevice, Under Deposit, and Water-Line Corrosion)

3.6 Intergranular Corrosion

3.7 Selective Dissolution/Selective Attack

3.8 Flow-Assisted/Erosion/Cavitation Corrosion

3.9 Stress Corrosion Cracking

3.10 Hydrogen Damage

3.11 Stray Current Corrosion

3.12 High Temperature Corrosion

References

Chapter 4 Materials of Construction for Chemical Process Industries

4.1 Introduction

4.2 Cast Irons

4.3 Carbon Steels

4.4 Low Alloy Steels

4.5 Stainless Steels

4.6 Nickel Base Alloys

4.7 Copper Base Alloys

4.8 Titanium

4.9 Aluminum Alloys

4.10 Nonmetallic Materials

4.11 Ceramics/Inorganic Oxide Glasses

4.12 Organic Polymers/Plastics

4.13 Materials Selection for Corrosion Prevention in Hydrocarbon Service

References

Chapter 5 Failure Analysis Procedure with Reference to Corrosion Failures

5.1 Introduction

5.2 Purpose of Failure Analysis Investigations

5.3 Failure Analysis Steps

5.4 Failure Analysis Report: Contents and Preparation

References

Chapter 6 Case Studies

6.1 Preamble

Index

End User License Agreement

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Guide

Cover

Table of Contents

Begin Reading

List of Illustrations

Figure 1.1

Figure 2.1

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Figure 2.5

Figure 2.6

Figure 2.7

Figure 2.8

Figure 3.1

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List of Tables

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ABOUT THE AUTHORS

Dr. K. Elayaperumal holds degrees in Metallurgical Engineering from Indian Institute of Science, Bangalore, India, and Massachusetts Institute of Technology, Cambridge, Massachusetts, USA. He has acquired vast R&D experience in the field of corrosion of metallic materials in the nuclear power industry and the related chemical process industry in his two-decade career in the Department of Atomic Energy, Government of India, Bhabha Atomic Research Centre. His advisory consultancy services in the field of analysis of corrosion failure in chemical process industries have generated a great amount of interesting case studies and brought out in this book. He is a recipient of National Metallurgist Award by Govt. of India and Life Time Achievement Award by NACE India Section.

Prof. V. S. Raja received his doctoral degree from Indian Institute of Science, Bangalore, India. He is a Professor of Corrosion Science and Engineering in the Department of Metallurgical Engineering and Materials Science and also Institute Chair Professor in the Indian Institute of Technology Bombay, India. For the past 28 years, he taught several corrosion and materials related courses, supervising about 20 doctoral students. His main research lies in understanding the interrelation between metallurgy and corrosion, especially passivity, localized corrosion, and stress corrosion cracking. He is also actively involved in solving industrial problems related to corrosion. He has received several awards for his contribution to teaching, research, and industry and is a NACE International Fellow.

FOREWORD

In this unique book, the authors provide a concise presentation of the essence of corrosion principles with an orientation toward corrosion failures and management of corrosion to prevent failures. By appropriate design, construction, operation, and maintenance, the cost of failure can, indeed, be avoided. The book is divided into the following six chapters that are essential reading for any person concerned with the use of materials in applications where safety, integrity, and reliable, cost-effective operation are required:

Introduction: The significance of corrosion failures is described in economic and engineering terms.

Thermodynamics and kinetics of corrosion: The basic principles of corrosion are presented along with an outline of techniques for assessing the extent of corrosion in engineering installations.

Forms of corrosion: Ten basic forms of corrosion are described, including the critical controlling factors for each form. The authors present a valuable collection of photographs to illustrate the forms of corrosion.

Materials of construction for chemical process industries: An extensive discussion of the materials available is presented, along with properties on which materials selection is based. The discussion includes not only metallic materials but also nonmetals – ceramics, glasses, and polymers.

Failure analysis procedures with reference to corrosion failures: The steps involved in failure analysis are succinctly described from the perspective of developing an understanding of the cause of failure as necessary to prevent future failures.

Case studies: Eighty case studies are photographically illustrated, presented, and discussed. Each case study includes a description of the type of service involved, the specific problem, the material, observations, diagnosis, and remedy.

I am delighted to commend this book to all readers with an interest in reliable application of engineering materials, and I congratulate the authors on their success in achieving the completion of this valuable book.

R. Winston Revie

CANMET Materials Technology Laboratory

Ottawa, Ontario

Canada

PREFACE

Corrosion cuts across almost all industries, and the corroded components prematurely fail and/or operate at suboptimal level. It affects productivity, safety, and environments and devours nonrenewable natural resources and therefore is of great concern to society. Although industrial components do fail by other mechanisms such as mechanical overload, fatigue, creep, brittle fracture, corrosion remains the single most destruction causing the highest damage to all industrial components. For example, in chemical processing industries, corrosion of process equipment vessels and the associated piping, tubing, and utility components such as boilers, heat exchangers, and condensers is the most predominant damage-causing mechanism among the others mentioned earlier. Corrosion takes place on the inside surface of the vessels and other components because of the action of process chemicals and also on the outside surfaces because of the atmospheric moisture laden with chemical vapors and also by wet insulation materials. On the other hand, corrosion damage in aerospace and other transportation industry is relatively less, though found to be critical in life and safety and in the cost of the components. It is estimated that corrosion causes loss of about 3.5% of GNP of a nation. Hence, corrosion control becomes an important subject of science and engineering.