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- Herausgeber: John Wiley & Sons
- Kategorie: Fachliteratur
- Sprache: Englisch
CORROSION POLICY DECISION MAKING Explore the science, management, economy, ecology, and engineering of corrosion management and prevention In Corrosion Policy Decision Making, distinguished consultant and corrosion expert Dr. Reza Javaherdashti delivers an insightful overview of the fundamental principles of corrosion with a strong focus on the applicability of corrosion theory to industrial practice. The authors demonstrate various aspects of smart corrosion management and persuasively make the case that there is a real difference between corrosion management and corrosion knowledge management. The book contains seven chapters that each focuses on one important aspect of corrosion and corrosion management. Corrosion management is an issue that is not just corrosion science or corrosion engineering but rather a combination of both elements. To cover this paradoxical aspect of corrosion management, chapter 2 deals with some basic, introductory concepts and principles of corrosion and coating/painting (an important corrosion protection method) while chapter 3 explains the elements of smart corrosion management in detail. Another important principle of smart corrosion management is to be able to study the cost of corrosion, chapter 4 introduces important points in the economics involved in a smart corrosion management. As indicated earlier, corrosion engineering is also an integral part of corrosion management and thus chapter 5 looks at the engineering side of corrosion by detailing the example of Process Additives (EMPA). Chapter 6 for the first time looks at the possibility of using TRIZ (algorithm of invention) in corrosion management. Finally, chapter 7 presents the necessary elements for building a model that would explore the mutual interaction between corrosion and environment mainly by exploring the difference between environmental impact and environmental effect. Chapter 7 is also very important because the four models so far applied to estimate the cost of corrosion (Uhlig Method, Hoar Method, I/O method and LCC method) are not capable of suggesting any clear model or a sensible way of exploring the elements necessary to explain the impact of indirect costs of corrosion the most important of which being environmental damages imposed by corrosion. This book is ideal for engineers, students, and managers working or studying corrosion, Corrosion Policy Decision Making is also an indispensable resource for professionals in the fields of upstream and downstream, on-shore/off-shore oil and gas, transportation, mining, power generation as well as major sectors of other strategic industries.
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Table of Contents
Cover
Title Page
Copyright Page
Dedication Page
Preface
Authors and Contributors
1 Introduction
References
2 A Short Review of Some Important Aspects of the Science of Corrosion
2.1 Introduction
2.2 Important Technical Treatment Strategies for Corrosion Treatment
2.3 Conclusion
References
3 Smart Corrosion Management Elements
3.1 Introduction
3.2 Management of Corrosion and COVID19
3.3 Environment
3.4 Application of Management of Corrosion Scheme to Underground Fire Water Ring
4
3.5 Damage Management
3.6 Algorithm
3.7 Final Remarks
References
4 Economics and Corrosion
4.1 Introduction
4.2 Economics
4.3 Corrosion Economics
4.4 Corrosion and Sustainability
4.5 Conclusion
4.6 Summary
References
5 Effective Management of Process Additives (EMPA)
5.1 Introduction
5.2 A Gas Plant
5.3 Utilities
5.4 Process Additives (Chemicals)
5.5 Effective Management of Process Additives (EMPA)
5.6 Misleading Trends with Corrosion Conclusions
5.7 Chemicals, Their Corrosion, and Impacts of Their Corrosions on the Environment
5.8 Configuring EMPA
5.9 Setting up an EMPA
5.10 Consumption
5.11 Reporting
5.12 Documentation
5.13 Summary
References
6 Application of TRIZ for Corrosion Management
6.1 Introduction
6.2 Basic Structure of TRIZ
6.3 Level of Invention
6.4 History of TRIZ
6.5 About the Founder of TRIZ
6.6 Contradiction as a Means to Formulate an Inventive Problem
6.7 Procedure of Inventive Design
6.8 Concept Development Using TRIZ
6.9 Contradiction Matrix (39 × 39)
6.10 Using the TRIZ Matrix
6.11 Physical Contradiction Resolution
6.12 Ideality and the Ideal Final Result (IFR)
6.13 TRIZ Crossover QMS
6.14 The Evolutionary S‐Curve
6.15 Nine Windows
6.16 Trends of Engineering System Evolution
6.17 Geometric Evolution of Linear Constructions
6.18 Trimming
6.19 Input–Output–Trimming Operator (I–O–T)
6.20 Resource Analysis
6.21 Function Analysis
6.22 Substance‐Field Analysis
6.23 Tool‐Object‐Product (TOP) Function Analysis
6.24 Generic Model of a Function
6.25 TRIZ Offers Five Basic Function Models
6.26 Psychological Inertia
6.27 Size‐Time–Cost Operator
6.28 Applying the 40 Inventive Principles in Corrosion Management
6.29 Conclusion
6.30 Glossary of TRIZ Terms
6.A TRIZ Contradiction Table
References
7 Environmental Impacts of Corrosion and Assessment Strategies
7.1 Introduction
7.2 Some Uses of Rule 365
7.3 Conclusions
References
Index
End User License Agreement
List of Tables
Chapter 2
Table 2.1 Adhesion of a common zinc phosphate epoxy primer on the steel surf...
Table 2.2 Properties of tested abrasives in blasting.
Table 2.3 Effect of abrasives on adhesion of primer at humid and salty envir...
Chapter 3
Table 3.1 Consequence rating (F) of some consequence ratings.
Table 3.2 Some important features of corrosion control (CC) and corrosion pr...
Chapter 4
Table 4.1 GDP, expenditure approach (billions of dollars).
Table 4.2 Gross domestic income by type of income (billions of dollars).
Table 4.3 Value added by industry (billions of dollars).
Table 4.4 The Standard of National Account usage.
Table 4.5 The production account – uses.
Table 4.6 Industry‐by‐industry total requirements, after redefinitions (in p...
Table 4.7 Power plant operation and maintenance costs in the US in 2019, by ...
Chapter 5
Table 5.1 Various processes and their needs for different utilities in a ty...
Table 5.2 Utilities in a typical gas plant, their production processes, and...
Table 5.3 Details about process additives in hydrocarbon processing and off...
Table 5.4 Details about process additives in utility section of a typical g...
Table 5.5 Various main occurrences and their impacts on the entire operatio...
Table 5.6 Identified documents for each activity in EMPA.
Chapter 6
Table 6.1 List of TRIZ 40 inventive principles and their opposites.
Table 6.2 Technical contradiction examples.
Table 6.3 Physical contradictions examples.
Table 6.4 Idealization level behavior.
Table 6.5 Inventive principles related to trends of evolution.
Table 6.6 Resource analysis.
Table 6.7 Size–Time–Cost Operator.
List of Illustrations
Chapter 1
Figure 1.1 Corrosion engineering and its relation to other engineering disci...
Chapter 2
Figure 2.1 Two examples of severely corroded equipment leading into a throug...
Figure 2.2 Schematic presentation of electrochemical series with some reacti...
Figure 2.3 Some examples of active and passive metals in seawater at 25 °C f...
Figure 2.4 A typical Pourbaix diagram (simplified) for an Fe–water system at...
Figure 2.5 Materials selection chart for upstream exploration oil and gas in...
Figure 2.6 Carbon steel (hot rolled, cold rolled, and galvanized coils) pric...
Figure 2.7 Conceptualization of the elements of cathodic protection (CP); 1:...
Figure 2.8 Paint degradation on various substrates. (a) Rust on stainless st...
Figure 2.9 Paint defects because of Amin leakage on the equipment.
Figure 2.10 Paint checking due to weak resistance of the epoxy to the sunlig...
Figure 2.11 Lack of curing of ethyl silicate primer used in dry area.
Figure 2.12 Poor wetting and undesired mixing of primer components.
Figure 2.13 Chalking when the system exposes to sunlight because of the use ...
Figure 2.14 Some typical complications of the paints resulting from poor qua...
Figure 2.15 Examples of unqualified workers.
Figure 2.16 Some weakness of the surface preparation. Paint application on r...
Figure 2.17 Some examples of paint application problems. Rusting on primer d...
Figure 2.18 Weak inspection and management.
Figure 2.19 Rapid development of damage, especially in chemical and marine f...
Figure 2.20 Effective parameters on paint useful lifespan.
Chapter 3
Figure 3.1 Categorizing corrosion severity based on corrosion rates (general...
Figure 3.2 Damage of the inner layer of a protective coating applied inside ...
Figure 3.3 Risk categories and four zones created based on level of conseque...
Figure 3.4 An example of CUI (corrosion under insulation) on a piping which ...
Figure 3.5 Irritation situation zones, where P (probability) and C (conseque...
Figure 3.6 An example of corrosion reactions geometries.
Figure 3.7 An example of a rather complex corrosion geometry related to exte...
Figure 3.8 Corrosion safety procedure. The way corrosion must not proceed in...
Figure 3.9 Two alternative definitions of Zugzwang effect state. Based on th...
Figure 3.10 (a) A through‐wall hole (at 6 o'clock position) of a stainless s...
Figure 3.11 The relationship that exists between FFS, pseudo‐FFS, and Zugzwa...
Figure 3.12 Milestones in the life of an asset from its fresh state of FFS t...
Figure 3.13 Decision tree for corrosion management of a bioleaching tank bas...
Figure 3.14 Simplified schematic presentation of I/O model, where the output...
Figure 3.15 Components of an unsuitable workplace.
Figure 3.16 An example of a 115 month CKM scheme. This scheme is arbitrary a...
Figure 3.17 General schematic of a fire water ring as the corrosion system a...
Figure 3.18 Overall view of management of corrosion defined as per smart cor...
Figure 3.19 History of corrosion damage.
Chapter 5
Figure 5.1 Illustration of the limitations for presenting industrial cases....
Figure 5.2 The schematic of different operational processing units in a typi...
Figure 5.3 A schematic for the feeding of various chemicals into the utility...
Figure 5.4 Illustrating all process additive related details at different se...
Figure 5.5 Illustration of path event due to lack of generated steam influen...
Figure 5.6 How to deal with off‐spec products based on design in a typical g...
Figure 5.7 Schematic for off‐spec condensate (oily polluted) and its dumping...
Figure 5.8 Trends of laboratory results due to entry of non‐volatile organic...
Figure 5.9 Internal surface of a tube in a gas heater; corrosion products an...
Figure 5.10 Event schematic, sample points, and related analyzes.
Figure 5.11 Relationship between various impacts for consumption of chemical...
Figure 5.12 The schematic for influent streams and OWTP.
Figure 5.13 Gas condensate stabilization unit with off‐spec tank.
Figure 5.14 Acid corrosion at top of stabilization column (vapor outlet pipi...
Figure 5.15 Presentation of overdosing of a reverse demulsifier chemical int...
Figure 5.16 Free‐oil layer on clarifier next to a BIOX filter (BIOX filter w...
Figure 5.17 A corrosion coupon placed under oil layer in OWIS with occurred ...
Figure 5.18 Location of OWTP, off‐spec condensate tank, and an installed che...
Figure 5.19 Marine animal growth in a MED–TVC.
Figure 5.20 Seawater intake facilities and gas plant's utilities, chemical f...
Figure 5.21 Seawater desalination package, its quality control logic and dum...
Figure 5.22 Underdeposit corrosion in a water tube utility boiler.
Figure 5.23 Seawater desalination, desalinated water distribution, steam gen...
Figure 5.24 A corroded metal pipe in desalinated water distribution system....
Figure 5.25 Daily monitoring of LSI, AI, and residual chlorine in two identi...
Figure 5.26 A completely clogged nozzle of calcium chloride feed prior to dr...
Figure 5.27 Laboratory results for boiler D in steam‐generating unit.
Figure 5.28 Trends of pH in five operating boilers.
Figure 5.29 Specific conductivity trend for BW in boiler D.
Figure 5.30 Seawater desalination unit, its related sample points, and chemi...
Figure 5.31 Classification the impacts of chemical corrosions and impacts of...
Figure 5.32 A framework for EMPA.
Figure 5.33 Two corrosion coupons in same location of a sour water transferr...
Figure 5.34 A standard corrosion coupon in firewater system in low pH condit...
Figure 5.35 Biological growth on both sides of the cylinder (corrosion coupo...
Figure 5.36 Corrosion monitoring coupon in the firewater system before and a...
Figure 5.37 Corrosion monitoring coupon in the firewater system. There were ...
Figure 5.38 A standard coupon in glass holder (top left) and removed from th...
Figure 5.39 Improper storage of calcium chloride in an open warehouse at a t...
Figure 5.40 All steps in consumption of a chemical in a processing site.
Figure 5.41 A corroded plug of seawater feed valve to series of heat exchang...
Figure 5.42 Precipitation on a tube bundle of a kettle type reboiler in a so...
Figure 5.43 Same bundle after cleaning (localized corrosion, pits, are clear...
Figure 5.44 A liquid chemical feed package and its minimum requirement.
Figure 5.45 Two algorithms of feeding a chemical into a process stream.
Figure 5.46 Calibration graphs; (a) variable speed and variable stroke feed ...
Chapter 6
Figure 6.1 Basic structure of TRIZ.
Figure 6.2 Tool, Method, & Philosophical Levels of Systematic Innovation.
Figure 6.3 Reducing the contradiction.
Figure 6.4 General procedure for inventive design with TRIZ.
Figure 6.5 Process of concept development using TRIZ.
Figure 6.6 Altshuller's contradiction matrix.
Figure 6.7 The Four‐Box Scheme of Problem Solving Supported by Knowledge Bas...
Figure 6.8 A portion of the contradiction matrix.
Figure 6.9 Four major “Systematic Creativity” steps.
Figure 6.10 Example; Water faucets.
Figure 6.11 Example: Hot and cold water handles.
Figure 6.12 Example; Motorcycle chain.
Figure 6.13 Example; The Crayola kids crayons.
Figure 6.14 Moving from corrosion problem to IFR.
Figure 6.15 The fundamental dynamic of system evolution.
Figure 6.16 Nine windows matrix.
Figure 6.17 Hierarchy of trends.
Figure 6.18 Trend of increasing value and s‐curve evolution.
Figure 6.19 “Substance and Object Segmentation” trend.
Figure 6.20 “Substance and Object Segmentation” trend example for measuremen...
Figure 6.21 “Geometric Evolution of Linear Constructions” trend.
Figure 6.22 Example for straws' geometric evolution of linear constructions'...
Figure 6.23 Mono‐Bi‐Poly trend.
Figure 6.24 Mono‐Bi‐Poly trend for knife.
Figure 6.25 Mono‐Bi‐Poly trend for wrenches.
Figure 6.26 Trimming and system development.
Figure 6.27 Models of the simplest useful system.
Figure 6.28 Models of an incomplete useful system.
Figure 6.29 Model of the simplest system having a harmful action.
Figure 6.30 Model of a useful function.
Figure 6.31 Model of a harmful function.
Figure 6.32 Model of a conflict.
Figure 6.33 The TRIZ approach to overcome the psychological inertia in desig...
Figure 6.34 STC is a three‐dimensional thinking between 0 and ∞.
Chapter 7
Figure 7.1 A leaking underground oil pipeline [7].
Figure 7.2 A flow chart to determine the responsibility domain of parties in...
Figure 7.3 Competing trends between energies from fossil fuel sources in com...
Figure 7.4 Damaged concrete, probably the corrosive impact of chlorides comi...
Figure 7.5 A Pourbaix diagram for iron–water system with the presence of chl...
Figure 7.6 Conceptualization of the fate of petroleum hydrocarbons in a grou...
Figure 7.7 Toxicity anatomy of corrosion effects.
Figure 7.8 A suggested model to apply Rule 365 to deal with corrosion effect...
Guide
Cover Page
Title Page
Copyright Page
Dedication Page
Preface
Authors and Contributors
Table of Contents
Begin Reading
Index
Wiley End User License Agreement
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Corrosion Policy Decision Making
Science, Engineering, Management, and Economy
Edited by
Reza Javaherdashti
Eninco Engineering B.V.
The Netherlands
This edition first published 2022© 2022 John Wiley and Sons, Inc.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, except as permitted by law. Advice on how to obtain permission to reuse material from this title is available at http://www.wiley.com/go/permissions.
The right of Reza Javaherdashti to be identified as the author of the editorial material in this work has been asserted in accordance with law.
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Library of Congress Cataloging‐in‐Publication Data
Names: Javaherdashti, Reza, editor.Title: Corrosion policy decision making : science, engineering, management, and economy / edited by Reza Javaherdashti.Description: First edition. | Hoboken, NJ : Wiley, 2022. | Includes bibliographical references and index.Identifiers: LCCN 2021031559 | ISBN 9781119764311 (hardback) | ISBN 9781119764328 (adobe pdf) | ISBN 9781119764335 (epub)Subjects: LCSH: Corrosion and anti-corrosives.Classification: LCC TA462 .C65675 2022 | DDC 620.1/1223–dc23LC record available at https://lccn.loc.gov/2021031559
Cover Design: WileyCover Image: © Phonix_a Pk.sarote/Shutterstock
To:Nikola TeslaThe man who changed the world
Preface
Corrosion Management (CM) has become a very hot topic these days. Many professional groups related to corrosion from the USA to Australia invite their corrosion experts to give lectures/webinars on this topic. There are two common points among all these lectures and webinars; one is that the lecturers speak about how to address corrosion in their own industries and presumably manage it to an audience who are themselves corrosion professionals, and the other is that the invited speakers are always corrosion professionals themselves. Management of matter, that in our understanding is equal to CM, is no less important than management of energy, and therefore it must be explained in such a way that non‐corrosionists also understand and appreciate it. Namely, politicians, non‐corrosionist engineers and professionals, economists and environmentalists must also realize the significance of corrosion and its proper management.
The theme of CM has become so repetitive and predictable that one can envisage almost the entirety of the content: a few words about the economy of corrosion (normally borrowed from figures given in some well‐known websites); a few words about the systems(s) in which corrosion is of interest (or rather, what the speaker has some experience about); how the corrosion has been recognized and addressed technically in these systems; and then the section entitled “Lessons to Learn.”
However, none of these webinars or lectures point out matters which are out of “the box of corrosion”: there are no words about the impact of the thermodynamic nature of corrosion or its management and the difficulties it creates, or how to explain and control ecological measures imposed by corrosion and CM techniques, nor is there anything related to how creativity can be an essential issue in finding solutions for corrosion problems.
This book is first of its kind that looks at corrosion not just as a technical matter but as a multidisciplinary issue that involves many skills and faculties—mainly non‐technical in the sense that engineering literature and nomenclature are considered technical.
In this book we have tried to show that while due to the thermodynamic nature of corrosion, it cannot be stopped. It is necessary to recognize many misunderstandings associated with corrosion (such as the difference between corrosion prevention and corrosion control) and redefine many basic concepts (such as the concept of failure within the context of introducing the terms pseudo‐FFS and Zugzwang effect state) to understand it correctly from a practical point of view that can be called Management.
We would also like to call our approach toward CM “Smart Management of Corrosion” in the sense that it has the capability to adapt itself with all industries, not just a few, and also because management of corrosion benefits from contributions from both CM and Corrosion Knowledge Management (CKM).
We hope our readers will enjoy reading this book as much as we did writing it and applying its principles in our daily professional lives!
Reza Javaherdashti
The Netherlands
April 2021
Authors and Contributors
R. Javaherdashti
General Manager, Eninco Engineering B.V., The Netherlands
PhD (Materials science–Corrosion)
More than 25 years of experience; successfully delivered 400+ projects in corrosion management, problem‐solving, expert‐witnessing, and Root Cause Analysis in various industries globally
Certified corrosion and MIC lecturer by ASME (USA) and Society of Petroleum Engineers (USA)
Performed 5000+ hours of teaching corrosion management and MIC to various industries (from oil & gas to mining, aviation, and chemical industries worldwide)
Authored/co‐authored several internationally referenced books on corrosion (published by Elsevier, Springer, CRC Press, etc.) as well as research papers and Root Cause Analysis reports
E‐mail:
LinkedIn profile:
https://www.linkedin.com/in/dr‐reza‐javaherdashti‐9a2a2415/
F. Javaherdashti
Senior advisor at IMI (Industrail Management Institute), I.R. Iran
PhD (Management)
Senior advisor in business management, branding, and CRM
More than 28 years of experience in national and international management consulting
More than 10,000 hours of teaching management principles and consultancy for several industries
E‐mail:
A. Ghanbarzadeh
Research at RIPI (Research Institute of Petroluem), I.R. Iran
M.Sc. (Chemical Engineering)
Academic member and Head of research projects on protective coatings at RIPI
31 years of work experience
Authored four books and 12 papers
E‐mail:
LinkedIn profile:
https://www.linkedin.com/in/ali‐ghanbarzadeh‐a5abba55/
M. Mostashar Nezami
CEO, AtavArt, privately held co, I.R. Iran
MA in General Economics and BS in Accounting
More than 17 years of experience in the accounting, financial, and economic studies
Carried out an 8‐year research study in the economics of renewable energies, and introduced an applicable way for using renewable energies as resident's daily energy
More than 400 hours teaching of Accounting, Finance Management, and Economics
Attended “Model Thinking” traing course offerd by University of Michigan
Wrote more than ten articles in economic analysis in the National Press
E‐mail:
LinkedIn profile:
https://www.linkedin.com/in/mahsa‐mostashar‐nezami‐a539b578
M.R. Hamedghafarian
Senior Process Engineer of Gas Plants Utilities & Off‐Sites, Ministry of Petroleum, I.R. Iran
M.Sc. in Advanced Chemical Engineering
B.Sc. in Chemical Engineering (natural gas processing)
Committee member / Gas Plant Corrosion
Chairman Committee / Baseline Pollution Determination in gas plants (Wastewater Treatment)
More than twelve years of experience in operation and design of gas processing plants (Reception Facilities and Utilities)
Seven papers in classical thermodynamics, corrosion, environment, process additives management, and CO
2
capture in Iranian congresses
Translation of two books on water treatment chemicals, and technical report writing in chemical engineering
More than 1000 hours teaching Troubleshooting in Utility Processes, Corrosion, Heat Exchanger Design, Industrial Wastewater Treatment, Process Engineering Documentation, and Water Treatment topics in Refineries and Gas plants
Associate member of technical staff in Iranian Corrosion Association
Member of Iranian Society of Engineering Education
E‐mail:
LinkedIn profile:
https://www.linkedin.com/in/mohamedreza‐hamedghafarian‐955463a0/
M. Basirzadeh
Board member at Kavosh Meyar Tabasum Pasargad Company
Industrial Management MSC, Tehran Amirkabir University
Iranian TRIZ teacher and consultant
Author of four books in Farsi language about TRIZ and creativity
E‐mail:
LinkedIn profile:
https://www.linkedin.com/in/mehdi‐basirzadeh‐4980481
1Introduction
Reza Javaherdashti
General Manager, Eninco Engineering B.V., The Netherlands
This book is a first‐hand answer to two questions:
What
corrosion management
(
CM
) really means;
What to expect from CM.
Let us be more specific in describing what we mean by the above. For those of you who have been too engaged with your integrity management tasks that cannot find time to watch movies and particularly horror movies, I do recommend to watch the movie “Final Destination; Part 5,” and watch it with the eyes of a corrosion/integrity management specialist. In this movie (and its previous parts) what is shown is that something of little importance goes wrong, and in a series of unpredictable, sad events, one (or sometimes more) of the actors are killed in a very dramatic, graphic way. As said, the main lesson learned from this movie is that one problem can lead to another and in the end, a catastrophic result occurs. The same is also true with neglecting corrosion in an integrity management plan; something that one would think is not that important will lead to another, and if it is in its “pseudo‐FFS1” (Fit‐For‐Service State) stage, the result at its best could be arriving at a “Zugzwang effect” [1] stage, or simply said, failure.
In classical academic literature related to Management and its principles, perhaps one of the best definitions have been given by Henry Fayol as “To manage is to forecast and to plan, to organize, to command, to co‐ordinate and to control [1].” On the other hand, corrosion has also a clear definition that can be simplified as the chemical reaction between an electron donor (anode) and electron receiver (cathode) via a medium that allows exchange of ions and a metallic path that allows electron transfer.2 However, what is CM? In fact, when it comes to corrosion science, we know that we are talking about laboratories, white‐collar researchers, academic environments, and the search for understanding fundamentals and mechanisms of corrosion processes. In this context, innovation and how innovative research must be carried out is of fundamental significance. When we talk about corrosion engineering, it is the way the accumulated science and knowledge about corrosion and corrosion processes will become applicable in the field. For instance, the use of cathodic protection to let structures survive longer, or use of corrosion inhibitors and biocides to chemically control corrosion. Figure 1.1 can serve to show the essential elements of corrosion engineering and how corrosion engineering and other engineering disciplines are interconnected with each other. We see that when talking about corrosion engineering, we are actually talking about a multidimensional topic that in its wholeness is more complex than other engineering disciplines not in based on the subject of focus, but on the methodologies that apply to address corrosion and its various aspects such as monitoring and treatment:
Figure 1.1 Corrosion engineering and its relation to other engineering disciplines (right), essential features and components of corrosion engineering (left) (Used by permission from Eng. Riky Bernardo – Qatar).
All of these applications have their own codes and standards. When we talk about corrosion treatment, we know that we are talking about five strategies to deal with corrosion (physical measures, chemical measures, electrical measures, mechanical measures, and design/material selection measures). Corrosion monitoring is to address methods and technologies by which severity of corrosion within its course of action is studied by codes and measures pertaining to corrosion monitoring. All of the above bring to mind certain codes, working environments and specialties, and expertise. However, what is CM? It obviously has a part dealing with corrosion and a part dealing with management. The confusion arises from here; how can management which is seeming a non‐technical issue, be matched with corrosion which is a highly technical issue?
All the materials written to date on the management of corrosion are just looking at the science/engineering, and to some extent economy of corrosion, without detailing with the actual requirements (for example, about the economic nomenclature that is needed to understand cost of corrosion). Some of the publications about CM do suffer from the defects mentioned above. Some examples of CM literature are:
A. Morshed, “An Introduction to Corrosion Management in Industry,” NACE, USA, 2017.
A. Morshed, “An Introduction to Asset Corrosion Management in the Oil and Gas Industry, 2nd edition,” NACE, USA, 2016.
A.S. Groysman, “Corrosion Problems and Solutions in Oil Refining and Petrochemical Industry,” Springer, 2017.
“My Manual: Practical Corrosion Management,” a manual published by IDC Technologies, 2009, Perth, Australia.
Even IMPACT report by ex‐NACE (now AMPP) that was published in 2016 had some sections on management and economy without any focus on engineering and science aspect of corrosion.
No economist, environmental sciences specialist, or a non‐technical manager is likely to read those books (and similar ones) or attend CM seminars and webinars. The reason is simple; corrosion has not been defined for these non‐corrosionist professionals. Perhaps, the importance of corrosion has sometimes been flagged by some politicians,3 as well as passing bills to allow the establishment of certain corrosion related entities, say, within the army, but apart from those individual sparks, no overall, systematic understanding about corrosion and its various aspects exists yet.
Our iconoclast approach toward CM is what we call “Smart Management of Corrosion” in the sense that (i) it is smart because this system can adapt itself with any industry and, contrary to the existing assumption that CM is to be discussed within the context of a certain industry (oil and gas), smart management of corrosion is not industry‐specific; and (ii) it focuses of the management side rather+ than the corrosion side. Our understanding is that current CM systems mainly deali with the risk of corrosion, however it is essential to also deal with the cost of corrosion, whether economic cost or ecological cost. Management of corrosion is a term that acts as an umbrella to both CM (risk of corrosion) and corrosion knowledge management (CKM) (cost of corrosion) simultaneously and being as such, Management of Corrosion is a more general term than CM alone.
There are three very important features about corrosion:
Corrosion and Failure: Corrosion is inevitable and manageable; failure is inevitable and non‐manageable. Being non‐manageable does not mean that it cannot be prevented, it simply means that when failure happens, it happens! This distinguishment between these two terms if of vital importance; the prejudice of many who deal with corrosion issues is that they are entitled to find a way to prevent or control corrosion.
4
Corrosion occurs anyway due to the thermodynamic nature of it, it is our duty, though, to prevent failures. It is through failures and leaks that not only economic costs are imposed (from shut down costs to maintenance and replacement), but also environmental effects also occur. Study of corrosion processes ending in leak and failure is the task of a corrosion specialist, post‐mortem forensic investigation of the failure is what a forensic investigator does to help build a root cause analysis report, but who is to measure the seriousness of the environmental effects thus produced? Who is going to estimate the economic loss (direct cost and indirect cost)?
Risk and Likelihood: If the likelihood of getting a certain type of corrosion‐related failure is low, it does not necessarily mean that is risk is also low and vice versa. The confusion between risk and likelihood is with no doubt one of the most important sources of problems that can even reach to the level of disasters. It is the mindset that can be observed in industry quite frequently and it has the potential of being lethal.
Corrosion and Aging: Aging implies that a structure has been in service for quite a long time, whereas corrosion can actually occur in structures right after being put into service. Therefore, corrosion‐related failures could happen in structures after a relatively short period of service (sometimes months).
In our professional judgment, management of corrosion needs to address all aspects of corrosion as we have tried to do in this book; corrosion and the algorithm of innovation (TRIZ; the Theory of Inventive Problem Solving) have been covered to the required extent in Chapters 2 and 6. In Chapter 2, some important aspects of corrosion science is re‐defined, that is, as much as needed. The engineers looking after corrosion issues may not themselves have attended pre‐employment corrosion courses, and thus during their employment years they attend courses or conferences with specific titles, or even learn from each other and/or their colleagues verbally. There is a very small minority who, with a pre‐employment background in corrosion, still keep their knowledge up to date. This author during his more than two decades of consulting, as well as education training courses, has seen these issues very clearly.
The executive force for any management of corrosion scheme is humans and not robots, although we often forget this. Along with it, we also happen to forget the golden wisdom “To err is human.” In fact, a great number of industrial disasters—including those related to corrosion—stem from human error. One of the ways by which human error can be highly decreased is via training. In IMPACT report by AMPP, the cost for training is not mentioned as cost but as investment. Creating motivation and paying special attention to training is of paramount significance in a corrosion knowledge management (CKM) scheme, and is an integral part of smart management of corrosion. In addition to the science of corrosion, it is important to find the best way to invent solutions. With decades of splendid past, TRIZ can be an instrumental factor in creating innovation patterns. This author has shown the application power of TRIZ in some of his publications. Researchers need to be familiar with TRIZ to find better solutions which are innovative and feasible particularly in the field of management of corrosion.
The heart of this book which is Smart Management of corrosion is the topic of Chapter 3. Engineering aspects of corrosion is explained in Chapter 5. No matter what our interpretation about management of corrosion, understanding corrosion in action is a must.
Discussing enough about economics as required to define corrosion damage is addressed in Chapter 4, whereas environmental effects of corrosion has been addressed in Chapter 7.
This book is highly likely to experience a “Semmelweis Reflex” which essentially means “to stick to preexisting beliefs and to reject fresh ideas that contradict them [2]. No literature of CM known to us issues such details of economy, environment, TRIZ, and innovative interpretation of CM as we will cover in this text.
References
1
Aquinas, P.G. (2011).
Principles and Practices of Management
. Phagwara, India: Lovely Professional University.
2
Gupta, V. K., Saini, C., Oberoi, M. et al. (2020) “Semmelweis Reflex: An Age‐Old Prejudice,”
World Neurosurgery
.
https://pubmed.ncbi.nlm.nih.gov/31837492
, last visited 13 February 2021.
Notes
1
Please study
Chapter 3
for a better understanding of these terms.
2
The metallic path when referred to corrosion under real life conditions has no meaning because corrosion already is taking place on metals.
3
https://www.defenseindustrydaily.com/Sen‐Tom‐Coburn‐Americas‐Fiscal‐Defense‐Crisis‐06412
, last visited 15 February 2021.
4
Corrosion prevention and corrosion control are not the same and cannot be used interchangeably. We will get back to this concept later in this book.
