Corrosion Failures : Theory, Case Studies, and Solutions.

Cover -- Title Page -- Copyright -- Contents -- About the Authors -- Foreword -- Preface -- Chapter 1 Introduction -- 1.1 The Phenomenon of Corrosion -- 1.2 Importance of Corrosion -- 1.2.1 Cost of Corrosion: Direct and Indirect -- 1.3 The Purpose and Format of the Book -- References -- Chapter 2 Thermodynamics and Kinetics of Electrochemical Corrosion -- 2.1 Introduction -- 2.2 Thermodynamics -- 2.2.1 Corrosion Reactions and Gibbs Free Energy Change -- 2.2.2 Electrochemical Nature of Corrosion -- 2.2.3 Summary -- 2.3 Kinetics of Corrosion -- 2.3.1 Description of a Corrosion System -- 2.3.2 Predicting Corrosion -- 2.3.3 Passivity -- 2.3.4 Summary -- 2.4 Corrosion Evaluation and Monitoring -- 2.4.1 Electrochemical Techniques -- 2.4.2 Non-electrochemical Techniques -- References -- Chapter 3 Forms of Corrosion -- 3.1 Introduction -- 3.2 Uniform Corrosion -- 3.3 Galvanic Corrosion -- 3.3.1 Factors Affecting Galvanic Corrosion -- 3.3.2 Controlling Galvanic Corrosion -- 3.4 Pitting Corrosion -- 3.4.1 Pitting Process and Pitting Morphology -- 3.4.2 Factors Affecting Pitting Corrosion -- 3.4.3 Controlling Pitting Corrosion -- 3.5 Differential Aeration-Assisted Corrosion (Crevice, Under Deposit, and Water-Line Corrosion) -- 3.5.1 Characteristics of Differential Aeration Corrosion -- 3.5.2 Factors Affecting Differential Aeration Corrosion -- 3.5.3 Differential Aeration Corrosion Control -- 3.6 Intergranular Corrosion -- 3.6.1 IGC of Stainless Steels -- 3.6.2 Weld Decay of Stainless Steels -- 3.7 Selective Dissolution/Selective Attack -- 3.7.1 Characteristics of Selective Dissolution -- 3.7.2 Dezincification -- 3.7.3 Graphitic Corrosion -- 3.8 Flow-Assisted/Erosion/Cavitation Corrosion -- 3.8.1 Flow-Assisted Corrosion (FAC) -- 3.8.2 Erosion Corrosion -- 3.8.3 Cavitation Damage -- 3.9 Stress Corrosion Cracking -- 3.9.1 Characteristics of SCC.

3.9.2 Effect of SCC on Mechanical Properties -- 3.9.3 Factors Affecting SCC -- 3.9.4 Controlling SCC -- 3.10 Hydrogen Damage -- 3.10.1 Low Temperature Hydrogen-Induced Cracking -- 3.10.2 High Temperature Hydrogen Damage/Decarburization -- 3.11 Stray Current Corrosion -- 3.12 High Temperature Corrosion -- 3.12.1 Oxidation -- 3.12.2 Sulfidation -- 3.12.3 Hot Corrosion -- 3.12.4 Chloridation -- 3.12.5 Carburization/Metal Dusting -- References -- Chapter 4 Materials of Construction for Chemical Process Industries -- 4.1 Introduction -- 4.2 Cast Irons -- 4.3 Carbon Steels -- 4.3.1 Corrosion -- 4.3.2 Stress Corrosion Cracking, Including Hydrogen Cracking and Sulfide Stress Cracking -- 4.3.3 Caustic Stress Corrosion Cracking -- 4.3.4 Favorable and Unfavorable Points in Using Carbon Steel as MOC -- 4.4 Low Alloy Steels -- 4.5 Stainless Steels -- 4.5.1 Ferritic/Martensitic Stainless Steels -- 4.5.2 Austenitic Stainless Steels -- 4.5.3 Super Austenitic Stainless Steels -- 4.5.4 Duplex 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 -- 4.13.1 Materials Selection as per NACE MR0175 -- 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 -- 5.3.1 Site Visit -- 5.3.2 Tests on the Samples -- 5.3.3 Analysis, Interpretation, and Diagnosis of the Failure -- 5.4 Failure Analysis Report: Contents and Preparation -- References -- Chapter 6 Case Studies -- 6.1 Preamble -- Classification of Case Studies -- General -- CASE STUDY 1 Bromine Preheater in a Pharmaceutical Fine Chemical Plant.

CASE STUDY 2 Structurals in a White Clay Manufacturing Plant -- CASE STUDY 3 Sea Water Cooler Tubes in an Oil Refinery -- CASE STUDY 4 Package Boiler Tube in an Organic Chemical Plant -- CASE STUDY 5 Shell of a Packed Column for Ammonia and Water Contact in an Ammonia Processing Plant -- CASE STUDY 6 Instrumentation Tube in an Offshore Platform of an Oil and Gas Plant -- CASE STUDY 7 Plate Type Heat Exchanger/Cooler in a Sulfuric Acid Plant -- CASE STUDY 8 Dissimilar Stainless Steel Weld in an Organic Chemical Plant -- CASE STUDY 9 Digestor Preheater in a Pulp and Paper Plant -- CASE STUDY 10 Esterification Column in an Organic Chemical Plant -- CASE STUDY 11 Half Pipe Limpet Coil of a Stirred Reactor in an Organic Chemical Plant -- CASE STUDY 12 Firewater Lines Buried Underground in an Organic Chemical Plant -- CASE STUDY 13 Alcohol Superheater in a PVC Manufacturing Petrochemical Plant -- CASE STUDY 14 Package Boiler Tubes in an Alcohol Distillery Plant -- CASE STUDY 15 Reducers in a Reformer Tube in an Ammonia Plant of a Fertilizer Industry -- CASE STUDY 16 Pressure Safety Valve (PSV) Fitting on Instrumentation Tubes in an Off-shore Platform in an Oil and Gas Company -- CASE STUDY 17 Water Drum (Mud Drum) Shell in a Coal-Fired Steam Boiler -- CASE STUDY 18 Tubes in a Kettle Re-boiler of an Amine Plant -- CASE STUDY 19 Evaporator Tubes in an Organic Chemical Plant -- CASE STUDY 20 Top Tube Sheet Vent Equalizer Weld Zone of a Gas Cooler in a Petrochemical Plant -- CASE STUDY 21 Bottom Row Tubes in a Kettle Re-boiler of an Organic Chemical Plant -- CASE STUDY 22 Cages for Filter Bags in an Inorganic Chemical Plant -- CASE STUDY 23 High Temperature Generator (HTG) Tubes of Vapor Absorption Chiller of an Air-Conditioning and Refrigeration Unit -- CASE STUDY 24 Gasket Seat in a Shell and Tube Condenser in a Petrochemical Plant.

CASE STUDY 25 Acid Gas CO2 Cooler Condenser in Ammonia Plant of a Fertilizer Unit -- CASE STUDY 26 Naphtha Coolers in a Fertilizer Plant -- CASE STUDY 27 U Type Jet Dyeing Machine in a Textile Dyeing Unit -- CASE STUDY 28 Acetic Acid Manufacturing Unit in a Petrochemical Plant -- CASE STUDY 29 Large Stainless Steel Pipeline in a Urea Plant of a Fertilizer Unit -- CASE STUDY 30 Heat Recovery System of a PVC Unit in a Petrochemical Plant -- CASE STUDY 31 EDC Furnace Coil of a PVC Plant in a Petrochemical Unit -- CASE STUDY 32 Internals of a Stirred Reactor Processing Ortho Phosphoric Acid -- CASE STUDY 33 Salt Evaporator -- CASE STUDY 34 Cooler/Condenser Tubes of an Absorption Chiller Machine of an Airconditioning Plant -- CASE STUDY 35 Nitro Mass Cooler in an Organic Chemical Plant -- CASE STUDY 36 Fertilizer Industry Ammonia Plant Natural Gas Feed Preheater Coil -- CASE STUDY 37 Petrochemical Unit. PVC Plant. Radiant Coils of the EDC Pyrolysis Furnace -- CASE STUDY 38 Exhaust Gas Boiler in a Sugar Mill -- CASE STUDY 39 Domestic Storage Water Heater -- CASE STUDY 40 Stirred Reactor in a Rubber Chemical Plant -- CASE STUDY 41 Stainless Steel Tubes During Long Storage in Packed Condition -- CASE STUDY 42 Fertilizer Plant. Ammonia Units. Secondary Waste Heat Boiler Tubes -- CASE STUDY 43 Hospital Hydroclave for Treating Wastes -- CASE STUDY 44 Petrochemical Plant. Phosgene Absorption Column Internals -- CASE STUDY 45 Fertilizer Unit, Ammonia Plant, Start-Up Preheater Outlet Line -- CASE STUDY 46 Petrochemical Plant, Underground Fire-Water Pipelines -- CASE STUDY 47 Monel Clad Evaporator in a Pure Water Plant -- CASE STUDY 48 Loop Steamer Machine in a Textile Dyeing Unit -- CASE STUDY 49 Rubber Chemicals Plant: Leakage in Process Pipelines -- CASE STUDY 50 Clay Drier in a Clay manufacturing Plant -- CASE STUDY 51 Hydrogen Sulfide Processing Plant.

CASE STUDY 52 Textile Bleaching Vessel in a Dyeing Industry -- CASE STUDY 53 Condenser of an Absorption Chilling Machine in an Air-Conditioning Plant -- CASE STUDY 54 Petrochemical Complex: Lube Oil Cooler Tubes of Captive Gas Turbine Power Plant -- CASE STUDY 55 Petrochemical Plant: Plate Heat Exchanger (PHE) Exchanging Heat Between Spent Caustic and Vent Gas in a Cracker Plant -- CASE STUDY 56 Inorganic Chemical Plant: Distillation Pots -- CASE STUDY 57 Starch Industry: Economizer Tubes of High Pressure Captive Boilers -- CASE STUDY 58 Rubber Chemical Plant-Crump Slurry Tank -- CASE STUDY 59 Petrochemical Plant: Gas Cracker Unit, Dilute Steam Kettle Re-boiler -- CASE STUDY 60 Textile Dyeing Unit: Jet Dyeing Machine Shell -- CASE STUDY 61 Oil Refinery: 12 Inch Dia. Overhead Pipeline -- CASE STUDY 62 Fertilizer Plant: CO2 Compressor Inter-stage Cooler -- CASE STUDY 63 Oil Refinery: Flash Crude Heater Shell Cover Drain Nozzle -- CASE STUDY 64 Oil Refinery: Light Cycle Oil Steam Generator -- CASE STUDY 65 Organic Chemical Plant: High Pressure Autoclave in R&amp -- D Laboratory -- CASE STUDY 66 Fertilizer Industry: Captive Power Plant: Economizer Tube -- CASE STUDY 67 Inorganic Chemicals Plant: Reactor Shell -- CASE STUDY 68 Reactor for an Organic Chemical Plant -- CASE STUDY 69 Fertilizer Unit. Ammonia Plant. Primary Waste Heat Boiler -- CASE STUDY 70 Pulp and Paper Plant. TL Vertical Screen Inlet Line of the Paper Section -- CASE STUDY 71 Fertilizer Plant. Underground Sections of Cooling Water and Fire Hydrant Water Pipe Lines -- CASE STUDY 72 Thermal Power Plant. Condenser Cooling Sea Water In-take Line. Butter Fly Valve -- CASE STUDY 73 Petrochemical Plant. Pressure Transmitter Sensors -- CASE STUDY 74 Organic Chemicals Plant: Coolers and Condensors -- CASE STUDY 75 Organic Chemicals Plant: Alcohol Vaporizer.

CASE STUDY 76 Organic Chemicals Plant. Thermowells.

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