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51313-02220-Design Flaw Induced Corrosion

Picture for Design Flaw Induced Corrosion
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Product Number: 51313-02220-SG
ISBN: 02220 2013 CP
Author: Abdul Razzaq Al-Shamari
Publication Date: 2013
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Design Flaw Induced Corrosion (DFIC) is a new term coined by the authors to capture those corrosion failures in some exotic alloys that have occurred just after a few years of service – in some cases just two years. In DFIC corrosion failures occur by some known corrosion phenomena which actually should not exist due to the high grade of metallurgy used in construction of the equipment.

In the subject case a thermowell made of Monel metal and installed in a desalter corroded extensively and also perforated leading to leak of crude. This resulted in shut down of an entire unit for few days. The finding that Monel metal is highly compatible for the intended service and has failed within two years’ of service was an eye opener and lead to some gap analysis in the design stage.

This paper highlights the findings of an investigation of a failure of thermowell made from Monel material. Monel is highly resistant to chloride attack. But the thermowell still failed by extensive corrosion in a very short duration of two years. The failure is combination of galvanic action and then corrosive attack by iron chloride on Monel.

The paper discusses at length the conditions under which the Monel material had undergone aggravated corrosion and also discusses a few remedies.

Key words: Design flaw corrosion.
 

Design Flaw Induced Corrosion (DFIC) is a new term coined by the authors to capture those corrosion failures in some exotic alloys that have occurred just after a few years of service – in some cases just two years. In DFIC corrosion failures occur by some known corrosion phenomena which actually should not exist due to the high grade of metallurgy used in construction of the equipment.

In the subject case a thermowell made of Monel metal and installed in a desalter corroded extensively and also perforated leading to leak of crude. This resulted in shut down of an entire unit for few days. The finding that Monel metal is highly compatible for the intended service and has failed within two years’ of service was an eye opener and lead to some gap analysis in the design stage.

This paper highlights the findings of an investigation of a failure of thermowell made from Monel material. Monel is highly resistant to chloride attack. But the thermowell still failed by extensive corrosion in a very short duration of two years. The failure is combination of galvanic action and then corrosive attack by iron chloride on Monel.

The paper discusses at length the conditions under which the Monel material had undergone aggravated corrosion and also discusses a few remedies.

Key words: Design flaw corrosion.
 

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