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On March 8, 1862 in Hampton Roads, Virginia the first iron clad vessel on the seas, the CSS Virginia (known to Northerners as the Merrimac), had its way with the navy of the Union. It was able to sail unmolested among the ships of the Union Navy and fire at will while taking hits itself with impunity. When dusk arrived the Virginia went to anchorage to wait for sunrise when it could inflict more damage.
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Biocides are used in hydraulic fracturing operations to control the growth of contaminant microorganisms that lead to corrosion, souring, and conductivity loss.1,2 A variety of biocides are utilized and can be classified by mechanism of action, speed of kill, and the length of residual activity.In general, rapid-acting biocides such as chlorine dioxide (ClO2) and DBNPA (2,2-dibromo-3- nitrilopropionamide) inactivate bacteria quickly but have little to no residual activity. Glutaraldehyde (Glut) reacts more slowly and provides some residual activity, particularly at lower wellbore or reservoir temperatures.
Metal loss due to corrosion is a universal phenomenon in refineries which could in turn cause leakage or explosion if not well monitored. There are several units in a refinery such as crude distillation unit, hydro-processing unit, acid alkylation unit, etc. In each unit, there are hundreds of pressure vessels which have different potential damage mechanisms. Hence, it’s critical to establish an effective and efficient way to monitor thickness changing behavior.
For the design and materials selection of equipment in chemical plants the focus seems to mainly be on the “chemicals” but it is actually the water (steam) that causes corrosion issues in many cases. This paper presents two cases that demonstrate the poor design and materials selection that ended up causing severe corrosion issues. In both cases the equipment are fixed tubesheet type of heat exchangers (one is vertical and another is horizontal) and the concerned materials are mainly 300 series stainless steels. The root causes of failure in these two cases are due to poor design and non-ideal materials selection.Key words: Materials Selection Heat Exchangers Fixed Tubesheet Stress Design.PRESENTER BIOGRAPHYYouyu Lu Senior Corrosion Engineer Lloyd’s Register Energy Americas Inc.Vishal Lagad Senior Corrosion Engineer Lloyd’s Register Energy Americas Inc.Roxanna Alvarez Metallurgical Consultant Lloyd’s Register Energy Americas Inc.
Steel structures are often fabricated by bolting (or riveting) structural components together. Bolted joints result in multiple crevices between the bolted members and fasteners. These crevices are typically more susceptible to corrosion than flat surfaces because they tend to retain water/contaminants, they are difficult to properly coat, and the crevice geometry tends to support electrochemical phenomena that accelerate corrosion. This paper will evaluate the effectiveness of various coating practices at mitigating corrosion around these joints.
Protection of steel exposed to high temperature areas, in particular those which are insulated, provides some of the most demanding situations faced by coatings. Systems applied in these areas are required not only to give resistance to high operating temperatures (which are often cyclic) but also provide corrosion protection.
Extensive guidelines have been published for selecting where to search for corrosion under insulation (CUI). The guidelines are based on CUI failures and near misses. Piping CUI inspection programs collect the data outlined as relevant in specific company practices.
What would you say to someone if they accused you of intentionally accepting corrosion that led to damage or loss of military equipment, infrastructure and facilities or the injury, lost time, loss of lifer? The truth is, we do choose to accept corrosion and its negative consequences based on the tradeoffs/choices and limitations we are faced with. Scientists say that the average human makes thousands of decisions every day. Researchers at Cornell have found that the average human makes approximately 230 decisions a day on food alone.
Many industries are operating under severely limited O&M budgets and have been for some time. “Lean and mean” in today’s reality has become “mal-nourished and over stressed”. The last major corrosion study conducted in our industry showed a $276 Billion/Yr. deficit of which 75% was unrecoverable. Now a new study has determined that it is never too late to restore measurable viability to a facility's operation through adequate and proper preventive maintenance. This is good news, providing we can adequately demonstrate and use it.
Population growth in city centers has spurred the expansion and new construction of direct current (DC) powered transit systems throughout the world1. Despite stringent design criteria, quality assurance and quality control (QA/QC) monitored construction practices and ongoing track maintenance, it is a fact that DC stray current will eventually occur and negatively impact buried and/or submerged metallic structures immediately adjacent and within the transit right-of-way (ROW)2. In combination with other methods to reduce stray current such as high track-to-earth (TTE) resistance values and shorter distances between substations, transit agencies are specifying the welding of reinforced steel structures within their purview such as retaining walls and footings, approach slabs, aerial inverts, and bridge abutments to prevent stray current from reducing the design life of surrounding metallicstructures.
Fundamental aspects in the design and application of corrosion sensors, as well as challenges that may lead to the reporting of inaccurate or misleading corrosion data, has been discussed and illustrated by the case of under-deposit corrosion monitoring using a multi-electrode array.