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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.
In oil and gas production and transportation dissimilar materials are frequently combined for technical and economic reasons. However the combination of dissimilar metals can result in corrosion due to galvanic or bimetallic effects. The driving force for this kind of corrosion is the difference of the corrosion potentials of the individual materials in the given environment which causes element currents the magnitude of which depends on the sum of all system resistances (Ohmic Law). Any assessment of the corrosion rates at bimetallic couplings needs the information on the corrosion (rest) potentials of the bimetallic partners in the relevant medium.Due to the lack of consistent literature data a practical galvanic series was established in this work for standard oil country tubular goods (OCTG) steels corrosion resistant alloys (CRA) as well as graphite (as gasket material) in a model sweet upstream environment. From polarization resistance measurements information was obtained on the corrosion rate of the C-steels in the absence of bimetallic coupling. Furthermore the corrosion rates encountered at the partners of bimetallic couples were quantified via mass loss measurements. The results of this work allow better assessment of the severity of bimetallic corrosion and hence a more appropriate selection of materials which prevents corrosion failures increases the integrity of assets and saves costs.
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