XXX JSBO NBWBE DPN - dl.iran-mavad.com

1 corrosion WILEY SERIES IN CORROSIONR. Winston Revie, Series EditorCorrosion Inspection and Monitoring Pierre R. RobergeCorrosion Resistance of Aluminum and Magnesium Alloys: Understanding, Performance,and Testing Edward GhaliMicrobiologically Influenced corrosion Brenda J. Little and Jason S. LeeCorrosion Resistance of Aluminum and Magnesium Alloys Edward GhaliMetallurgy and corrosion control in Oil and Gas Production Robert HeidersbachGreen corrosion Inhibitors: Theory and Practice V. S. SastriHeterogenous Electode Processes and Localized corrosion Yongjun TanStress corrosion Cracking of Pipelines Y.

2 Frank ChengChallenges in corrosion : Costs, Causes, Consequences and control V. S. SastriCorrosion Failures: Theory, Case Studies, and Solutions K. Elayaperumal and V. S . R corrosion FAILUREST heory, Case Studies, and SolutionsK. ELAYAPERUMALC orrosion and Metallurgical Consultant, 3034, Sobha Amethyst, Kannamangala,Bangalore 560 067 RAJAP rofessor, Dept. of Metallurgical Engineeringand MaterialsScience,Indian Institute ofTechnologyBombay,Powai, Mumbai, Copyright 2015 byJohn Wiley&Sons, byJohn Wiley&Sons, Inc., Hoboken, NewJerseyPublishedsimultaneouslyin CanadaNo part of thispublicationmaybe reproduced,stored in a retrievalsystem,ortransmitted in anyformorbyanymeans, electronic,mechanical, photocopying, recording,scanning, or otherwise, except aspermittedunder Section 107 or 108 of the 1976 United StatesCopyright Act,withouteitherthe priorwritten permission of thePublisher, or authorization throughpayment of the appropriate per-copyfee tothe Copyright Clearance Center, Inc.

3 , 222 Rosewood Drive, Danvers, MA 01923, (978) 750-8400, fax(978) 750-4470, or on theweb thePublisher for permissionshouldbe addressed to thePermissionsDepartment, John Wiley&Sons, Inc., 111 River Street, Hoboken, NJ07030, (201) 748-6011, fax (201) 748-6008, or online at of Liability/Disclaimerof Warranty: While the publisher and author haveused their besteffortsinpreparingthisbook, theymake no representationsorwarrantieswith respect to the accuracyorcompletenessof the contentsof thisbook andspecificallydisclaimanyimpliedwarrant iesofmerchantabilityor fitnessfor a particular purpose. Nowarrantymaybe created or extended advice andstrategiescontainedhereinmaynot besuitableforyoursituation.

4 Youshould consultwith a professionalwhere appropriate. Neither the publisher norauthorshall be liable for anylossof profit or anyother commercial damages,includingbut not limited tospecial, incidental, consequential, or other information on our other productsandservicesor for technicalsupport, please contact ourCustomer Care DepartmentwithintheUnited Statesat (800) 762-2974, outside the United Statesat(317) 572-3993 or fax (317) a varietyof electronic content that appearsin printmaynot be available in electronic information about Wileyproducts,visit ourwebsite of Congress Cataloging-in-Publication Data:Elayaperumal, K. (Kailasanathan), 1937- Raja, (Vngaranahalli Srinivasan),1958- corrosion failures: theory,casestudies,andsolutions/K.

5 Elayaperumal, referencesand 978-0-470-45564-7 (cloth)1. corrosion and anti-corrosives. 2. Metals-Stresscorrosion 1223 dc232015000046 Cover RajaTypeset in 11pt/13ptTimesbyLaserwordsPrivate Limited, Chennai, IndiaPrinted in the United Statesof America109876543211 CONTENTSA bout the AuthorsxiiiForewordxvPrefacexvii1 The Phenomenon of corrosion , Importance of corrosion , Cost of corrosion : Direct and Indirect, The Purpose and Format of the Book, 6 References, 72 Thermodynamics and Kinetics of Electrochemical Introduction, Thermodynamics, corrosion Reactions and Gibbs Free Energy Change, Electrochemical Nature of corrosion , Summary, Kinetics of corrosion , Description of a corrosion System, Predicting corrosion , Passivity, Summary, corrosion Evaluation and Monitoring, Electrochemical Techniques, Non-electrochemical Techniques, 26 References, 273 Forms of Introduction, Uniform corrosion , Galvanic corrosion , Factors Affecting Galvanic corrosion .

6 Controlling Galvanic corrosion , Pitting corrosion , Pitting Process and Pitting Morphology, Factors Affecting Pitting corrosion , Controlling Pitting corrosion , Differential Aeration-Assisted corrosion (Crevice, Under Deposit,and Water-Line corrosion ), Characteristics of Differential Aeration corrosion , Factors Affecting Differential Aeration corrosion , Differential Aeration corrosion control , Intergranular corrosion , IGC of Stainless Steels, Weld Decay of Stainless Steels, Selective Dissolution/Selective Attack, Characteristics of Selective Dissolution, Dezincification, Graphitic corrosion , Flow-Assisted/Erosion/Cavitation corrosion , Flow-Assisted corrosion (FAC)

7 , Erosion corrosion , Cavitation Damage, Stress corrosion Cracking, Characteristics of SCC, Effect of SCC on Mechanical Properties, Factors Affecting SCC, Controlling SCC, Hydrogen Damage, Low Temperature Hydrogen-Induced Cracking, High Temperature Hydrogen Damage/Decarburization, Stray Current corrosion , High Temperature corrosion , Oxidation, Sulfidation, Hot corrosion , Chloridation, Carburization/Metal Dusting, 72 References, 724 Materials of Construction for Chemical Process Introduction, Cast Irons, Carbon Steels, corrosion , Stress corrosion Cracking, Including Hydrogen Crackingand Sulfide Stress Cracking, Caustic Stress corrosion Cracking, Favorable and Unfavorable Points in Using Carbon Steel asMOC, Low Alloy Steels, Stainless Steels, Ferritic/Martensitic Stainless Steels, Austenitic Stainless Steels, Super Austenitic Stainless Steels, Duplex Stainless Steels, Nickel Base Alloys, Copper Base Alloys, Titanium, Aluminum Alloys, Nonmetallic Materials, Ceramics/Inorganic Oxide Glasses, Organic Polymers/Plastics, Materials Selection for corrosion Prevention in HydrocarbonService, Materials Selection as per NACE MR0175, 107 References.

8 1095 Failure Analysis Procedure with Reference to Introduction, Purpose of Failure Analysis Investigations, Failure Analysis Steps, Site Visit, Tests on the Samples, Analysis, Interpretation, and Diagnosis of theFailure, Failure Analysis Report: Contents and Preparation, 117 References, 1186 Case Preamble, 119 Classification of Case Studies, 120 General, 1231 Bromine Preheater in a Pharmaceutical Fine ChemicalPlant, 1242 Structurals in a White Clay Manufacturing Plant, 1253 Sea Water Cooler Tubes in an Oil Refinery, 1264 Package Boiler Tube in an Organic Chemical Plant, 1275 Shell of a Packed Column for Ammonia and Water Contactin an Ammonia Processing Plant, 1286 Instrumentation Tube in an Offshore Platform of an Oil andGas Plant, 1297 Plate Type Heat Exchanger/Cooler in a Sulfuric AcidPlant, 1308 Dissimilar Stainless Steel Weld in an Organic ChemicalPlant.

9 1319 Digestor Preheater in a Pulp and Paper Plant, 13210 Esterification Column in an Organic Chemical Plant, 13311 Half Pipe Limpet Coil of a Stirred Reactor in an OrganicChemical Plant, 13412 Firewater Lines Buried Underground in an OrganicChemical Plant, 13513 Alcohol Superheater in a PVC ManufacturingPetrochemical Plant, 13614 Package Boiler Tubes in an Alcohol Distillery Plant, 13715 Reducers in a Reformer Tube in an Ammonia Plant of aFertilizer Industry, 13816 Pressure Safety Valve (PSV) Fitting on InstrumentationTubes in an Off-shore Platform in an Oil and GasCompany, 13917 Water Drum (Mud Drum) Shell in a Coal-Fired SteamBoiler, 14018 Tubes in a Kettle Re-boiler of an Amine Plant, CONTENTSix19 Evaporator Tubes in an Organic Chemical Plant, 14220 Top Tube Sheet Vent Equalizer Weld Zone of a Gas Coolerin a Petrochemical Plant, 14321 Bottom Row Tubes in a Kettle Re-boiler of an OrganicChemical Plant, 14422 Cages for Filter Bags in an Inorganic Chemical Plant, 14523 High Temperature Generator (HTG)

10 Tubes of VaporAbsorption Chiller of an Air-Conditioning andRefrigeration Unit, 14624 Gasket Seat in a Shell and Tube Condenser in aPetrochemical Plant, 14725 Acid Gas CO2 Cooler Condenser in Ammonia Plant of aFertilizer Unit, 14826 Naphtha Coolers in a Fertilizer Plant, 14927 U Type Jet Dyeing Machine in a Textile Dyeing Unit, 15028 Acetic Acid Manufacturing Unit in a PetrochemicalPlant, 15129 Large Stainless Steel Pipeline in a Urea Plant of a FertilizerUnit, 15230 Heat Recovery System of a PVC Unit in a PetrochemicalPlant, 15331 EDC Furnace Coil of a PVC Plant in a PetrochemicalUnit, 15532 Internals of a Stirred Reactor Processing Ortho PhosphoricAcid, 15733 Salt Evaporator, 15834 Cooler/Condenser Tubes of an Absorption Chiller Machineof an Airconditioning Plant, 15935 Nitro Mass Cooler in an Organic Chemical Plant, 16136 Fertilizer Industry Ammonia Plant Natural Gas FeedPreheater Coil, 16237 Petrochemical Unit.