Alireza Bahadori
Corrosion and Materials Selection
Alireza Bahadori
Corrosion and Materials Selection
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The petroleum and chemical industries contain a wide variety of corrosive environments, many of which are unique to these industries. Oil and gas production operations consume a tremendous amount of iron and steel pipe, tubing, pumps, valves, and sucker rods. Metallic corrosion is costly. However, the cost of corrosion is not just financial. Beyond the huge direct outlay of funds to repair or replace corroded structures are the indirect costs - natural resources, potential hazards, and lost opportunity. Wasting natural resources is a direct contradiction to the growing need for sustainable…mehr
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The petroleum and chemical industries contain a wide variety of corrosive environments, many of which
are unique to these industries. Oil and gas production operations consume a tremendous amount of iron
and steel pipe, tubing, pumps, valves, and sucker rods. Metallic corrosion is costly. However, the cost of
corrosion is not just financial. Beyond the huge direct outlay of funds to repair or replace corroded structures are the indirect costs - natural resources, potential hazards, and lost opportunity. Wasting natural resources is a direct contradiction to the growing need for sustainable development.
By selecting the correct material and applying proper corrosion protection methods, these costs can be
reduced, or even eliminated. This book provides a minimum design requirement for consideration when
designing systems in order to prevent or control corrosion damage safely and economically, and addresses:
- Corrosion problems in petroleum and chemical industries
- Requirements for corrosion control
- Chemical control of corrosive environments
- Corrosion inhibitors in refineries and petrochemical plants
- Materials selection and service life of materials
- Surface preparation, protection and maintainability
- Corrosion monitoring - plant inspection techniques and laboratory corrosion testing techniques
Intended for engineers and industry personnel working in the petroleum and chemical industries, this book is also a valuable resource for research and development teams, safety engineers, corrosion specialists and researchers in chemical engineering, engineering and materials science.
Hinweis: Dieser Artikel kann nur an eine deutsche Lieferadresse ausgeliefert werden.
are unique to these industries. Oil and gas production operations consume a tremendous amount of iron
and steel pipe, tubing, pumps, valves, and sucker rods. Metallic corrosion is costly. However, the cost of
corrosion is not just financial. Beyond the huge direct outlay of funds to repair or replace corroded structures are the indirect costs - natural resources, potential hazards, and lost opportunity. Wasting natural resources is a direct contradiction to the growing need for sustainable development.
By selecting the correct material and applying proper corrosion protection methods, these costs can be
reduced, or even eliminated. This book provides a minimum design requirement for consideration when
designing systems in order to prevent or control corrosion damage safely and economically, and addresses:
- Corrosion problems in petroleum and chemical industries
- Requirements for corrosion control
- Chemical control of corrosive environments
- Corrosion inhibitors in refineries and petrochemical plants
- Materials selection and service life of materials
- Surface preparation, protection and maintainability
- Corrosion monitoring - plant inspection techniques and laboratory corrosion testing techniques
Intended for engineers and industry personnel working in the petroleum and chemical industries, this book is also a valuable resource for research and development teams, safety engineers, corrosion specialists and researchers in chemical engineering, engineering and materials science.
Hinweis: Dieser Artikel kann nur an eine deutsche Lieferadresse ausgeliefert werden.
Produktdetails
- Produktdetails
- Verlag: Wiley & Sons
- 1. Auflage
- Seitenzahl: 576
- Erscheinungstermin: 11. August 2014
- Englisch
- Abmessung: 250mm x 175mm x 35mm
- Gewicht: 1162g
- ISBN-13: 9781118869222
- ISBN-10: 1118869222
- Artikelnr.: 40783439
- Verlag: Wiley & Sons
- 1. Auflage
- Seitenzahl: 576
- Erscheinungstermin: 11. August 2014
- Englisch
- Abmessung: 250mm x 175mm x 35mm
- Gewicht: 1162g
- ISBN-13: 9781118869222
- ISBN-10: 1118869222
- Artikelnr.: 40783439
Alireza Bahadori School of Environment, Science and Engineering, Southern Cross University, Australia.
About the Author xxi Preface xxiii Acknowledgements xxv 1. Fundamentals of
Corrosion in the Oil, Gas, and Chemical Industries 1 1.1 Uniform Corrosion
2 1.2 Localized Corrosion 3 1.3 Low-Temperature Corrosion 6 1.4
High-Temperature Corrosion 12 2. Corrosion Problems in the Petroleum and
Chemical Industries 17 2.1 Stress Corrosion Cracking and Embrittlement 17
2.2 Hydrogen Attack 30 2.3 Corrosion Fatigue 33 2.4 Liquid-Metal
Embrittlement 33 2.5 Basic Definition of Erosion-Corrosion 35 2.6
Mixed-Phase Flow 35 2.7 Entrained Catalyst Particles 36 2.8 Systematic
Analysis of Project 36 2.9 Forms of Corrosion and Preventive Measures 43
2.10 Selective Leaching or De-Alloying Corrosion 49 2.11 Erosion-Corrosion
50 2.12 Stress Corrosion Cracking 52 2.13 Types of Hydrogen Damage 54 2.14
Concentration Cell Corrosion 55 2.15 Filiform Corrosion 56 2.16 Types of
Intergranular Corrosion 56 2.17 Microbiologically Influenced Corrosion 57
2.18 Corrosion in Concrete 58 3. Corrosion Considerations in Material
Selection 61 3.1 Corrosion in Oil and Gas Products 61 3.2 Corrosives and
Corrosion Problems in Refineries and Petrochemical Plants 74 4. Engineering
Materials 89 4.1 The Range of Materials 89 4.2 Properties of Engineering
Materials 89 4.3 Corrosion Prevention Measures 91 4.4 Material Selection
Procedure 93 4.5 Guidelines on Material Selection 93 4.6 Procedure for
Material Selection 96 4.7 Process Parameters 97 4.8 Corrosion Rate and
Corrosion Allowances 97 4.9 Corrosion Allowance 100 4.10 Selection of
Corrosion-Resistance Alloys 100 4.11 Economics in Material Selection 102
4.12 Materials Appreciation and Optimization 103 4.13 Corrosion in Oil and
Gas Products 104 4.14 Engineering Materials 105 4.15 Cast Iron 112 4.16
Non-Ferrous Metals 113 4.17 Polymers 116 4.18 Ceramics and Glasses 120 4.19
Composite Materials 123 5. Chemical Control of Corrosive Environments 125
5.1 General Requirements and Rules for Corrosion Control 125 5.2 Basic
Types of Inhibitors and How They Work 127 5.3 Corrosive Environments 137
5.4 Techniques for the Application of Inhibitors 139 5.5 Inhibitor
Mechanisms 140 5.6 Criteria for Corrosion Control by Inhibitors 141 5.7
System Condition 141 5.8 Selection of Inhibitors 143 5.9 Economics of
Inhibition 150 5.10 Environmental Factors for Corrosion Inhibitor
Applications 151 6. Requirements for Corrosion Control in the Petroleum and
Petrochemical Industries 159 6.1 Exploration 159 6.2 Production 167 6.3
System Requirements for Corrosion Control of Oil Fields by Inhibitors 169
6.4 Types of Inhibitor 172 6.5 Selection of Inhibitor 173 6.6 Measurement
174 6.7 Factors Governing Oil Well Corrosion 175 6.8 Application of
Inhibitor 177 6.9 Water Flooding and Water Disposal 181 6.10 Transportation
and Storage 181 6.11 Biological Control in Oil and Gas Systems 183 6.12
Scale Control in Oil Systems 185 7. Corrosion Inhibitors in Refineries and
Petrochemical Plants 205 7.1 Nature of Corrosive Fluids 205 7.2 Corrosion
of Steel 206 7.3 Corrosion of Copper Alloys 207 7.4 Neutralizing Corrosion
Inhibitors 207 7.5 Filming Inhibitors 208 7.6 Special Concepts in the Use
of Corrosion Inhibitors in Refineries 209 7.7 Economic Aspects of Chemical
Inhibition and Other Measures for Corrosion Prevention 210 7.8 Special
Refinery Processes Amenable to Corrosion Inhibitors 211 7.9 Corrosion in
Gas Processing Units 212 7.10 Miscellaneous Refinery Corrosion Problems 213
7.11 Selection of Inhibitor 214 7.12 Control of Fouling 214 7.13 Utility
(Cooling Water and Boiler Systems) 218 7.14 Boiler Corrosion Problems 221
7.15 Treatment of Acid Systems 235 7.16 Chemical Cleaning of Process
Equipment 237 7.17 Critical Equipment Areas 239 7.18 Identification of
Deposits 239 7.19 Chemical Cleaning 242 8. Corrosion Inhibitor Evaluations
247 8.1 On-Line Monitoring of Corrosion 247 8.2 Corrosion Monitoring
Techniques 248 8.3 Selecting a Technique for Corrosion Monitoring 248 8.4
Corrosion Monitoring Strategy 254 8.5 Measurement of Dissolved Solids 267
8.6 Measurement of Suspended Solids 267 8.7 Corrosion Product Analysis 267
8.8 Design Requirements 268 8.9 Automated Systems 270 8.10 Evaluation of
Corrosion Inhibitors 273 8.11 Detection of Corrosion 275 8.12 Miscellaneous
Corrosion Tests 278 8.13 Results of the Test Method 278 8.14 Field Testing
of Inhibitors 279 8.15 Inhibitor Properties Other Than Effectiveness in
Mitigating Corrosion 283 8.16 Monitoring of Corrosion Inhibitors 286 8.17
Corrosion Behavior of High-Alloy Tubular Materials in Inhibited Acidizing
Conditions 288 9. Compatibility in Material Selection 295 9.1 Requirements
for Compatibility 296 9.2 Structures and Equipment 300 9.3 Piping Systems
302 9.4 Fasteners 304 9.5 Encapsulation, Sealing, and Enveloping 306 9.6
Electrical and Electronic Equipment 306 9.7 Coatings, Films, and Treatments
308 9.8 Chemical Compatibility 310 9.9 Environment 311 9.10 Stray Currents
311 9.11 Beneficial Results 313 9.12 Shape or Geometry 313 9.13 Structures
315 9.14 Mechanics 322 10. Surface Preparation, Protection and Maintenance
337 10.1 Surface 337 10.2 Protection 350 10.3 Maintenance 373 10.4
Economics 376 11. Fabrication and Choice of Material to Minimize Corrosion
Damage 385 11.1 Design 385 11.2 Materials 387 11.3 Fabrication 389 11.4
Welding Procedure 408 11.5 Welding and Joining 413 11.6 Soldered Joints 416
11.7 Brazed Joints 417 11.8 Pipe Bending and Forming 418 12. Heat Treatment
423 12.1 General Heat Treatment Requirements 423 12.2 Heat Treatment
Process 427 12.3 Preheating of Metals 429 12.4 Surface Treatment of
Stainless Steel 432 12.5 Handling, Transport, Storage, and Erection of
Coated Metalwork 434 12.6 Inspection 437 12.7 Corrosion of Carbon Steel
Weldments 438 Discussion 442 Conclusions 443 12.8 Corrosion of Austenitic
Stainless Steel Weldments 444 12.9 Corrosion of Ferritic Stainless Steel
Weldments 448 12.10 Corrosion of Duplex Stainless Steel Weldments 451 12.11
Stress-Corrosion Cracking 456 12.12 Use of High-Alloy Filler Metals 456
12.13 Corrosion of Nickel-Bases Alloys 456 Glossary of Terms 461
Bibliography 523 Index 535
Corrosion in the Oil, Gas, and Chemical Industries 1 1.1 Uniform Corrosion
2 1.2 Localized Corrosion 3 1.3 Low-Temperature Corrosion 6 1.4
High-Temperature Corrosion 12 2. Corrosion Problems in the Petroleum and
Chemical Industries 17 2.1 Stress Corrosion Cracking and Embrittlement 17
2.2 Hydrogen Attack 30 2.3 Corrosion Fatigue 33 2.4 Liquid-Metal
Embrittlement 33 2.5 Basic Definition of Erosion-Corrosion 35 2.6
Mixed-Phase Flow 35 2.7 Entrained Catalyst Particles 36 2.8 Systematic
Analysis of Project 36 2.9 Forms of Corrosion and Preventive Measures 43
2.10 Selective Leaching or De-Alloying Corrosion 49 2.11 Erosion-Corrosion
50 2.12 Stress Corrosion Cracking 52 2.13 Types of Hydrogen Damage 54 2.14
Concentration Cell Corrosion 55 2.15 Filiform Corrosion 56 2.16 Types of
Intergranular Corrosion 56 2.17 Microbiologically Influenced Corrosion 57
2.18 Corrosion in Concrete 58 3. Corrosion Considerations in Material
Selection 61 3.1 Corrosion in Oil and Gas Products 61 3.2 Corrosives and
Corrosion Problems in Refineries and Petrochemical Plants 74 4. Engineering
Materials 89 4.1 The Range of Materials 89 4.2 Properties of Engineering
Materials 89 4.3 Corrosion Prevention Measures 91 4.4 Material Selection
Procedure 93 4.5 Guidelines on Material Selection 93 4.6 Procedure for
Material Selection 96 4.7 Process Parameters 97 4.8 Corrosion Rate and
Corrosion Allowances 97 4.9 Corrosion Allowance 100 4.10 Selection of
Corrosion-Resistance Alloys 100 4.11 Economics in Material Selection 102
4.12 Materials Appreciation and Optimization 103 4.13 Corrosion in Oil and
Gas Products 104 4.14 Engineering Materials 105 4.15 Cast Iron 112 4.16
Non-Ferrous Metals 113 4.17 Polymers 116 4.18 Ceramics and Glasses 120 4.19
Composite Materials 123 5. Chemical Control of Corrosive Environments 125
5.1 General Requirements and Rules for Corrosion Control 125 5.2 Basic
Types of Inhibitors and How They Work 127 5.3 Corrosive Environments 137
5.4 Techniques for the Application of Inhibitors 139 5.5 Inhibitor
Mechanisms 140 5.6 Criteria for Corrosion Control by Inhibitors 141 5.7
System Condition 141 5.8 Selection of Inhibitors 143 5.9 Economics of
Inhibition 150 5.10 Environmental Factors for Corrosion Inhibitor
Applications 151 6. Requirements for Corrosion Control in the Petroleum and
Petrochemical Industries 159 6.1 Exploration 159 6.2 Production 167 6.3
System Requirements for Corrosion Control of Oil Fields by Inhibitors 169
6.4 Types of Inhibitor 172 6.5 Selection of Inhibitor 173 6.6 Measurement
174 6.7 Factors Governing Oil Well Corrosion 175 6.8 Application of
Inhibitor 177 6.9 Water Flooding and Water Disposal 181 6.10 Transportation
and Storage 181 6.11 Biological Control in Oil and Gas Systems 183 6.12
Scale Control in Oil Systems 185 7. Corrosion Inhibitors in Refineries and
Petrochemical Plants 205 7.1 Nature of Corrosive Fluids 205 7.2 Corrosion
of Steel 206 7.3 Corrosion of Copper Alloys 207 7.4 Neutralizing Corrosion
Inhibitors 207 7.5 Filming Inhibitors 208 7.6 Special Concepts in the Use
of Corrosion Inhibitors in Refineries 209 7.7 Economic Aspects of Chemical
Inhibition and Other Measures for Corrosion Prevention 210 7.8 Special
Refinery Processes Amenable to Corrosion Inhibitors 211 7.9 Corrosion in
Gas Processing Units 212 7.10 Miscellaneous Refinery Corrosion Problems 213
7.11 Selection of Inhibitor 214 7.12 Control of Fouling 214 7.13 Utility
(Cooling Water and Boiler Systems) 218 7.14 Boiler Corrosion Problems 221
7.15 Treatment of Acid Systems 235 7.16 Chemical Cleaning of Process
Equipment 237 7.17 Critical Equipment Areas 239 7.18 Identification of
Deposits 239 7.19 Chemical Cleaning 242 8. Corrosion Inhibitor Evaluations
247 8.1 On-Line Monitoring of Corrosion 247 8.2 Corrosion Monitoring
Techniques 248 8.3 Selecting a Technique for Corrosion Monitoring 248 8.4
Corrosion Monitoring Strategy 254 8.5 Measurement of Dissolved Solids 267
8.6 Measurement of Suspended Solids 267 8.7 Corrosion Product Analysis 267
8.8 Design Requirements 268 8.9 Automated Systems 270 8.10 Evaluation of
Corrosion Inhibitors 273 8.11 Detection of Corrosion 275 8.12 Miscellaneous
Corrosion Tests 278 8.13 Results of the Test Method 278 8.14 Field Testing
of Inhibitors 279 8.15 Inhibitor Properties Other Than Effectiveness in
Mitigating Corrosion 283 8.16 Monitoring of Corrosion Inhibitors 286 8.17
Corrosion Behavior of High-Alloy Tubular Materials in Inhibited Acidizing
Conditions 288 9. Compatibility in Material Selection 295 9.1 Requirements
for Compatibility 296 9.2 Structures and Equipment 300 9.3 Piping Systems
302 9.4 Fasteners 304 9.5 Encapsulation, Sealing, and Enveloping 306 9.6
Electrical and Electronic Equipment 306 9.7 Coatings, Films, and Treatments
308 9.8 Chemical Compatibility 310 9.9 Environment 311 9.10 Stray Currents
311 9.11 Beneficial Results 313 9.12 Shape or Geometry 313 9.13 Structures
315 9.14 Mechanics 322 10. Surface Preparation, Protection and Maintenance
337 10.1 Surface 337 10.2 Protection 350 10.3 Maintenance 373 10.4
Economics 376 11. Fabrication and Choice of Material to Minimize Corrosion
Damage 385 11.1 Design 385 11.2 Materials 387 11.3 Fabrication 389 11.4
Welding Procedure 408 11.5 Welding and Joining 413 11.6 Soldered Joints 416
11.7 Brazed Joints 417 11.8 Pipe Bending and Forming 418 12. Heat Treatment
423 12.1 General Heat Treatment Requirements 423 12.2 Heat Treatment
Process 427 12.3 Preheating of Metals 429 12.4 Surface Treatment of
Stainless Steel 432 12.5 Handling, Transport, Storage, and Erection of
Coated Metalwork 434 12.6 Inspection 437 12.7 Corrosion of Carbon Steel
Weldments 438 Discussion 442 Conclusions 443 12.8 Corrosion of Austenitic
Stainless Steel Weldments 444 12.9 Corrosion of Ferritic Stainless Steel
Weldments 448 12.10 Corrosion of Duplex Stainless Steel Weldments 451 12.11
Stress-Corrosion Cracking 456 12.12 Use of High-Alloy Filler Metals 456
12.13 Corrosion of Nickel-Bases Alloys 456 Glossary of Terms 461
Bibliography 523 Index 535
About the Author xxi Preface xxiii Acknowledgements xxv 1. Fundamentals of
Corrosion in the Oil, Gas, and Chemical Industries 1 1.1 Uniform Corrosion
2 1.2 Localized Corrosion 3 1.3 Low-Temperature Corrosion 6 1.4
High-Temperature Corrosion 12 2. Corrosion Problems in the Petroleum and
Chemical Industries 17 2.1 Stress Corrosion Cracking and Embrittlement 17
2.2 Hydrogen Attack 30 2.3 Corrosion Fatigue 33 2.4 Liquid-Metal
Embrittlement 33 2.5 Basic Definition of Erosion-Corrosion 35 2.6
Mixed-Phase Flow 35 2.7 Entrained Catalyst Particles 36 2.8 Systematic
Analysis of Project 36 2.9 Forms of Corrosion and Preventive Measures 43
2.10 Selective Leaching or De-Alloying Corrosion 49 2.11 Erosion-Corrosion
50 2.12 Stress Corrosion Cracking 52 2.13 Types of Hydrogen Damage 54 2.14
Concentration Cell Corrosion 55 2.15 Filiform Corrosion 56 2.16 Types of
Intergranular Corrosion 56 2.17 Microbiologically Influenced Corrosion 57
2.18 Corrosion in Concrete 58 3. Corrosion Considerations in Material
Selection 61 3.1 Corrosion in Oil and Gas Products 61 3.2 Corrosives and
Corrosion Problems in Refineries and Petrochemical Plants 74 4. Engineering
Materials 89 4.1 The Range of Materials 89 4.2 Properties of Engineering
Materials 89 4.3 Corrosion Prevention Measures 91 4.4 Material Selection
Procedure 93 4.5 Guidelines on Material Selection 93 4.6 Procedure for
Material Selection 96 4.7 Process Parameters 97 4.8 Corrosion Rate and
Corrosion Allowances 97 4.9 Corrosion Allowance 100 4.10 Selection of
Corrosion-Resistance Alloys 100 4.11 Economics in Material Selection 102
4.12 Materials Appreciation and Optimization 103 4.13 Corrosion in Oil and
Gas Products 104 4.14 Engineering Materials 105 4.15 Cast Iron 112 4.16
Non-Ferrous Metals 113 4.17 Polymers 116 4.18 Ceramics and Glasses 120 4.19
Composite Materials 123 5. Chemical Control of Corrosive Environments 125
5.1 General Requirements and Rules for Corrosion Control 125 5.2 Basic
Types of Inhibitors and How They Work 127 5.3 Corrosive Environments 137
5.4 Techniques for the Application of Inhibitors 139 5.5 Inhibitor
Mechanisms 140 5.6 Criteria for Corrosion Control by Inhibitors 141 5.7
System Condition 141 5.8 Selection of Inhibitors 143 5.9 Economics of
Inhibition 150 5.10 Environmental Factors for Corrosion Inhibitor
Applications 151 6. Requirements for Corrosion Control in the Petroleum and
Petrochemical Industries 159 6.1 Exploration 159 6.2 Production 167 6.3
System Requirements for Corrosion Control of Oil Fields by Inhibitors 169
6.4 Types of Inhibitor 172 6.5 Selection of Inhibitor 173 6.6 Measurement
174 6.7 Factors Governing Oil Well Corrosion 175 6.8 Application of
Inhibitor 177 6.9 Water Flooding and Water Disposal 181 6.10 Transportation
and Storage 181 6.11 Biological Control in Oil and Gas Systems 183 6.12
Scale Control in Oil Systems 185 7. Corrosion Inhibitors in Refineries and
Petrochemical Plants 205 7.1 Nature of Corrosive Fluids 205 7.2 Corrosion
of Steel 206 7.3 Corrosion of Copper Alloys 207 7.4 Neutralizing Corrosion
Inhibitors 207 7.5 Filming Inhibitors 208 7.6 Special Concepts in the Use
of Corrosion Inhibitors in Refineries 209 7.7 Economic Aspects of Chemical
Inhibition and Other Measures for Corrosion Prevention 210 7.8 Special
Refinery Processes Amenable to Corrosion Inhibitors 211 7.9 Corrosion in
Gas Processing Units 212 7.10 Miscellaneous Refinery Corrosion Problems 213
7.11 Selection of Inhibitor 214 7.12 Control of Fouling 214 7.13 Utility
(Cooling Water and Boiler Systems) 218 7.14 Boiler Corrosion Problems 221
7.15 Treatment of Acid Systems 235 7.16 Chemical Cleaning of Process
Equipment 237 7.17 Critical Equipment Areas 239 7.18 Identification of
Deposits 239 7.19 Chemical Cleaning 242 8. Corrosion Inhibitor Evaluations
247 8.1 On-Line Monitoring of Corrosion 247 8.2 Corrosion Monitoring
Techniques 248 8.3 Selecting a Technique for Corrosion Monitoring 248 8.4
Corrosion Monitoring Strategy 254 8.5 Measurement of Dissolved Solids 267
8.6 Measurement of Suspended Solids 267 8.7 Corrosion Product Analysis 267
8.8 Design Requirements 268 8.9 Automated Systems 270 8.10 Evaluation of
Corrosion Inhibitors 273 8.11 Detection of Corrosion 275 8.12 Miscellaneous
Corrosion Tests 278 8.13 Results of the Test Method 278 8.14 Field Testing
of Inhibitors 279 8.15 Inhibitor Properties Other Than Effectiveness in
Mitigating Corrosion 283 8.16 Monitoring of Corrosion Inhibitors 286 8.17
Corrosion Behavior of High-Alloy Tubular Materials in Inhibited Acidizing
Conditions 288 9. Compatibility in Material Selection 295 9.1 Requirements
for Compatibility 296 9.2 Structures and Equipment 300 9.3 Piping Systems
302 9.4 Fasteners 304 9.5 Encapsulation, Sealing, and Enveloping 306 9.6
Electrical and Electronic Equipment 306 9.7 Coatings, Films, and Treatments
308 9.8 Chemical Compatibility 310 9.9 Environment 311 9.10 Stray Currents
311 9.11 Beneficial Results 313 9.12 Shape or Geometry 313 9.13 Structures
315 9.14 Mechanics 322 10. Surface Preparation, Protection and Maintenance
337 10.1 Surface 337 10.2 Protection 350 10.3 Maintenance 373 10.4
Economics 376 11. Fabrication and Choice of Material to Minimize Corrosion
Damage 385 11.1 Design 385 11.2 Materials 387 11.3 Fabrication 389 11.4
Welding Procedure 408 11.5 Welding and Joining 413 11.6 Soldered Joints 416
11.7 Brazed Joints 417 11.8 Pipe Bending and Forming 418 12. Heat Treatment
423 12.1 General Heat Treatment Requirements 423 12.2 Heat Treatment
Process 427 12.3 Preheating of Metals 429 12.4 Surface Treatment of
Stainless Steel 432 12.5 Handling, Transport, Storage, and Erection of
Coated Metalwork 434 12.6 Inspection 437 12.7 Corrosion of Carbon Steel
Weldments 438 Discussion 442 Conclusions 443 12.8 Corrosion of Austenitic
Stainless Steel Weldments 444 12.9 Corrosion of Ferritic Stainless Steel
Weldments 448 12.10 Corrosion of Duplex Stainless Steel Weldments 451 12.11
Stress-Corrosion Cracking 456 12.12 Use of High-Alloy Filler Metals 456
12.13 Corrosion of Nickel-Bases Alloys 456 Glossary of Terms 461
Bibliography 523 Index 535
Corrosion in the Oil, Gas, and Chemical Industries 1 1.1 Uniform Corrosion
2 1.2 Localized Corrosion 3 1.3 Low-Temperature Corrosion 6 1.4
High-Temperature Corrosion 12 2. Corrosion Problems in the Petroleum and
Chemical Industries 17 2.1 Stress Corrosion Cracking and Embrittlement 17
2.2 Hydrogen Attack 30 2.3 Corrosion Fatigue 33 2.4 Liquid-Metal
Embrittlement 33 2.5 Basic Definition of Erosion-Corrosion 35 2.6
Mixed-Phase Flow 35 2.7 Entrained Catalyst Particles 36 2.8 Systematic
Analysis of Project 36 2.9 Forms of Corrosion and Preventive Measures 43
2.10 Selective Leaching or De-Alloying Corrosion 49 2.11 Erosion-Corrosion
50 2.12 Stress Corrosion Cracking 52 2.13 Types of Hydrogen Damage 54 2.14
Concentration Cell Corrosion 55 2.15 Filiform Corrosion 56 2.16 Types of
Intergranular Corrosion 56 2.17 Microbiologically Influenced Corrosion 57
2.18 Corrosion in Concrete 58 3. Corrosion Considerations in Material
Selection 61 3.1 Corrosion in Oil and Gas Products 61 3.2 Corrosives and
Corrosion Problems in Refineries and Petrochemical Plants 74 4. Engineering
Materials 89 4.1 The Range of Materials 89 4.2 Properties of Engineering
Materials 89 4.3 Corrosion Prevention Measures 91 4.4 Material Selection
Procedure 93 4.5 Guidelines on Material Selection 93 4.6 Procedure for
Material Selection 96 4.7 Process Parameters 97 4.8 Corrosion Rate and
Corrosion Allowances 97 4.9 Corrosion Allowance 100 4.10 Selection of
Corrosion-Resistance Alloys 100 4.11 Economics in Material Selection 102
4.12 Materials Appreciation and Optimization 103 4.13 Corrosion in Oil and
Gas Products 104 4.14 Engineering Materials 105 4.15 Cast Iron 112 4.16
Non-Ferrous Metals 113 4.17 Polymers 116 4.18 Ceramics and Glasses 120 4.19
Composite Materials 123 5. Chemical Control of Corrosive Environments 125
5.1 General Requirements and Rules for Corrosion Control 125 5.2 Basic
Types of Inhibitors and How They Work 127 5.3 Corrosive Environments 137
5.4 Techniques for the Application of Inhibitors 139 5.5 Inhibitor
Mechanisms 140 5.6 Criteria for Corrosion Control by Inhibitors 141 5.7
System Condition 141 5.8 Selection of Inhibitors 143 5.9 Economics of
Inhibition 150 5.10 Environmental Factors for Corrosion Inhibitor
Applications 151 6. Requirements for Corrosion Control in the Petroleum and
Petrochemical Industries 159 6.1 Exploration 159 6.2 Production 167 6.3
System Requirements for Corrosion Control of Oil Fields by Inhibitors 169
6.4 Types of Inhibitor 172 6.5 Selection of Inhibitor 173 6.6 Measurement
174 6.7 Factors Governing Oil Well Corrosion 175 6.8 Application of
Inhibitor 177 6.9 Water Flooding and Water Disposal 181 6.10 Transportation
and Storage 181 6.11 Biological Control in Oil and Gas Systems 183 6.12
Scale Control in Oil Systems 185 7. Corrosion Inhibitors in Refineries and
Petrochemical Plants 205 7.1 Nature of Corrosive Fluids 205 7.2 Corrosion
of Steel 206 7.3 Corrosion of Copper Alloys 207 7.4 Neutralizing Corrosion
Inhibitors 207 7.5 Filming Inhibitors 208 7.6 Special Concepts in the Use
of Corrosion Inhibitors in Refineries 209 7.7 Economic Aspects of Chemical
Inhibition and Other Measures for Corrosion Prevention 210 7.8 Special
Refinery Processes Amenable to Corrosion Inhibitors 211 7.9 Corrosion in
Gas Processing Units 212 7.10 Miscellaneous Refinery Corrosion Problems 213
7.11 Selection of Inhibitor 214 7.12 Control of Fouling 214 7.13 Utility
(Cooling Water and Boiler Systems) 218 7.14 Boiler Corrosion Problems 221
7.15 Treatment of Acid Systems 235 7.16 Chemical Cleaning of Process
Equipment 237 7.17 Critical Equipment Areas 239 7.18 Identification of
Deposits 239 7.19 Chemical Cleaning 242 8. Corrosion Inhibitor Evaluations
247 8.1 On-Line Monitoring of Corrosion 247 8.2 Corrosion Monitoring
Techniques 248 8.3 Selecting a Technique for Corrosion Monitoring 248 8.4
Corrosion Monitoring Strategy 254 8.5 Measurement of Dissolved Solids 267
8.6 Measurement of Suspended Solids 267 8.7 Corrosion Product Analysis 267
8.8 Design Requirements 268 8.9 Automated Systems 270 8.10 Evaluation of
Corrosion Inhibitors 273 8.11 Detection of Corrosion 275 8.12 Miscellaneous
Corrosion Tests 278 8.13 Results of the Test Method 278 8.14 Field Testing
of Inhibitors 279 8.15 Inhibitor Properties Other Than Effectiveness in
Mitigating Corrosion 283 8.16 Monitoring of Corrosion Inhibitors 286 8.17
Corrosion Behavior of High-Alloy Tubular Materials in Inhibited Acidizing
Conditions 288 9. Compatibility in Material Selection 295 9.1 Requirements
for Compatibility 296 9.2 Structures and Equipment 300 9.3 Piping Systems
302 9.4 Fasteners 304 9.5 Encapsulation, Sealing, and Enveloping 306 9.6
Electrical and Electronic Equipment 306 9.7 Coatings, Films, and Treatments
308 9.8 Chemical Compatibility 310 9.9 Environment 311 9.10 Stray Currents
311 9.11 Beneficial Results 313 9.12 Shape or Geometry 313 9.13 Structures
315 9.14 Mechanics 322 10. Surface Preparation, Protection and Maintenance
337 10.1 Surface 337 10.2 Protection 350 10.3 Maintenance 373 10.4
Economics 376 11. Fabrication and Choice of Material to Minimize Corrosion
Damage 385 11.1 Design 385 11.2 Materials 387 11.3 Fabrication 389 11.4
Welding Procedure 408 11.5 Welding and Joining 413 11.6 Soldered Joints 416
11.7 Brazed Joints 417 11.8 Pipe Bending and Forming 418 12. Heat Treatment
423 12.1 General Heat Treatment Requirements 423 12.2 Heat Treatment
Process 427 12.3 Preheating of Metals 429 12.4 Surface Treatment of
Stainless Steel 432 12.5 Handling, Transport, Storage, and Erection of
Coated Metalwork 434 12.6 Inspection 437 12.7 Corrosion of Carbon Steel
Weldments 438 Discussion 442 Conclusions 443 12.8 Corrosion of Austenitic
Stainless Steel Weldments 444 12.9 Corrosion of Ferritic Stainless Steel
Weldments 448 12.10 Corrosion of Duplex Stainless Steel Weldments 451 12.11
Stress-Corrosion Cracking 456 12.12 Use of High-Alloy Filler Metals 456
12.13 Corrosion of Nickel-Bases Alloys 456 Glossary of Terms 461
Bibliography 523 Index 535