Corrosion Policy Decision Making

1 Cover

2 Title Page

3 Copyright Page

4 Dedication Page

5 Preface

6 Authors and Contributors

7 1 Introduction References

8 2 A Short Review of Some Important Aspects of the Science of Corrosion 2.1 Introduction 2.2 Important Technical Treatment Strategies for Corrosion Treatment 2.3 Conclusion References

9 3 Smart Corrosion Management Elements 3.1 Introduction 3.2 Management of Corrosion and COVID19 3.3 Environment 3.4 Application of Management of Corrosion Scheme to Underground Fire Water Ring 4 3.5 Damage Management 3.6 Algorithm 3.7 Final Remarks References

10 4 Economics and Corrosion 4.1 Introduction 4.2 Economics 4.3 Corrosion Economics 4.4 Corrosion and Sustainability 4.5 Conclusion 4.6 Summary References

11 5 Effective Management of Process Additives (EMPA) 5.1 Introduction 5.2 A Gas Plant 5.3 Utilities 5.4 Process Additives (Chemicals) 5.5 Effective Management of Process Additives (EMPA) 5.6 Misleading Trends with Corrosion Conclusions 5.7 Chemicals, Their Corrosion, and Impacts of Their Corrosions on the Environment 5.8 Configuring EMPA 5.9 Setting up an EMPA 5.10 Consumption 5.11 Reporting 5.12 Documentation 5.13 Summary References

12 6 Application of TRIZ for Corrosion Management 6.1 Introduction 6.2 Basic Structure of TRIZ 6.3 Level of Invention 6.4 History of TRIZ 6.5 About the Founder of TRIZ 6.6 Contradiction as a Means to Formulate an Inventive Problem 6.7 Procedure of Inventive Design 6.8 Concept Development Using TRIZ 6.9 Contradiction Matrix (39 × 39) 6.10 Using the TRIZ Matrix 6.11 Physical Contradiction Resolution 6.12 Ideality and the Ideal Final Result (IFR) 6.13 TRIZ Crossover QMS 6.14 The Evolutionary S‐Curve 6.15 Nine Windows 6.16 Trends of Engineering System Evolution 6.17 Geometric Evolution of Linear Constructions 6.18 Trimming 6.19 Input–Output–Trimming Operator (I–O–T) 6.20 Resource Analysis 6.21 Function Analysis 6.22 Substance‐Field Analysis 6.23 Tool‐Object‐Product (TOP) Function Analysis 6.24 Generic Model of a Function 6.25 TRIZ Offers Five Basic Function Models 6.26 Psychological Inertia 6.27 Size‐Time–Cost Operator 6.28 Applying the 40 Inventive Principles in Corrosion Management 6.29 Conclusion 6.30 Glossary of TRIZ Terms 6.A TRIZ Contradiction Table References

13 7 Environmental Impacts of Corrosion and Assessment Strategies 7.1 Introduction 7.2 Some Uses of Rule 365 7.3 Conclusions References

14 Index

15 End User License Agreement

1 Chapter 2 Table 2.1 Adhesion of a common zinc phosphate epoxy primer on the steel surf... Table 2.2 Properties of tested abrasives in blasting. Table 2.3 Effect of abrasives on adhesion of primer at humid and salty envir...

2 Chapter 3 Table 3.1 Consequence rating (F) of some consequence ratings. Table 3.2 Some important features of corrosion control (CC) and corrosion pr...

3 Chapter 4Table 4.1 GDP, expenditure approach (billions of dollars).Table 4.2 Gross domestic income by type of income (billions of dollars).Table 4.3 Value added by industry (billions of dollars).Table 4.4 The Standard of National Account usage.Table 4.5 The production account – uses.Table 4.6 Industry‐by‐industry total requirements, after redefinitions (in p...Table 4.7 Power plant operation and maintenance costs in the US in 2019, by ...

4 Chapter 5Table 5.1 Various processes and their needs for different utilities in a ty...Table 5.2 Utilities in a typical gas plant, their production processes, and...Table 5.3 Details about process additives in hydrocarbon processing and off...Table 5.4 Details about process additives in utility section of a typical g...Table 5.5 Various main occurrences and their impacts on the entire operatio...Table 5.6 Identified documents for each activity in EMPA.

5 Chapter 6Table 6.1 List of TRIZ 40 inventive principles and their opposites.Table 6.2 Technical contradiction examples.Table 6.3 Physical contradictions examples.Table 6.4 Idealization level behavior.Table 6.5 Inventive principles related to trends of evolution.Table 6.6 Resource analysis.Table 6.7 Size–Time–Cost Operator.

1 Chapter 1 Figure 1.1 Corrosion engineering and its relation to other engineering disci...

2 Chapter 2 Figure 2.1 Two examples of severely corroded equipment leading into a throug... Figure 2.2 Schematic presentation of electrochemical series with some reacti... Figure 2.3 Some examples of active and passive metals in seawater at 25 °C f... Figure 2.4 A typical Pourbaix diagram (simplified) for an Fe–water system at... Figure 2.5 Materials selection chart for upstream exploration oil and gas in... Figure 2.6 Carbon steel (hot rolled, cold rolled, and galvanized coils) pric... Figure 2.7 Conceptualization of the elements of cathodic protection (CP); 1:... Figure 2.8 Paint degradation on various substrates. (a) Rust on stainless st... Figure 2.9 Paint defects because of Amin leakage on the equipment. Figure 2.10 Paint checking due to weak resistance of the epoxy to the sunlig... Figure 2.11 Lack of curing of ethyl silicate primer used in dry area. Figure 2.12 Poor wetting and undesired mixing of primer components. Figure 2.13 Chalking when the system exposes to sunlight because of the use ... Figure 2.14 Some typical complications of the paints resulting from poor qua... Figure 2.15 Examples of unqualified workers. Figure 2.16 Some weakness of the surface preparation. Paint application on r... Figure 2.17 Some examples of paint application problems. Rusting on primer d... Figure 2.18 Weak inspection and management. Figure 2.19 Rapid development of damage, especially in chemical and marine f... Figure 2.20 Effective parameters on paint useful lifespan.

3 Chapter 3 Figure 3.1 Categorizing corrosion severity based on corrosion rates (general... Figure 3.2 Damage of the inner layer of a protective coating applied inside ... Figure 3.3 Risk categories and four zones created based on level of conseque... Figure 3.4 An example of CUI (corrosion under insulation) on a piping which ... Figure 3.5 Irritation situation zones, where P (probability) and C (conseque... Figure 3.6 An example of corrosion reactions geometries. Figure 3.7 An example of a rather complex corrosion geometry related to exte... Figure 3.8 Corrosion safety procedure. The way corrosion must not proceed in... Figure 3.9 Two alternative definitions of Zugzwang effect state. Based on th... Figure 3.10 (a) A through‐wall hole (at 6 o'clock position) of a stainless s... Figure 3.11 The relationship that exists between FFS, pseudo‐FFS, and Zugzwa... Figure 3.12 Milestones in the life of an asset from its fresh state of FFS t...Figure 3.13 Decision tree for corrosion management of a bioleaching tank bas...Figure 3.14 Simplified schematic presentation of I/O model, where the output...Figure 3.15 Components of an unsuitable workplace.Figure 3.16 An example of a 115 month CKM scheme. This scheme is arbitrary a...Figure 3.17 General schematic of a fire water ring as the corrosion system a...Figure 3.18 Overall view of management of corrosion defined as per smart cor...Figure 3.19 History of corrosion damage.

4 Chapter 5Figure 5.1 Illustration of the limitations for presenting industrial cases....Figure 5.2 The schematic of different operational processing units in a typi...Figure 5.3 A schematic for the feeding of various chemicals into the utility...Figure 5.4 Illustrating all process additive related details at different se...Figure 5.5 Illustration of path event due to lack of generated steam influen...Figure 5.6 How to deal with off‐spec products based on design in a typical g...Figure 5.7 Schematic for off‐spec condensate (oily polluted) and its dumping...Figure 5.8 Trends of laboratory results due to entry of non‐volatile organic.