Corrosion as a Risk

The potential for corrosion as a result of the reactions of noncondensable gases present in steam-water circuits is a major area of risk. The dissolved oxygen (DO) content of MU water is recognized as a primary source of gas entering a boiler system, and effective deaeration of MU and FW is therefore critical. 

Economizers are always subject to a risk of very severe pitting corrosion as a result of the release of DO with rapid increase of water temperature. Therefore, they should be inspected at every available opportunity. 

Data required for developing a risk assessment program are often acquired during the analysis of failed components and systems. However, conducting a failure analysis is not an easy or straightforward task. Early recognition of corrosion as a factor in a failure is critical, since much important corrosion information can be lost if a failure scene is altered or changed before appropriate observations and tests can be made. 

When a customer agrees to purchase gas, product quality is specified in terms of the calorific value of the gas, measured by the Wobbe index (calorific value divided by density), the hydrocarbon dew point and the water dew point, and the fraction of other gases such as Nj, COj, HjS. The Wobbe index specification ensures that the gas the customer receives has a predictable calorific value and hence predictable burning characteristics. If the gas becomes lean, less energy is released, and if the gas becomes too rich there is a risk that the gas burners flame out . Water and hydrocarbon dew points (the pressure and temperature at which liquids start to drop out of the gas) are specified to ensure that over the range of temperature and pressure at which the gas is handled by the customer, no liquids will drop out (these could cause possible corrosion and/or hydrate formation). 

Shipment of hydrazine solutions is regulated in the United States by the Department of Transportation (DOT) which classifies all aqueous solutions between 64.4 and 37% N2H4 as "Corrosive" materials with a subsidiary risk of "Poison". Hydrazine has been identified by both the Environmental Protection Agency and the DOT as a hazardous material and has been assigned a reportable quantity (RQ) of 0.450 kg (1 lb) if spilled. Dmms for the shipment of these solutions must bear both the DOT specification "Corrosive" and "Poison" labels in association with the markings "RQ Hydrazine Aqueous Solution UN 2030." Aqueous solutions of 37% concentration or less are a hazard Class 6.1, UN 3293, Packing Group III and require "Keep Away From Food" placards and labels. 

Initially, knowledge of the process is required. It is assumed that the component is free m defects, e.g. porosity, as this will affect surface integrity, and free from residual stresses caused by any previous manufacturing process. There is also a risk in the reduction of component fatigue life associated with some surface coating processes. The compatibility between mating surfaces in service must also be addressed because of possible galvanic corrosion failure... 

Note that Reference" draws attention to the possibility of an increase of anodic polarisation of the more negative member of a couple leading to a decrease in galvanic corrosion rate. There can also be a risk of increased corrosion of the more positive member of a couple. Both these features can arise as a result of active/passive transition effects on certain metals in certain environments. 

Table 10.9 lists some common zinc anode alloys. In three cases aluminium is added to improve the uniformity of dissolution and thereby reduce the risk of mechanical detachment of undissolved anode material . Cadmium is added to encourage the formation of a soft corrosion product that readily crumbles and falls away so that it cannot accumulate to hinder dissolution. The Military Specification material was developed to avoid the alloy passivating as a result of the presence of iron . It later became apparent that this material suffered intergranular decohesion at elevated temperatures (>50°C) with the result that the material failed by fragmentation". The material specified by Det Norske Veritas was developed to overcome the problem the aluminium level was reduced under the mistaken impression that it produced the problem. It has since been shown that decohesion is due to a hydrogen embrittlement mechanism and that it can be overcome by the addition of small concentrations of titanium". It is not clear whether... 

Sulphates and chlorides are present in industrial and marine atmospheres. In water they accelerate the corrosion of steel. Avoiding lodgement areas for water and dirt reduces the risk of the latter acting as a poultice in which the corrosive salts can build up. 

Oil and Gas Production This sector is a major user of corrosion monitoring equipment, in particular for offshore fields where ramifications of corrosion and consequent maintenance are far more serious and costly compared with onshore production. Carbon steel is used for approximately 70-80 70 of production facilities. The development of a field is assessed on a defined corrosion risk which may not be correct, leading to serious corrosion. In addition, a reservoir may become more corrosive as the field is extracted owing to (a) increased water content, and (b) eventual souring of the field (hydrogen sulphide production). 

In smaller boiler systems, the FW tank often acts as a common condensate receiver, MU water heater, and deaerating vessel. As such, the tank is subject to the same corrosion problem risks that befall deaerators, economizers, and FW lines. Smaller systems often are inadequately designed and constructed, with the result that they may suffer serious oxygen corrosion in a particularly short time. (It is not unknown for tank wall perforation to occur within 3 to 6 months of the installation of a new FW tank as a result of pitting corrosion.)... 

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