Explore the science, management, economy, ecology, and engineering of corrosion management and prevention
In Corrosion Policy Decision Making, distinguished consultant and corrosion expert Dr. Reza Javaherdashti delivers an insightful overview of the fundamental principles of corrosion with a strong focus on the applicability of corrosion theory to industrial practice. The authors demonstrate various aspects of smart corrosion management and persuasively make the case that there is a real difference between corrosion management and corrosion knowledge management.
The book contains seven chapters that each focuses on one important aspect of corrosion and corrosion management.
Corrosion management is an issue that is not just corrosion science or corrosion engineering but rather a combination of both elements. To cover this paradoxical aspect of corrosion management, chapter 2 deals with some basic, introductory concepts and principles of corrosion and coating/painting (an important corrosion protection method) while chapter 3 explains the elements of smart corrosion management in detail. Another important principle of smart corrosion management is to be able to study the cost of corrosion, chapter 4 introduces important points in the economics involved in a smart corrosion management. As indicated earlier, corrosion engineering is also an integral part of corrosion management and thus chapter 5 looks at the engineering side of corrosion by detailing the example of Process Additives (EMPA). Chapter 6 for the first time looks at the possibility of using TRIZ (algorithm of invention) in corrosion management. Finally, chapter 7 presents the necessary elements for building a model that would explore the mutual interaction between corrosion and environment mainly by exploring the difference between environmental impact and environmental effect. Chapter 7 is also very important because the four models so far applied to estimate the cost of corrosion (Uhlig Method, Hoar Method, I/O method and LCC method) are not capable of suggesting any clear model or a sensible way of exploring the elements necessary to explain the impact of indirect costs of corrosion the most important of which being environmental damages imposed by corrosion.
This book is ideal for engineers, students, and managers working or studying corrosion, Corrosion Policy Decision Making is also an indispensable resource for professionals in the fields of upstream and downstream, on-shore/off-shore oil and gas, transportation, mining, power generation as well as major sectors of other strategic industries.
Table of Contents
Preface xiii
Authors and Contributors xv
1 Introduction 1
Reza Javaherdashti
References 5
2 A Short Review of Some Important Aspects of the Science of Corrosion 7
Reza Javaherdashti and Ali Ghanbarzadeh
2.1 Introduction 7
2.1.1 Essentials of Electrochemical Corrosion 9
2.1.2 Prediction of Corrosion 12
2.1.2.1 Standard Hydrogen Electrode/Electrochemical Series 12
2.1.2.2 Galvanic Series 13
2.1.2.3 Pourbaix Diagrams 15
2.2 Important Technical Treatment Strategies for Corrosion Treatment 16
2.2.1 Design Modification-change/Materials Selection 17
2.2.2 Chemical Treatment 21
2.2.3 Electrical Treatment 22
2.2.4 Mechanical Treatment 23
2.2.5 Physical Treatment 23
2.2.5.1 Paints, Coating Systems, and Premature Destruction in Industrial Facilities 23
2.2.5.2 Features of Substrate 24
2.2.5.3 Characteristics of the Environment and Local Features 26
2.2.5.4 Paints Quality Control 34
2.2.5.5 Paint Warehousing and Storage 35
2.2.5.6 Role of Executors and Contractors 36
2.2.5.7 Surface Preparation 36
2.2.5.8 Technical Painting Operations 39
2.2.5.9 Inspection and Management 41
2.3 Conclusion 43
References 44
3 Smart Corrosion Management Elements 47
Reza Javaherdashti and Faranak Javaherdashti
3.1 Introduction 47
3.1.1 Risk, Importance, and How They Are Interrelated? 48
3.1.2 Corrosion Management: What It Is and What It Is Not 56
3.1.3 Management of Corrosion 58
3.1.3.1 Corrosion Reactions Geometry 59
3.1.3.2 Failure 60
3.1.3.3 Corrosion Prevention and Corrosion Control 67
3.1.3.4 cm Model 69
3.1.4 Phase 1: Definition 70
3.1.5 Phase 2: Application 73
3.1.6 Phase 3: Monitoring 74
3.1.7 Phase 4: Feedback 75
3.1.7.1 Corrosion Cost Estimation Model 76
3.1.7.2 Corrosion Knowledge Management (CKM) 79
3.2 Management of Corrosion and COVID-19 90
3.3 Environment 93
3.4 Application of Management of Corrosion Scheme to Underground Fire Water Ring 96
3.5 Damage Management 99
3.6 Algorithm 100
3.7 Final Remarks 104
References 107
4 Economics and Corrosion 111
Mahsa Mostashar-Nezami
4.1 Introduction 111
4.2 Economics 112
4.2.1 What Is Economics 112
4.2.2 Gross Domestic Product 114
4.2.2.1 The Expenditure Approach 115
4.2.2.2 The Income Approach 117
4.2.2.3 The Value-Added Approach 117
4.2.2.4 Income, Consumption, Saving, and Investment 117
4.2.2.5 Gross National Product 123
4.2.3 Introduction to National Account 123
4.2.3.1 Production Account, the Intermediate Consumption, and the Consumption of Fixed Capital 124
4.2.4 Net Present Value (NPV) and Net Future Value (NFV) 128
4.2.5 Input-Output Model in Economics 129
4.2.5.1 Technical Coefficients 130
4.2.5.2 Price and the Input-output Table 135
4.2.5.3 Dynamic Input-output Analysis 137
4.2.6 Depreciation, Consumption of Fixed Capital, or Corrosion 137
4.3 Corrosion Economics 138
4.3.1 Input-output Model in Corrosion 138
4.3.1.1 Matrix of Technical Coefficients 139
4.3.1.2 Matrix of Capital Coefficients 140
4.3.1.3 Input-output Model 142
4.3.1.4 Final Demand 143
4.3.1.5 World I, World Ii, World III 144
4.3.1.6 Estimating Corrosion Cost by Battelle 144
4.3.2 Life Cycle Cost (LCC) 149
4.3.2.1 Life-Cycle Cost Model 149
4.4 Corrosion and Sustainability 152
4.5 Conclusion 154
4.6 Summary 155
References 155
5 Effective Management of Process Additives (EMPA) 159
Mohamedreza Hamedghafarian
5.1 Introduction 159
5.2 A Gas Plant 160
5.3 Utilities 161
5.4 Process Additives (Chemicals) 165
5.5 Effective Management of Process Additives (EMPA) 175
5.5.1 Production Costs 175
5.5.2 Quality Control 175
5.5.3 Corrosion 176
5.5.4 Energy 177
5.5.5 Environment 178
5.5.6 Process Issues 180
5.5.6.1 Production Reduction 180
5.5.6.2 Off-spec Products 181
5.5.6.3 Operation History 1 202
5.5.6.4 Operation History 2 203
5.5.6.5 Operation History 3 214
5.5.6.6 Operation History 4 214
5.6 Misleading Trends with Corrosion Conclusions 215
5.6.1 Phosphate Solution Preparation (Boiler Internal Treatment) 215
5.6.2 Putting A Kettle-type Reboiler into Service that Has Been Under Maintenance 219
5.6.3 Problems in Sampling from Deaerator and Oxygen Scavenger Analyzation 220
5.6.4 Problems in Sampling and Analyzing Specific Conductivity from Demineralized Water 222
5.6.5 An Improper Sample Point and Mistake in Determining Free Residual Chlorine 223
5.7 Chemicals, Their Corrosion, and Impacts of Their Corrosions on the Environment 225
5.7.1 Operation History 5 226
5.8 Configuring EMPA 226
5.9 Setting up an EMPA 229
5.9.1 Description of Activities 230
5.9.1.1 Selection 230
5.9.1.2 Operation History 6 230
5.9.1.3 Operation History 7 232
5.9.1.4 Operation History 8 233
5.9.1.5 Operation History 9 234
5.9.1.6 Procurement 236
5.9.1.7 Operation History 10 236
5.9.1.8 Operation History 11 237
5.9.1.9 Delivery 237
5.9.1.10 Operation History 12 238
5.9.1.11 Operation History 13 239
5.9.2 Storage 240
5.9.2.1 Operation History 14 241
5.9.2.2 Operation History 15 242
5.9.2.3 Operation History 16 242
5.9.2.4 Operation History 17 243
5.9.2.5 Operation History 18 244
5.10 Consumption 245
5.10.1 Operation History 19 246
5.10.2 Operation History 20 246
5.10.3 Operation History 21 247
5.10.4 Operation History 22 248
5.10.5 Operation History 23 249
5.10.6 Operation History 24 249
5.10.7 Operation History 25 256
5.10.8 Operation History 26 257
5.10.9 Operation History 27 257
5.10.10 Operation History 28 259
5.11 Reporting 259
5.12 Documentation 260
5.13 Summary 263
Abbreviations 263
References 265
6 Application of TRIZ for Corrosion Management 269
Reza Javaherdashti and Mehdi Basirzadeh
6.1 Introduction 269
6.2 Basic Structure of TRIZ 271
6.2.1 The Essence of TRIZ in 50 Words 273
6.3 Level of Invention 274
6.4 History of TRIZ 275
6.5 About the Founder of TRIZ 276
6.5.1 Genrich Saulovich Altshuller 276
6.6 Contradiction as a Means to Formulate an Inventive Problem 278
6.7 Procedure of Inventive Design 280
6.8 Concept Development Using TRIZ 281
6.9 Contradiction Matrix (39 × 39) 283
6.9.1 List of the 39 Features 284
6.9.2 List of the 40 Principles 285
6.10 Using the TRIZ Matrix 286
6.10.1 TRIZ Problem Solving Methodology 286
6.10.2 Reality of the “Four-Box Scheme” Theory 288
6.11 Physical Contradiction Resolution 289
6.12 Ideality and the Ideal Final Result (IFR) 294
6.13 TRIZ Crossover QMS 299
6.14 The Evolutionary S-Curve 299
6.15 Nine Windows 301
6.16 Trends of Engineering System Evolution 302
6.17 Geometric Evolution of Linear Constructions 305
6.18 Trimming 306
6.18.1 Making Things Better and Less Expensive 306
6.19 Input-Output-Trimming Operator (I-O-T) 308
6.20 Resource Analysis 310
6.21 Function Analysis 311
6.22 Substance-Field Analysis 312
6.23 Tool-Object-Product (TOP) Function Analysis 312
6.24 Generic Model of a Function 314
6.24.1 Precise Description of a Function 315
6.24.2 Link between Functions 315
6.24.3 Increasing Effectiveness of Function Analysis 315
6.25 TRIZ Offers Five Basic Function Models 315
6.26 Psychological Inertia 315
6.27 Size-Time-Cost Operator 317
6.28 Applying the 40 Inventive Principles in Corrosion Management 318
6.29 Conclusion 334
6.30 Glossary of TRIZ Terms 334
6.a TRIZ Contradiction Table 339
References 345
7 Environmental Impacts of Corrosion and Assessment Strategies 349
Reza Javaherdashti
7.1 Introduction 349
7.1.1 Characterization of the Disaster 350
7.1.2 Why Environment? 352
7.1.3 Corrosion Impact and Corrosion Effect 355
7.1.4 Modeling Environmental Impacts 356
7.1.4.1 Necessary Elements for Construction of Corrosion Impact Modeling 358
7.2 Some Uses of Rule 365 363
7.2.1 Application of Rule 365 to Assess Corrosion Effects 364
7.3 Conclusions 365
References 365
Index 369
