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API (American Petroleum Institute) tracks and analyzes the cause of leaks / releases of hydrocarbons based on data reported to PHMSA (Pipeline and Hazardous Materials Safety Administration). One study took a statistical look at the causes of internal corrosion for onshore liquid pipelines. In a 10-year period, a total of 503 incidents were responsible for 53,000 barrels spilled and property damage of $188,000,000.
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There are many factors to consider when optimizing your coating system for corrosion resistance. Waterborne coatings present a unique challenge due to their inherent hydrophilic nature and ability to readily conduct electrons. Waterborne resin technology has evolved greatly since its inception. If formulated properly one is able to meet and or exceed the performance of their solvent borne counterparts.
In late 2021, several leaks were observed inside the waste heat boiler coil of the steam reformer furnace at the refinery. The leaks were located in the first row of tubes of the hot bank in the vertically-oriented coil, where boiler water inside the tubes is heated via waste heat of the reformer stack. The waste heat boiler coil has a design duty of 69.59 MMBtu/hr (~20.4 MW), with design pressures and temperatures of 1010 psig (6.9 MPa) and 700°F (371°C), respectively.
In this paper, several cases will be showcased to highlight the contributing causes and underlying mechanisms of corrosion damage of components that resulted in significant releases of hazardous substances onto operator’s property, rights-of-way, and the environment. The objectives of this paper are to understand the causes of the failures and their consequences, to identify the risk factors involved, to discuss mitigative measures after failure, and to observe trends that may indicate the need for additional preventative and mitigative actions. The over-riding goal is to provide details in areas for potential improvement in pipeline operations to reduce risk and improve integrity management.
X-ray fluorescence microscopy (XFM) maps of corrosion products removed from corroded fasteners that had been in contact with preservative treated wood clearly show the presence of copper and confirm the mechanism of corrosion in treated wood.
Root cause analysis involves a detailed process of evidence collection, investigation of the evidence, subsequent analysis, and identification of corrective actions based on conclusions drawn from the evidence. The process when diagrammed out seems simple, however paramount to the process is identifying the problem or failure accurately. Misunderstanding the failure leads to misidentification of the root cause which in turn begets mitigation efforts that may or may not impactfully remediate the original failure.
Since the dawn of mankind, or at least since the advent of the very first accelerated corrosion cabinet, it has been the goal of coatings evaluators to develop an accelerated corrosion testing protocol which reflects the real world of corrosion in totality. There have been passionate arguments promoting one or another testing protocol while demonizing others, but that one protocol has yet to be developed to everyone’s satisfaction.