Decreasing Corrosion Rate

by sahsanb 30 May 2012, 13:29

We recently carried out thorough internal inspection of one of our 47% caustic storage tanks. Upon computing thickness monitoring data, it was revealed that if we compare corrosion rate/year of shell, roof & bottom plate for the first 9 years ( time last inspection was done) to the corrosion rate of to complete life of equipment i.e. 15 years, corrosion rate has actually decreased. In your experience how common is this kind of result, and what if any points that we may have overlooked could be causing such results. Vessel Material : SS 304L Service : 47% Caustic Temperature : Ambient Pressure : Atmospheric Thickness Probe Accuracy : +/- 0.1 mm
sahsanb Senior Member Posts: 70 Joined: 13 Apr 2012, 18:01 Area of interest: Mechanical Engineering T o p

Re: Decreasing Corrosion Rate

by ben 30 May 2012, 15:52

Can you please elaborate your query with a bit more data. What is the actual thickness of shell or other plates, thickness recorded after 9 years and after 15 years? Generally, if we talk about increasing or decreasing trend of corrosion rates, this can happen in either way and can even stay the samevwith minor difference (see the difference in your case). The factors to which corrosion rate depends are following: 1. Service type 2. Material of construction 3. Corrosion type (Erosion driven corrosion or some other form) 4. Thickness monitoring methods 5. Thickness locations (exactly the old ones or new)

6. Operator using thickness measuring device 7. Proper calibration

ben Senior Member Posts: 423 Joined: 24 Aug 2010, 03:11 Area of interest: Mechanical Engineering T o p

Re: Decreasing Corrosion Rate

by sahsanb 30 May 2012, 17:04

1.The vessel has been used all this time for 47% caustic storage tank. 2.Original shell thickness is 8 mm after 9 years it was 7.35 mm and now after 15 years its 7.2mm 3.Material of construction is SS 304L 4.Ultrasonic thickness monitoring 5.Exactly the same Thickness Monitoring Locations were used
sahsanb Senior Member Posts: 70 Joined: 13 Apr 2012, 18:01 Area of interest: Mechanical Engineering T o p

Re: Decreasing Corrosion Rate

by kumarS 30 May 2012, 19:42

There is nothing abnormal with your data. Corrosion rate isn't required to only increase with time. Especially stainless steel exhibit some corrosion at the start of the service due to contamination with carbon steel and breakage of oxide layer which then reforms after initial corrosion while in service.

kumarS Posts: 61 Joined: 29 Apr 2012, 05:57 Area of interest: Mechanical Engineering T o p

Re: Decreasing Corrosion Rate

by ace 30 May 2012, 23:09

sahsanb, do you have data for corrosion rate during first 1-2 years of operation? explaining a little bit more of kumarS comments, SS depends on oxide layer to resist corrosion. on first installation after fabrication, there is possibility that the oxide layer is not yet fully uniform and stable, it takes some time, that is one reason why higher corrosion rate in early operation. corrosion rate also related to variation of impurities level, during first year of plant startup, it is not uncommon to have product with more contamination, hence increased in corrosion rate. by the way, is the same thing happened to other equipments?
ace Senior Member Posts: 47 Joined: 02 Jan 2012, 06:51 Area of interest: Metallurgy Engineering T o p

Re: Decreasing Corrosion Rate

by irish 02 Jun 2012, 04:50

Explanation provided by kumarS and ace are reasonably good. Just want to emphasize that corrosion rate can drop or rise with time. There isn't any thing strange in it. You just need to re-check your TMLs, equipment used and personnel appointed for this job.