boron-free-e-cr-glass-frp composites outperforms stainless steels in corrosive environments
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Boron-Free-E-CR-Glass-FRP Composites Outperforms Stainless-Steels in
Corrosive Environments
Dr. Amol Vaidya, Kevin Spoo, Matt Lieser Owens Corning
October 13-16, 2014 Orange County Convention Center
Orlando, FL
Risk & Cost Implications of Metallic Corrosion •A recent estimate of the worldwide direct cost of corrosion – for prevention as well as repair and replacement – exceeded $1.8 Trillion. (Source: Gunter Schmitt, 2009) •There are more than 8.5 million tanks in the U.S. The annual cost of corrosion on storage tanks and piping is estimated to be $7 Billion. (Source: ACI Structural Journal, February 2007) •In the United States, the total annual direct cost of corrosion on natural gas distribution systems alone is estimated at $5-6 Billion. (Source: Pipeline and Gas Journal) • In 2009 cost of corrosion in water/wastewater systems alone in the U.S. was estimated to exceed $50 Billion. (Source: NACE Corrosion, 2010)
Infrastructure 16.40% ($22.6
billion)
Utilities 34.70% ($47.9
billion) Transportation 21.50% ($29.7
billion)
Production & Manufacturing 12.80% ($17.6
billion)
Government 14.60% ($20.1
billion)
Cost Implications of Metallic Corrosion
Ref: DoD Cost of corrosion- 2005-2013
Cost of corrosion by industry categories : $137.9 Billions
(1)Material selection
(2)Chemical treatments
(3)Use of coatings
(4)Cathodic protection
(5)Process and equipment control
(6)Design per codes
(7) Inspection and monitoring
Exposure
Mechanical Properties
Availability of design and test data
Cost
Availability
Maintainability
Compatibility with other components
Reliability
Appearance
Ref: Dawson et.al., “Management of Corrosion in the Oil and Gas Industry”, 2010
Planning: Front End Engineering Design (FEED)
Material Choices for Engineers • Rubber lined steel • Resin lined steel • Stainless Steel (SS) alloys • High nickel alloy clad carbon steel
• Fiberglass reinforced polymer (FRP) material
Equals an engineered material system resulting in unique attributes replacing traditional materials
+ Other Materials
Resins Additives
Fire retardant UV, Etc.
Reinforcements
Glass Fiber 95%
Other
What is FRP? (Fiberglass Reinforced Polymer)
FRP Properties Delivering High Performance and Lower Costs
Lightweight
Durable
Corrosion resistance
High strength
Fatigue resistant
Non-conductive
Design flexibility
Properties Industries
Power & Energy
Mining
Chemical Processing
Water / Treatment
Food Processing
Other Industrial
Contributes in reducing RISK & COST of Corrosion
Materials Under Consideration
Metallic structure FRP structure
Material selection is critical for each layer
Construction of Metallic Tank vs. FRP Tank
Superior corrosion performance is offered by Boron-Free-E-CR Glass-FRP over metals
Typical Properties: FRP vs. Metals
Ref: Britt Engineering- White paper “Design of FRP pipe systems”
AISI type
Cmax Mnmax Pmax Smax Simax Cr Ni Mo
SS- 304 0.08 2 0.045 0.03 1 18 -20 8 - 12
SS-316L 0.03 2 0.045 0.03 1 16 - 18 10 - 14 2 - 3
Material Composition Makes a Difference in Corrosion Performance Composition %
Composition of the metal dictates the corrosion performance
Reinforcements per Standards
Table Ref: ISO-2078
ASTM-D-578
Glass type
B2O3 CaO Al2O3 SiO2 MgO Na2O+
K2O TiO2 Fe2O3 Fluoride
E-Glass General purpose 0 - 10
16 - 25 12 - 16 52 - 62 0 - 5 0 - 2 0 - 1.5 0.05 -0.08 0 - 1
Boron Free-E-
CR-Glass Corrosion
Application 0 16 - 25 12 - 16 52 - 62 0 - 5 0 - 2 0 - 1.5 0.05 -0.08 0 - 1
Composition %
Similar to Metals: Composition of Glass Fibers Dictates Corrosion Performance
Why Boron-free-E-CR-glass is preferred per ASTM-D-578 Elements of the
E-glass fiber are leached and replaced with hydrogen. This results in a porous exterior.
E-CR glass being Boron-Free; resists leaching and offers superior corrosion performance
2 hours in 5% HCl @ 80ºC
Corrosion in Metals and Metal Alloys
(1)Dry Corrosion: Dry corrosion is concerned with oxidation of metals at high temperatures.
(2)Wet Corrosion: Corrosion occurs in aqueous solutions encountered by chemical storage tanks. a. Uniform or general corrosion b. Galvanic/bi-metallic corrosion c. Crevice corrosion d. Pitting corrosion e. Inter-granular corrosion f. Stress corrosion cracking g. Corrosion fatigue h. Selective corrosion
Testing and Analysis
(1) Uniform Corrosion & Weight Loss Testing
(2) Stress Corrosion Cracking (SCC) Testing
Uniform OR General Corrosion of Metals
Uniform (general) corrosion is the form that corrodes the metallic surface more or less uniformly due to chemical exposure or oxidation
Results in a reduction of the wall thickness and weight-loss of the tank or pipe
Iso-corrosion charts aid corrosion engineers for proper material selection FRP does not undergo Uniform Corrosion: Material cross section constant overtime
Ref: APV Corrosion Handbook, “Handbook of Corrosion Data” 2nd Edition, ASM.
Uniform OR General Corrosion of Metals
Metals: Tank wall thickness reduces over time → Safety factor drops FRP: Tank wall thickness constant → Strength drops due to corrosion attack
Ref: UT Comp: 2012 PEERS Conference
Metal tank wall thickness drops over time
FRP tank wall thickness constant
Weight Loss Testing
Weigh Immersion •Temperature
•Concentration •Duration
Weigh again
Glass fibers (no sizing), Metals without coating
Microscopic
analysis
Weight Loss Testing
Glass fibers tested in 10% HCl
Metals tested in 5% HCl
Boron-Free-E-CR Glass: Correct Glass
Metals vs. E-glass vs. Boron-free-E-CR
Boron-Free-E-CR Glass: Correct Glass
† Boron-free-E-CR-Glass considered in this paper is Advantex®-Glass fiber which is a registered trademark of Owens Corning at One-Owens Corning Parkway, Toledo, Ohio 43604
†
Stress Corrosion Cracking (SCC)
50% of failures in SS structures are associated with this mode of failure*
SCC designates failure by cracking under the combined action of corrosion and an applied stress
The morphology of this type of failure is invariably a fine filamentous crack which propagates through the metal in transgranular manner
Ref: * Web article: “Stress Corrosion Cracking”, National Association of Corrosion Engineering (NACE) http://events.nace.org/library/corrosion/Forms/scc.asp (visited 15th July 2013) Image: http://www.offshore-mag.com/content/dam/etc/medialib/offshore/2010/april/70496.res/_jcr_content/renditions/original (visited 20th J 2014)
Chloride-induced stress corrosion cracking in 316 stainless steel (100X magnification).
Stress Corrosion Cracking of FRP
Boron-Free-E-CR Glass: Correct Glass
• Stress rupture of Composite Rods in 1 Normal Acids (HCl - H2SO4) • Superior corrosion resistant resin used in for both samples • Boron-Free-E-CR-Glass-FRP provides superior corrosion performance over E-Glass-FRP
Ref: “Glass Fiber Reinforcement Chemical Resistance Guide”, Owens Corning- Edition 1-A, March-2011
The stress-corrosion testing places a composite rod in tension while exposing it to a corrosive media at a selected temperature.
Multiple stress levels are selected and the time to failure (a tensile break) is recorded.
When plotted as a log/log plot a straight line linear regression can be obtained.
Stress Corrosion Cracking (SCC) Testing
Patterned after ASTM D-3681
E-CR-FRP Outperforming SS-304 and SS-316 in NaCl and HCl: Superior service life Weight savings Cost saving
Stress Corrosion Cracking (SCC) Results
Boron-Free-E-CR Glass: Correct Glass
Material Weight per linear foot
Service Life in 5% NaCl
Service Life in 3.65% HCl
(lbs) (Years) (Years)
Boron-Free- E-CR-FRP 0.04 58 years 20 years
SS 304 0.38 12 years 3 years SS 316 0.38 23 years 3 years
Cost Analysis
Boron-Free-E-CR-FRP cost competitive over Metals?
Answer is: YES!
Boron-Free-E-CR-FRP Lowering Cost of Corrosion
Scrubber system built with SS-2205 → Inspected after 12 months → Severe corrosion inspected → resulted in $5 million losses within a short period of time E-CR-FRP material offered exceptional corrosion resistance for such units. These FRP units in operation with minimal maintenance → Lowering the cost of corrosion
Coal power plants scrubber units Each scrubber unit holds ~ 1 million gallons of lime slurry → highly corrosive environment Each unit costs ~ $200- $500 Million → Huge investment
Ref: Lieser, M., “How to Use FRP Material to Lower Corrosion Costs”, Polymer Society vol. 5, No.5, (2013): p.22-27
•Assembled cost comparison for 6000 gallons Sodium Hypophosphite tank •Quotes obtained from tank fabricators in North America •Boron-Free-E-CR-FRP fabricated using E-CR glass with Vinyl Ester Resin •Tanks designed per ASTM-D-3299
Ref: Based on fabricated tank cost in Aug.2013
Boron-Free-E-CR-Glass-FRP Reducing Project Cost
Boron-Free-E-CR-Glass-FRP Reducing Project Cost
Typical Concerns Cost Category
Boron-Free-E-CR-FRP benefit in corrosive environment
Inspection Direct cost Non-corrosive- lowers inspection frequencies
Chemical inhibitors Direct cost Inhibitors not required
Corrosion monitoring Direct cost Monitoring is easy – in-use – no production stops
Coating maintenance Direct cost Does not require coating in most cases
Increased maintenance
Indirect cost Lower maintenance as doesn’t corrode
Deferred production Indirect cost Less outages – lesser deferred productions
Logistics Indirect cost Light weight hence lower machinery to operate
Project COST can be minimized by selecting Boron-Free-E-CR-Glass-FRP
Take Away Points….. • All metals are not the same – All FRP is not same as well →
specify Boron-Free-E-CR-Glass reinforcements and choose resin wisely
• Boron-Free-E-CR-Glass-FRP can offer exceptional performance
+ cost benefits over expensive alloys • “Glass Fiber Reinforcement Chemical Resistance Guide”
provides recommendation for selection of FRP for corrosive environments to ensure longevity of the structures
• Contact material suppliers to obtain detailed information on materials and their performance
Boron-Free-E-CR Glass:
Correct Glass
• Geoff Clarkson- UTComp
Acknowledgements
Dr. Amol Vaidya Senior Engineer Owens Corning
Amol.vaidya@owenscorning.com 740-321-7491
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