Cover -- Title Page -- Copyright -- Contents -- About the Authors -- Foreword -- Preface -- Chapter 1 Introduction -- 1.1 The Phenomenon of Corrosion -- 1.2 Importance of Corrosion -- 1.2.1 Cost of Corrosion: Direct and Indirect -- 1.3 The Purpose and Format of the Book -- References -- Chapter 2 Thermodynamics and Kinetics of Electrochemical Corrosion -- 2.1 Introduction -- 2.2 Thermodynamics -- 2.2.1 Corrosion Reactions and Gibbs Free Energy Change -- 2.2.2 Electrochemical Nature of Corrosion -- 2.2.3 Summary -- 2.3 Kinetics of Corrosion -- 2.3.1 Description of a Corrosion System -- 2.3.2 Predicting Corrosion -- 2.3.3 Passivity -- 2.3.4 Summary -- 2.4 Corrosion Evaluation and Monitoring -- 2.4.1 Electrochemical Techniques -- 2.4.2 Non-electrochemical Techniques -- References -- Chapter 3 Forms of Corrosion -- 3.1 Introduction -- 3.2 Uniform Corrosion -- 3.3 Galvanic Corrosion -- 3.3.1 Factors Affecting Galvanic Corrosion -- 3.3.2 Controlling Galvanic Corrosion -- 3.4 Pitting Corrosion -- 3.4.1 Pitting Process and Pitting Morphology -- 3.4.2 Factors Affecting Pitting Corrosion -- 3.4.3 Controlling Pitting Corrosion -- 3.5 Differential Aeration-Assisted Corrosion (Crevice, Under Deposit, and Water-Line Corrosion) -- 3.5.1 Characteristics of Differential Aeration Corrosion -- 3.5.2 Factors Affecting Differential Aeration Corrosion -- 3.5.3 Differential Aeration Corrosion Control -- 3.6 Intergranular Corrosion -- 3.6.1 IGC of Stainless Steels -- 3.6.2 Weld Decay of Stainless Steels -- 3.7 Selective Dissolution/Selective Attack -- 3.7.1 Characteristics of Selective Dissolution -- 3.7.2 Dezincification -- 3.7.3 Graphitic Corrosion -- 3.8 Flow-Assisted/Erosion/Cavitation Corrosion -- 3.8.1 Flow-Assisted Corrosion (FAC) -- 3.8.2 Erosion Corrosion -- 3.8.3 Cavitation Damage -- 3.9 Stress Corrosion Cracking.

3.9.1 Characteristics of SCC -- 3.9.2 Effect of SCC on Mechanical Properties -- 3.9.3 Factors Affecting SCC -- 3.9.4 Controlling SCC -- 3.10 Hydrogen Damage -- 3.10.1 Low Temperature Hydrogen-Induced Cracking -- 3.10.2 High Temperature Hydrogen Damage/Decarburization -- 3.11 Stray Current Corrosion -- 3.12 High Temperature Corrosion -- 3.12.1 Oxidation -- 3.12.2 Sulfidation -- 3.12.3 Hot Corrosion -- 3.12.4 Chloridation -- 3.12.5 Carburization/Metal Dusting -- References -- Chapter 4 Materials of Construction for Chemical Process Industries -- 4.1 Introduction -- 4.2 Cast Irons -- 4.3 Carbon Steels -- 4.3.1 Corrosion -- 4.3.2 Stress Corrosion Cracking, Including Hydrogen Cracking and Sulfide Stress Cracking -- 4.3.3 Caustic Stress Corrosion Cracking -- 4.3.4 Favorable and Unfavorable Points in Using Carbon Steel as MOC -- 4.4 Low Alloy Steels -- 4.5 Stainless Steels -- 4.5.1 Ferritic/Martensitic Stainless Steels -- 4.5.2 Austenitic Stainless Steels -- 4.5.3 Super Austenitic Stainless Steels -- 4.5.4 Duplex Stainless Steels -- 4.6 Nickel Base Alloys -- 4.7 Copper Base Alloys -- 4.8 Titanium -- 4.9 Aluminum Alloys -- 4.10 Nonmetallic Materials -- 4.11 Ceramics/Inorganic Oxide Glasses -- 4.12 Organic Polymers/Plastics -- 4.13 Materials Selection for Corrosion Prevention in Hydrocarbon Service -- 4.13.1 Materials Selection as per NACE MR0175 -- References -- Chapter 5 Failure Analysis Procedure with Reference to Corrosion Failures -- 5.1 Introduction -- 5.2 Purpose of Failure Analysis Investigations -- 5.3 Failure Analysis Steps -- 5.3.1 Site Visit -- 5.3.2 Tests on the Samples -- 5.3.3 Analysis, Interpretation, and Diagnosis of the Failure -- 5.4 Failure Analysis Report: Contents and Preparation -- References -- Chapter 6 Case Studies -- 6.1 Preamble -- Classification of Case Studies -- General.

CASE STUDY 1 Bromine Preheater in a Pharmaceutical Fine Chemical Plant -- CASE STUDY 2 Structurals in a White Clay Manufacturing Plant -- CASE STUDY 3 Sea Water Cooler Tubes in an Oil Refinery -- CASE STUDY 4 Package Boiler Tube in an Organic Chemical Plant -- CASE STUDY 5 Shell of a Packed Column for Ammonia and Water Contact in an Ammonia Processing Plant -- CASE STUDY 6 Instrumentation Tube in an Offshore Platform of an Oil and Gas Plant -- CASE STUDY 7 Plate Type Heat Exchanger/Cooler in a Sulfuric Acid Plant -- CASE STUDY 8 Dissimilar Stainless Steel Weld in an Organic Chemical Plant -- CASE STUDY 9 Digestor Preheater in a Pulp and Paper Plant -- CASE STUDY 10 Esterification Column in an Organic Chemical Plant -- CASE STUDY 11 Half Pipe Limpet Coil of a Stirred Reactor in an Organic Chemical Plant -- CASE STUDY 12 Firewater Lines Buried Underground in an Organic Chemical Plant -- CASE STUDY 13 Alcohol Superheater in a PVC Manufacturing Petrochemical Plant -- CASE STUDY 14 Package Boiler Tubes in an Alcohol Distillery Plant -- CASE STUDY 15 Reducers in a Reformer Tube in an Ammonia Plant of a Fertilizer Industry -- CASE STUDY 16 Pressure Safety Valve (PSV) Fitting on Instrumentation Tubes in an Off-shore Platform in an Oil and Gas Company -- CASE STUDY 17 Water Drum (Mud Drum) Shell in a Coal-Fired Steam Boiler -- CASE STUDY 18 Tubes in a Kettle Re-boiler of an Amine Plant -- CASE STUDY 19 Evaporator Tubes in an Organic Chemical Plant -- CASE STUDY 20 Top Tube Sheet Vent Equalizer Weld Zone of a Gas Cooler in a Petrochemical Plant -- CASE STUDY 21 Bottom Row Tubes in a Kettle Re-boiler of an Organic Chemical Plant -- CASE STUDY 22 Cages for Filter Bags in an Inorganic Chemical Plant.

CASE STUDY 23 High Temperature Generator (HTG) Tubes of Vapor Absorption Chiller of an Air-Conditioning and Refrigeration Unit -- CASE STUDY 24 Gasket Seat in a Shell and Tube Condenser in a Petrochemical Plant -- CASE STUDY 25 Acid Gas CO2 Cooler Condenser in Ammonia Plant of a Fertilizer Unit -- CASE STUDY 26 Naphtha Coolers in a Fertilizer Plant -- CASE STUDY 27 U Type Jet Dyeing Machine in a Textile Dyeing Unit -- CASE STUDY 28 Acetic Acid Manufacturing Unit in a Petrochemical Plant -- CASE STUDY 29 Large Stainless Steel Pipeline in a Urea Plant of a Fertilizer Unit -- CASE STUDY 30 Heat Recovery System of a PVC Unit in a Petrochemical Plant -- CASE STUDY 31 EDC Furnace Coil of a PVC Plant in a Petrochemical Unit -- CASE STUDY 32 Internals of a Stirred Reactor Processing Ortho Phosphoric Acid -- CASE STUDY 33 Salt Evaporator -- CASE STUDY 34 Cooler/Condenser Tubes of an Absorption Chiller Machine of an Airconditioning Plant -- CASE STUDY 35 Nitro Mass Cooler in an Organic Chemical Plant -- CASE STUDY 36 Fertilizer Industry Ammonia Plant Natural Gas Feed Preheater Coil -- CASE STUDY 37 Petrochemical Unit. PVC Plant. Radiant Coils of the EDC Pyrolysis Furnace -- CASE STUDY 38 Exhaust Gas Boiler in a Sugar Mill -- CASE STUDY 39 Domestic Storage Water Heater -- CASE STUDY 40 Stirred Reactor in a Rubber Chemical Plant -- CASE STUDY 41 Stainless Steel Tubes During Long Storage in Packed Condition -- CASE STUDY 42 Fertilizer Plant. Ammonia Units. Secondary Waste Heat Boiler Tubes -- CASE STUDY 43 Hospital Hydroclave for Treating Wastes -- CASE STUDY 44 Petrochemical Plant. Phosgene Absorption Column Internals -- CASE STUDY 45 Fertilizer Unit, Ammonia Plant, Start-Up Preheater Outlet Line -- CASE STUDY 46 Petrochemical Plant, Underground Fire-Water Pipelines.

CASE STUDY 47 Monel Clad Evaporator in a Pure Water Plant -- CASE STUDY 48 Loop Steamer Machine in a Textile Dyeing Unit -- CASE STUDY 49 Rubber Chemicals Plant: Leakage in Process Pipelines -- CASE STUDY 50 Clay Drier in a Clay manufacturing Plant -- CASE STUDY 51 Hydrogen Sulfide Processing Plant -- CASE STUDY 52 Textile Bleaching Vessel in a Dyeing Industry -- CASE STUDY 53 Condenser of an Absorption Chilling Machine in an Air-Conditioning Plant -- CASE STUDY 54 Petrochemical Complex: Lube Oil Cooler Tubes of Captive Gas Turbine Power Plant -- CASE STUDY 55 Petrochemical Plant: Plate Heat Exchanger (PHE) Exchanging Heat Between Spent Caustic and Vent Gas in a Cracker Plant -- CASE STUDY 56 Inorganic Chemical Plant: Distillation Pots -- CASE STUDY 57 Starch Industry: Economizer Tubes of High Pressure Captive Boilers -- CASE STUDY 58 Rubber Chemical Plant-Crump Slurry Tank -- CASE STUDY 59 Petrochemical Plant: Gas Cracker Unit, Dilute Steam Kettle Re-boiler -- CASE STUDY 60 Textile Dyeing Unit: Jet Dyeing Machine Shell -- CASE STUDY 61 Oil Refinery: 12 Inch Dia. Overhead Pipeline -- CASE STUDY 62 Fertilizer Plant: CO2 Compressor Inter-stage Cooler -- CASE STUDY 63 Oil Refinery: Flash Crude Heater Shell Cover Drain Nozzle -- CASE STUDY 64 Oil Refinery: Light Cycle Oil Steam Generator -- CASE STUDY 65 Organic Chemical Plant: High Pressure Autoclave in R&D Laboratory -- CASE STUDY 66 Fertilizer Industry: Captive Power Plant: Economizer Tube -- CASE STUDY 67 Inorganic Chemicals Plant: Reactor Shell -- CASE STUDY 68 Reactor for an Organic Chemical Plant -- CASE STUDY 69 Fertilizer Unit. Ammonia Plant. Primary Waste Heat Boiler -- CASE STUDY 70 Pulp and Paper Plant. TL Vertical Screen Inlet Line of the Paper Section.

CASE STUDY 71 Fertilizer Plant. Underground Sections of Cooling Water and Fire Hydrant Water Pipe Lines.