Boron-Free-E-CR-Glass-FRP Composites Outperforms Stainless Steels in Corrosive Environments

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Transcript of Boron-Free-E-CR-Glass-FRP Composites Outperforms Stainless Steels in Corrosive Environments

Page 1: Boron-Free-E-CR-Glass-FRP Composites Outperforms Stainless Steels in Corrosive Environments
Page 2: Boron-Free-E-CR-Glass-FRP Composites Outperforms Stainless Steels in Corrosive Environments

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

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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)

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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

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(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)

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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)

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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

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Materials Under Consideration

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Metallic structure FRP structure

Material selection is critical for each layer

Construction of Metallic Tank vs. FRP Tank

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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”

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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

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Reinforcements per Standards

Table Ref: ISO-2078

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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

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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

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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

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Testing and Analysis

(1) Uniform Corrosion & Weight Loss Testing

(2) Stress Corrosion Cracking (SCC) Testing

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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.

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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

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Weight Loss Testing

Weigh Immersion •Temperature

•Concentration •Duration

Weigh again

Glass fibers (no sizing), Metals without coating

Microscopic

analysis

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Weight Loss Testing

Glass fibers tested in 10% HCl

Metals tested in 5% HCl

Boron-Free-E-CR Glass: Correct Glass

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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

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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).

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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

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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

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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

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Cost Analysis

Boron-Free-E-CR-FRP cost competitive over Metals?

Answer is: YES!

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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

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•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

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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

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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

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• Geoff Clarkson- UTComp

Acknowledgements

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Dr. Amol Vaidya Senior Engineer Owens Corning

[email protected] 740-321-7491

Questions?