A corrosion test system based on the electrical resistance method permits continuous monitoring of corrosion rates in refinery equipment without interrupting normal operations. Corrosion decreases the cross-section, and consequently the electrical conductivity, of a metal specimen exposed to refinery fluids at high temperatures and inaccessible locations. From the decrease in conductivity, or increase in resistance, the amount of corrosion which occurs between measurements can be determined. The system has been used successfully under all conditions of temperature and pressure encountered in a refinery. It has measured corrosion rates in vapor and liquid phases, with both oil and aqueous media. With the aid of the corrosion probe, corrosion rates in operating refinery equipment have been determined quantitatively in a few hours' time, as compared with months required for coupon measurements, water analyses, and unit inspections. Refinery corrosion inhibitors have been compared rapidly in actual use. Effects of changes in unit operating procedures upon corrosion rates have been observed shortly after the changes were made. Sensitive locations where corrosion is expected have been monitored frequently. 2.2.1
Discusses variables in a refinery which affect selection of alloy materials to be used in construction of units. Gives examples of failures caused by lack of evaluation of alloys in new processes before fabrication of units. Presents reasons a laboratory and pilot plant corrosion testing program should be established and information on effects of temperature, concentration ^ and time that should be obtained from this program. Also discusses metallurgical considerations which should be made in selection of alloys: weld metal structure, grain boundary precipitation effects in stainless steels and in other alloys, problems in clad vessels, stress corrosion cracking in alloys and effects of hydrogen on alloys. Emphasizes the need to maintain effective records of tests, chemical composition and heat treatment history of each specimen. Briefly discusses need to continue alloy evaluation by corrosion monitoring in process equipment. 6.5
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