Ageing on static equipment

Table of content

Containing
Erosion
equipment

Static
Corrosion Valves
equipment

Heating
Vibration
equipment

2 Ageing a practical guide

Static Equipment
 1. Static equipment

Containment Heating Control

Piping Heat exchangers Valves
S Pressure vessels S Re boilers S Actuators
St Storage tanks Furnaces & Heaters St Safety/pressure valves
Sta Drums Sta Non return valves
Sta Reactors Sta Hydrant systems
ta i Filters ta i
Civil metal constructions
tci Flair systems
Sa tci
a
Metal constructions
Stci tci
ta
ci S Lighting poles ci
a
tc St c
ti ta
ci t
a
c ti
ci
c

4 Ageing a practical guide

Corrosion
 2. Corrosion 1/7

The chemical or electrochemical

reaction between a material and its
environment that produces a
deterioration of the material and its
properties.

Metallic iron “wants” to become iron

ore again.

6 Ageing a practical guide

 2. Corrosion 2/7

Material type

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 2. Generaal Corrosion 3/7
Atmospheric Corrosion

Carbon Dioxide
(Sweet) Corrosion

Hydrogen Sulphide
(Sour) Corrosion

Microbial
Corrosion

8 Ageing a practical guide

 2. Generaal Corrosion rate 4/7

RL = (WT - MAWT) / CR
• RL = Remnant Life calculated from the last inspection
date
• WT = Actual Wall Thickness
• MAWT = Minimum Allowable Wall Thickness
• CR = Corrosion Rate

Corrosion Rate : 0.048 mm/year at rural sites

0.079 mm/year at marine sites
0.170 mm/year in some industrial atmospheres
0,003 mm/year driest atmosphere on earth

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 2. Localized Corrosion 5/7
Pitting corrosion

Crevice corrosion

Galvanic corrosion

Erosion
Corrosion

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 2. Localized Corrosion 6/7
Cavitational corrosion

Chloride Stress
Corrosion Cracking (SCC)

Hydrogen induced
cracking (HIC)

Corrosion Fatigue
Corrosion Under Insulation (CUI)
Buried Pipes

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 2. Corrosion Protection 7/7

• Coatings
• Cathodic protection: impressed currents
• Cathodic protection: sacrificial anodes

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Erosion
 3. Erosion

Erosion is the removal of the surface

of a material by abrasion

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Vibration
 4. Vibration

At resonance, stresses (vibrations) can

cause failure of components

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Containing Equipment
 5. Ageing mechanisms

Containment equipment can be subject to

• Corrosion
• Erosion
• Vibration

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Heating Equipment
 6. Ageing mechanisms
Heating equipment has the same ageing
mechanisms as containing equipment
• Corrosion
• Erosion
• Vibration

Temperature and chemical agents

accelerate the corrosion process

Heating and cooling cycles can produce

low cycle fatigue

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Valves
 7.1 Valves types

Valve categories by purpose Valve categories by operation

Isolating valves Manually
S Regulating valves S Pneumatical Actuated
St Relief valves St Electrical Actuated
Sta Non return or Check valves Sta
Sta Solenoid valves Pressure vessels ta
ta i ti
a
Valve tci
a categories by build up tci
tci ci
ci c
c

22 Ageing a practical guide

 7.2 Ageing mechanisms 1/2

• Actuators are more prone to failure than valves

• Erosion can occure with abresive medium in the flow
• PRV’s have limited ageing but setpoint can deviate

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 7.2 Ageing mechanisms 2/2

In general valves will not be the limiting ageing factor

• Valves 100.000 to 1.000.000 cycles or 25 to 50 years

• Actuator 100.000 to 1.000.000 cycles or up to 40 years
• Check valves 1.000.000 cycles 50 years (20 to 25y overhaul)
• Solenoid valves 1 to 2 million continuous, 2 to 15 million
normal, 50 million heavy duty or 17 to 45 years

24 Ageing a practical guide