Download - Advantex glass for industrial corrosion - An industry issue creates an opportunity for FRP material
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Advantex® glass for Industrial Corrosion
An industry issue creates an opportunity for FRP Material
Matt Lieser, Owens Corning, Composites Specification Manager [email protected], 614-507-5828
The Problem of Corrosion
Direct and indirect economic losses derived from corrosion include the following Replacement of damaged
equipment Overdesign to allow for corrosion Preventative maintenance Shut down due to corrosion
failure Efficiency decrease Health & Safety issues
The cost of Corrosion in the USA accounts for a total of $276 Billion per year
Source: NACE 2012
Storage Tank - Corrosion
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:
Source: ACI Structural Journal, February 2007
316L Coated Stainless Steel Tank Corroding
Cost of Corrosion - Water Supply
2009 cost of corrosion in water/wastewater systems alone in the U.S. was estimated to exceed $50 billion.
Over 6 billion gallons of treated water are lost everyday. Corrosion is the leading cause of leaks and breaks in piping systems
Source: NACE Corrosion 2010, University of Akron – 2012 Corrosion Forum
2014 NA Industrial Investment Outlook An Attractive Market
Source: Industrial Information Resources, January, 2014
Billion Dollars
18% 17%
17%
4%
5%
12% 11%
0 20 40 60 80 100 120
Pharmaceutical & Biotech
Industrial Manufacturing
Food & Beverage
Pulp, Paper & Wood
Metals & Minerals
Chemical Processing
Petroleum Refining
Alternative Fuel
Prodeuction (Onshore Oil & …
Pipelines (Oil, Gas, Liquids)
Terminals (Oil, Gas, Liquids)
Electric Generation
201420132012
6%
$438 Billion of spending in forecast for 2014, a 9% Annual Increase vs. 2013 2014 NA Industrial Investment Outlook
Please contact Owens Corning for details as presented.
Matt Lieser Specification Manager
614-507-5828 [email protected]
Material Choices for Engineers
Rubber lined steel Resin lined steel Stainless Steel alloys High nickel alloy clad carbon steel Fiberglass reinforced polymer (FRP)
composites Dual laminates (Thermoplastic lined FRP)
Advantex®-FRP: FRP with Corrosion Resistant Glass combined with Resin
Fiber Reinforced Polymer (FRP) Composites
Fiber types: Glass (95% or more), Carbon, Aramid
Contribute in Reducing Overall Project Costs
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
FRP Is A Competitive Material
Source: Owens Corning and US Bureau of Labor Statistics – April, 2013
Producer Price Index Comparison Competing Materials
100
120
140
160
180
200
220
240
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012
Inde
x (1
982=
100)
Composite PipeSteel Mill ProductsUS CPI
2013 data = As of April 2013
2013
Please contact Owens Corning for details as presented.
Matt Lieser Specification Manager
614-507-5828 [email protected]
Many FRP Applications are Lower in Cost
1) Modeled by IBIS and Associates, July 2012. Simple single wall cylindrical tank with no manway, vents, flanged ports etc. Validated by quotations
Advantex FRP
316L SS Tank
Storage Tank Comparison
Please contact Owens Corning for details as presented.
Matt Lieser Specification Manager
614-507-5828 [email protected]
Assembled Tank Cost Comparison: Sodium Hypophosphite
Cost Comparison for 6,000 Gallons Tank Showing Advantex-FRP Tank as the Cost-Efficient Solution [based on quotes obtained in August-2013]
Advantex® FRP-Tank
Advantex FRP
Please contact Owens Corning for details as presented.
Matt Lieser Specification Manager
614-507-5828 [email protected]
Advantex® FRP Outperforms Stainless Steel Lowering Corrosion Costs For End-Users
Corrosion Comparison between 3/8inch diameter stainless steel rod vs. 1/4inch Advantex FRB rod in 5% NaCI at Room Temperature
20000
15000
10000
Appl
ied
Load
(N)
0 100000 200000 300000 400000 500000 50 years Time to failure (hr)
Please contact Owens Corning for details as presented.
Matt Lieser Specification Manager
614-507-5828 [email protected]
Advantex® FRP Outperforms Stainless Steel Hydrochloric Acid
Corrosion Comparison between 1/4"inch diameter stainless steel rod vs. 1/4inch ECR-RFP rod in 3.65% (1N) Hydrocholric Acid
Please contact Owens Corning for details as presented.
Matt Lieser Specification Manager
614-507-5828 [email protected]
Weight Loss Comparison - Reinforcement
BAD
GOOD
Carbon steel in 5% HCI @ 96C-4 hours
Stainless Steel-304 in
5% HCI @ 96C – 4 hours
Stainless Steel – 316-L in 5% HCI @
96C – 4 hours
E-Glass in 10% HCI @
96C – 24 hours
E-Glass in 10% HCI @ 96C – 168
hours
Advantex® in 10% HCI @
96C – 24 hours
Advantex® in 10% HCI @ 96C – 168
hours
62%
6% 9%
32% 32%
8%
12%
Please contact Owens Corning for details as presented.
Matt Lieser Specification Manager
614-507-5828 [email protected]
Advantex® is the Best Performing Primary Reinforcement Material
Carbon Steel in 5% HCl@96C after 4 hours
SS-304 in 5% HCl@96C after 4 hours
E-Glass in 10% HCl@96C after 24 hours
Advantex® in 10% HCl@96C after 24 hours
SS-316-L in 5% HCl@96C after 4 hours
Please contact Owens Corning for details as presented.
Matt Lieser Specification Manager
614-507-5828 [email protected]
Typical Steps in Corrosion Mitigation
Ref: Dawson et.al., “Management of Corrosion in the Oil and Gas Industry”, 2010
Front End Engineering Design (FEED) phase
Exposure Mechanical Properties Availability of design and
test data Cost Availability Maintainability Compatibility with other
components Reliability Appearance
(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
What Prevents End-Users From… …Using FRP Material Solutions
Source: Owens Corning Webinar – “How to Lower Corrosion Costs Using FRP”- Poll Question, April, 2012 (300 Attendees, from 50 countries)
QUESTION: What prevents you from using more Composites (FRP)?
Please contact Owens Corning for details as presented.
Matt Lieser Specification Manager
614-507-5828 [email protected]
Steel Selection For Corrosive Environments
Factors that influence corrosion performance of metal & alloy: Service Environment & Applications Material Condition & Fabrication
Levels of Corrosion Resistance
Chloride Stress Corrosion Cracking
Sulfuric Acid Oil Field Environments
Outstanding Nickel or Cobalt-Base Alloys – C-276
Nickel or Cobalt-Base Alloys – C-276
Nickel or Cobalt-Base Alloys – C-276
Excellent Duplex Stainless Steel – 2205 Metals and Alloys
Good Austenitic Stainless Steel - 316
Duplex & Austenitic Stainless Steel - 316
Duplex & Austenitic Stainless Steel - 316
Alloy Comparisons for selection in various environments
FRP Material Selection is as Important as Selecting Steel Type
Selecting the best suited materials for applications facing corrosive environments are key to long-term success
Glass Reinforcements Provides Strength and
Modulus
Orientation Maximizes Directional Properties
Glass Type Optimizes Corrosion Performance
Resin Locks fibers in place
Determines heat resistance, flame retardance
Certain types offer higher corrosion resistance
Factors that influence corrosion performance of FRP: Service Environment & Applications: Temperature, pH & concentration, velocity of corodent Material Condition & Fabrication: Fabrication process, design of the laminate
Use of Proper FRP Material Is Important
Glass Fiber Reinforcements Glass Types: A-glass, C-glass, E-glass,
Advantex®, E-CR glass, H-glass, R-glass, S-glass
Multiple product forms depending upon the manufacturing process
Veil Type C-glass, Advantex®, Polyester, Carbon,
etc.
Resin Unsaturated Polyester, Bisphenol
Fumarate, Chlorendic Anhydride, Epoxy Vinyl Ester, Novolac Epoxy, Brominated Epoxy
Additives Abrasion resistance Fire retardant UV protection
Contact Owens Corning To Provide The Material Selections
Materials used to make FRP equipment facing corrosive environments:
Material selection is critical for each layer
Construction of Metallic Tank vs. FRP Tank
Metallic structure
Paint layer for
Protection against nature elements
Barrier layer
Sacrificial layer
Base metal
EXTERIOR INTERIOR
FRP structure
How To Get Started To Lower Corrosion Costs
Identify suitable applications for FRP material Implement company FRP material
construction standards Specify proper materials to construct an FRP
application for the environment Partner with quality fabricators Understand how to inspect the material
Owens Corning Supporting End-Users To Become More Competitive in the Marketplace
Identify Suitable Applications For FRP Material
When considering the use of FRP vs. traditional materials to lower corrosion costs: Confirm suitability of the environment
Temperature conditions Chemical environment Strength requirements (including pressure/vacuum)
Verify FRP will perform better than traditional materials Case histories, FRP coupon testing
Validate overall lifetime costs will be lower with FRP vs. traditional materials
Application Development Determine the possibility of FRP vs. traditional
materials
Owens Corning Can Help You Identify Suitability
Example: Suitable FRP Applications Delivering Performance
FRP Pipe System Length: 4,300 lineal feet of 12” & 16” diameter FRP pipe.
Weight Savings: 677,760 lbs. saved vs. 316 SS
Projected Service Life: 50 Years
National 911 Memorial Fountains at New York City’s World Trade Center
Source: Industrial Fiberglass Specialties
Key Facts: FRP Composite Pipe
Verify FRP Will Perform Better… …Than Traditional Materials
Corrosion Performance: FRP corrosion resistance in many cases surpasses stainless steel and
high nickel alloy
Corrosion Performance FRP 2205 SS C0276 Alloy
Hydrochloric Acid 900O C to 15% concentration
60O C to 1% concentration
80O C to 15% concentration
Add Chloride 100O C in all 65O C with 2,000PPM @ low
65O C with 50,000PPM @ low
Strength Properties: In the fiber direction, FRP is stronger than conventional steels and
C-276 Conventional steels and C-276 are both initially stiffer than FRP, but
yield and begin elongating early FRP is significantly lighter than other corrosion-resistant materials –
density is lower by a factor of four
FRP Company Specification Protocol
Every company using FRP should have an
internal FRP General Specification to ensure consistent quality material, design and fabrication methods are used.
This specification will include requirements for: Governing standards to follow Drawings and calculations Fabrication methods FRP Laminate properties FRP Laminate sequence
Goal: To Create Consistent Quality FRP Assets Across Your Enterprise
Inspection & Maintenance Protocol
Similar to metal you will want to conduct inspections of your FRP assets
Different Inspection protocols will be used depending on the severity of the chemical environment Visual Inspection Acoustic Emission Ultrasonic Destructive Testing Digital Radiography
UTComp Inc.
Goal: Safe and reliable FRP assets
Owens Corning – Making It Easy… …To Use FRP Material…And Lower Corrosion Costs
Stop Feeding Corrosion
We can link you with 1,000’s of qualified fabricator around the world
Partner with Owens Corning to identify opportunities from the 1,000’s of available applications
Support new application development to solve a problem
We can provide material specification & recommendations for standards
Recommend inspection options and services to implement proper inspection protocols.
Lowering Cost of
Corrosion
End-Users: Chemical Industrial Mining Oil & Gas
Material Specifications
Applications
Owens Corning
Inspection
Fabricators
Copyright © 2014 Owens Corning. All Rights Reserved. Images © istockphoto.com
Thank You For More Information Please Contact: Matt Lieser 614-507-5828 [email protected]