Corrosion failures

This chapter aims to cover the corrosion failure analysis in detail. As corrosion is considered one of the deteriorating processes of metallic equipment (among overload fracture, fatigue, creep, wear, and so on), leading to either “slow deterioration” in functionality (thickness reduction, insulating scale build-up, choking, and so on) or unexpected “sudden” failures (stress corrosion cracking, hydrogen cracking, and so on). All failures, on the other hand, are not caused by corrosion, and all corrosion events are not failures. One cannot, and should not, conclude about the method of failure unless they do a systematic exercise that probes into all facets of the experienced failure; this analysis is known as failure analysis. Every unexpected failure must be thoroughly investigated in order to determine the root cause and take preventative measures to avoid future failures. Replacement would not ensure that subsequent failures would not occur. Immediate replacement, on the other hand, is an essential and financial need.