11101 Contributions to Safe Plant Construction and Operation

There is a common misconception that presupposes that the responsibility for optimum component or plant lifetime rests with the user. To maximize cost effectiveness in terms of capital outlay and minimize running costs, including maintenance costs, requires the cooperation of the designer, manufacturer, and customer (end user); see Fig. 11.25. The individual parties concerned should take a responsible role in ensuring an optimum corrosion control strategy is implemented. In this respect the following considerations should be made:

Designer:

• Prevent the use of geometrical shapes that can cause corrosion problems.

• Select the correct choice of materials.

• Based on the above take account of operational environment.

• Consider the application of protective coatings or the use of electrical protection methods.

Manufacturer:

• Ensure accurate reproduction of design.

• Restrict the use of materials to those specified at the design stage.

• Use correct heat treatments where appropriate.

TABLE 11.17 Identification of Corrosion Control Options Required at Different Stages of Project

Project Stage Input

• Conceptual design

• Preliminary design

• Appraisal of Cost

• Engineering design

• Construction and commissioning

Corrosion control options considered Select specific control options Estimate cost of options chosen Corrosion control specifications agreed Material selection/compatibility evaluated CP design confirmed

Coating type, method, and application agreed Checks on materials/CP systems/coatings, etc. Monitor corrosion control systems

FIGURE 11.25 Interaction between designer/manufacturer and customer for maximum cost effectiveness and minimum corrosion risk.

discuss feasibility of design discuss feasibility of design

FIGURE 11.25 Interaction between designer/manufacturer and customer for maximum cost effectiveness and minimum corrosion risk.

• Ensure correct fabrication techniques are applied.

• Correctly apply any protective coating systems.

Customer:

• Ensure correct maintenance procedures are applied.

• Ensure the correct replacement of materials.

• Progressively monitor environmental conditions.

• Maintain protective coatings.

• Monitor the progress of any electrical protection systems.

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