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]

mailto:[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





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





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





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)





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





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%





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





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)?





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]

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Advantex glass for industrial corrosion - An industry issue creates an opportunity for FRP material