Complex Engineering Problems (MM-435)
Problem - 1 Statement
The reversible potential for H+/H2 is -0.236 vs SHE and that of Zn+2/Zn is -0.285 vs SHE in the cell where
the zinc corroded in aerated solution of Ph 4.0. If corrosion rate in mpy is 1.5, Icorr is 0.8µA/cm2. The value
of the cathodic, bc, and anodic, ba, Tafel slopes are -0.25 and +0.20 V/decade, respectively then
(a) Calculate the activities of Zn=2 ion and H+ ion in the solution, Ecorr, corrosion potential of the reaction
and corrosion rate in mpy, mdd, gmd.
(b) Recalculate the values of the parameters estimated in (a) for pH of 6, 12, and 3, and plot the dependence
of the corrosion rate on pH.
Problem - 2 Statement
Consider two metals C and D with anodic and cathodic equilibrium polarization values of -0.637V and -
0.356V respectively. The values of equilibrium dissolution potentials were -0.45 and -0,5V respectively. If
Ecorr is -0.19V. Assume all Tafel constant to be 0.15 V /decade. Please use concepts of Mixed Potential
Theory to calculate:
(a) Icorr, and exchange current densities when coupled.
(b) Dissolved species concentrations of [A2+] and [B2+].
(c) Icorr, and exchange current densities when not coupled.
(d) Effect of two dissolved species concentration while changing the concentration of A from 4×10-6 to 1 M.
Problem - 3 Statement
Mixed potential theory is used to estimate the galvanic current and the galvanic potential in an active-
passive metal that passivates at potentials less noble than the reversible hydrogen potential. A galvanic
couple between titanium and platinum of equal area of 1.0 cm2 is exposed to 1.0 M HCl. The
electrochemical parameters for the active-passive alloy are eq, Ti = -1.63V vs. SHE; anodic Tafel, ba,Ti =
0.1; exchange current density, ioTi = 10-7A/cm2; passivation potential, Epp= -0.73 V; passivation current,
Ipass = 10-2 A/cm2; trans-passive potential, Etr = 0.4 V vs. SHE; and activity of dissolved species [Ti2+] =
1.0 M. The exchange current densities, io H+ / H2 , on platinum and titanium are 10-3 and 10-8 A/cm2,
respectively. The cathodic Tafel slopes for both platinum and titanium are b c = -0.14 V/decade. After
analyzing all the corrosion conditions and provided data, please evaluate
(a) Ti corrosion potential and rate for Ti metal using the Tafel equation.
(b) Galvanic potential and current in the platinum-titanium couple.
(c) Discuss and give your opinion about the results obtained at parts (a) and (b). You can take help from
the following figure:
Problem - 4 Statement
(a) Consider an engineering structure designed by zinc metal which is immersed in the solution
having current density of zinc is 10-3A /cm2 saturated with oxygen where potential pressure of
oxygen, PO2= 5 atm. Evaluate and comment on the corroding probability of this structure by
calculating the corrosion current and the corrosion potential. Calculate the pH.
(b) Also estimate the cathodic protection current required to completely avoid the corrosion in the
above iron structure. Following additional information can be of help.
Additional information: [Zn+2] = 1M P𝑂2 = 5 atm
ba = 0.07V/decade bc = -0.05V/decade
Current density of OH- ions = 10-5 A/cm2
Problem - 5 Statement
Assuming the test section of bare pipe 2 mile long, 5-7/8’’ OD, is to be protected , with current requirement
is 15 A. Few amount of current has been introduced in this pipe in the buried condition. The values of the
different parameters based ion the hands-on experience of cathodic protection engineer. Later this
approximate quantity is modified on the basis of the results obtained from the polarization plot. Please
evaluate the overall scenario and find out the exact current requirement for this case.
Problem - 6 Statement
The interior of a tank is to be protected. The tank contains 4567 barrels of salt water. The following data is
provided:
(1) Water level = 10 Ft
(2) Height of tank = 28 ft
(3) Diameter of tank = 40 ft
(4) Water level is maintained at 10 ft
(5) Current density = 5 mA/ft2
(6) Resistivity of water = 20 Ohm – cm
(7) Length of 2 AWG wire = 110 ft
(8) Resistance = 0.19 × 10-4 Ohms/ft
From the above data, calculate the following:
(1) Current requirement.
(2) Current output per anode if 3” ×5’ graphite anodes are used and the anode current density is 2.0 A/ft2.
(3) Number of anodes required.
(4) Anode to electrolyte resistance.
(5) Resistance of lead wire (Rw) 130 ft long.
(6) Resistance of anode.
(7) Potential drop in the circuit.
(8) Size of the rectifier to be selected.
Problem - 7 Statement
A tin structure corrodes in a solution saturated with oxygen. The pH of the solution is 6 and the partial
pressure of oxygen is 2 atm. For a sacrificial Ni-Ti alloy anode which is coupled with Mg for the protection
of structure. Calculate
(i) Corrosion current and potential of the system.
(a) Potential and sacrificial anode galvanic current required for the protection of structure.
(b) Corrosion current of the protected structure.
(iii) Is the applied sacrificial protection system satisfactory? Does the system offer overprotection or under
protection?
Following extra information is provided:
IoSn = 10-5A/cm2
ba = 0.1V / decade bc = - 0.9 V/ decade
P O2 = 5 atm [Sn+2] = 0.5 M
EZnMn = 1.3 V vs SCE
eoSn/Sn+2 = -0.4V vs SCE
Problem - 8 Statement
The reboiler which planned for sending solution of amine to the stripper. Diethanolamine (DEA) (20–22
wt%) Aqueous solution enter at one inlet which is present at the bottom of shell, which flows in between
the tubes and leave through two outlets present at the top of shell at 120 oC. Steam at the temperature 150
o
C which has inward flows in the tubes.
Materials of construction: Shell (wall thickness is 5 mm)—carbon steel ASTM A516 Gr.70. U-tubes—
SS 304.
Service period before the failure: 12 years.
(a) Discuss the Failure of the Reboiler at the Amine Treating Unit in detail
(b) Discuss the different types of corrosion failure in all figures
(c) Failure phenomenon
(d) Cause of failure and its explanation
(e) Conclusions, solutions, and recommendations.
Problem - 9 Statement
The two valves which were functioned in the overhead vacuum system. The material was ASTM A216
WCB Carbon steel. Water vapors and hydrocarbon gases like H2S flow inside of two valves at 50 °C. The
application of corrosion inhibitor or neutralizer was not actually applied. Service period before the
failure: 3 year. Following figure shows the corrosion in the Valves.
(a) Visual examination and findings.
(b) Discus the corrosion phenomena in all figures in detail.
(c) Failure phenomenon..
(d) Cause of failure and its explanation.
(e) Solutions and recommendations.
Problem - 10 Statement
(f) The heat exchanger is designed to heat sour water by cooling the water in SRU. Sour water flowed inside
the tubes at * 40 ° C. Cool water flowed inside shell at 30-35 ° C and 4 bar. Building materials. Tubes -
SS 304L. Tube sheet - carbon steel A105 integrated with SS316L (10 mm thick). Shell - carbon steel A516
Gr. 70 dressed with SS316L (3 mm thickness).
Term of service before failure: 3 years.
(a) Visual examination and findings.
(b) Failure phenomena.
(c) Cause of failure and its explanation.
(d) Solutions and recommendations.
Problem - 11 Statement
Hydrocarbon C5 flows through a reflux pipe at 60-70 ° C and 0.5 bar. Hydrocarbon leaks were found in
the hole. The pipe and pump phase has been replaced due to rust and erosion for 4 years before final
failure. Building materials. Carbon steel. Diameter - 150 mm. Service time before failure: two months
(a) Visual examination and findings.
(b) Failure phenomenon.
(c) Cause of failure and its explanation.
(d) Solutions and recommendations.
Problem - 12 Statement
Above is the tafel curve of the magnesium, and other graphene oxide coatings on AZ31B magnesium alloy
calculate the
(a) Corrosion rate in mpy, mdd
(b) Flade potential
(c) Pessivation potential
(d) Discuss the corrosion behavior in all curves and explain which curve has less corrosion resistance
Problem 13
In the following figures the Corrosion Fatigue of Aluminum Fins in the Fin-Fan Air Cooler (CCR Unit)
has been shown along with its SEM analysis. Discuss its failure analysis in the given conditions and also
answer following questions.
Conditions.
Air cooler composing from carbon steel tubes and aluminum fins is intended for cooling of gas oil by fans
located under the tubes at the HDS unit. The temperature of aluminum fins reaches 140 °C
(a) Visual examination and findings
(b) SEM examination
(c) Metallographic examination.
(d) Failure phenomenon:
(e) Cause of failure and its explanation.
(f) Solution and recommendation
