Expert Details

Expert in Corrosion, Failure Analysis, Materials Selection, API 584, API 580/ 581, Refinery Damage Mechanisms

Expert ID: 714994 Texas, USA

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Expert has more than 37 years of experience with laboratory failure investigations of metals, alloys and non-metals. He has a strong background in identifying damage and corrosion/cracking mechanisms and integrity operating windows for damage mechanisms in refinery and chemical plant processes. This experience has encompassed evaluating and solving corrosion-related failures of components, equipment, and structures in the chemical process, refining, oil and gas, and pulp and paper industries. This expertise includes conducting API 579 fitness for service and remaining life assessments, selecting materials and alloys for corrosion resistance and corrosion mitigation implementation. Expert also has extensive experience with API 581 risk based inspection implementation.

Expert's experience covers most of the corrosion and environmental degradation mechanisms, including electrochemical corrosion, uniform corrosion, acidic corrosion, alkali corrosion, aqueous corrosion, intergranular corrosion, intergranular cracking, rusting, weld corrosion, localized corrosion, oxygen corrosion, hot corrosion, stress corrosion cracking, corrosion fatigue, hydrogen embrittlement, H2S corrosion, microbiological corrosion, carbon dioxide corrosion, erosion-corrosion, elevated-temperature corrosion, oxidation, sulfidation, and carburization. These corrosion mechanisms and their root cause solutions have been studied in most of the commercial alloys and metals including cast irons, carbon steels, low-alloy steels (including chromium steel), stainless steels (including the austenitic, ferritic, martensitic, precipitation hardening, and duplex stainless steels), nickel and nickel alloys, copper and copper alloys, and aluminum and aluminum alloys.

One cannot obtain a fundamental understanding of corrosion mechanisms of industrial metals and alloys without gaining a corresponding knowledge of their physical and mechanical as well as their corrosion properties. The ability to properly select metals, alloys, nonmetallic materials, linings, and coatings is integral to solving corrosion-related problems and failures. A major emphasis of Expert's work has involved material selection for chemical processes and new design applications. Example areas that Expert has consulted in include recommending and specifying heat-resistant and carburization-resistant furnace tubes for reforming and ethylene pyrolysis heaters; highly alloyed steels for hydrocarbon fuel and municipal waste combustion gas environments; stainless steels and nickel alloys to resist aggressive aqueous, acidic, and alkaline aqueous processing environments; downhole alloys and coatings for oil drilling and production applications; the use of copper and galvanized steel for portable water systems; pump impeller alloys for brine service; and powder metallurgy alloys for pelletizer blades. Expert also has experience in applying, evaluating, and specifying metallic coatings for metal and alloy substrates, including thermal-spray, galvanized, aluminized, electroless nickel, chromium plating, and other finishing operations. Expert has used this experience to develop specifications for clients for fabricating, welding, repairing, and procuring equipment and pressure vessels, and for testing and inspecting fabricated and welded components and equipment.


The third triangle of Expert's expertise is root cause failure analysis of components, equipment, metals, alloys, coatings, linings, and structures due to corrosion, environmental degradation, abuse, misapplication, and mechanical failure. His experience with failure analysis is particularly strong in the chemical processing, refining, oil and gas, and pulp and paper industries. Failure mechanisms he has evaluated include general corrosion, localized corrosion, intergranular corrosion, weld corrosion, stress corrosion cracking, fatigue, corrosion fatigue, fretting, wear, erosion, overload, brittle fracture, hydrogen embrittlement, H2S cracking, microbiological corrosion, oxidation, sulfidation, and carburization. These failure types have been investigated in such diverse components as pressure vessels, welded fabrication, piping, heater and boiler tubes, marina docks, storage tanks, drums, towers, columns, pumps, heat exchangers, forgings, bearings, compressors, and gearboxes.

Expert has years of experience studying the application of non-metallic coating systems for the protection of equipment and structures from corrosion and environmental degradation. A major emphasis has been on the specification of coating systems for severe service, including immersion service in corrosive environments and for concrete containment structures in hazardous waste storage tank systems. His coating system recommendation and failure analysis experience includes the epoxies, urethanes, organic zincs, alkyds, and silicones. Expert has also generated coating system application and inspection specifications for industrial users. He has acted as the primary consultant for the development and maintenance of a corporate coating standard for an international petrochemical company.

Expert has applied his knowledge of material and corrosion properties, metals and alloy testing, and inspection to the study of the suitability-for-service, remaining life, and mechanical integrity of equipment. Expert developed a risk-based inspection procedure to rank process equipment based on the probability of internal failure.

Expert as an offshoot of his other consulting activities has been involved with the evaluation, corrosion, failure analysis, and inspection and testing of aboveground storage tanks for years. He has used this experience to certify new and existing aboveground storage tanks to the EPA Hazardous Waste Storage Tanks regulations. More recently, Expert has inspected and conducted engineering evaluations on many API 650 storage tanks in support of API Standard 653, Tank Inspection, Alteration and Reconstruction. Expert is a certified API 653 Aboveground Storage Tank Inspector. Expert has written several papers on the subject of storage tank inspection and engineering evaluation and has acted as a consultant and expert witness involving storage tank failures, including those due to leaking of tank bottoms due to product-side and soil-side corrosion.

Expert's experience covers most of the corrosion and environmental degradation mechanisms, including electrochemical corrosion, uniform corrosion, acidic corrosion, alkali corrosion, aqueous corrosion, intergranular corrosion, intergranular cracking, rusting, weld corrosion, localized corrosion, oxygen corrosion, hot corrosion, stress corrosion cracking, corrosion fatigue, hydrogen embrittlement, H2S corrosion, microbiological corrosion, carbon dioxide corrosion, erosion-corrosion, elevated-temperature corrosion, oxidation, sulfidation, and carburization. These corrosion mechanisms and their root cause solutions have been studied in most of the commercial alloys and metals including cast irons, carbon steels, low-alloy steels (including chromium steel), stainless steels (including the austenitic, ferritic, martensitic, precipitation hardening, and duplex stainless steels), nickel and nickel alloys, copper and copper alloys, and aluminum and aluminum alloys.


On-site and laboratory evaluation of failed 304SS compression fittings in Buenos Aires, Argentina securing high voltage transmission towers.On-site assistance with assessing fire damage and fitness-for-service of pressure vessel equipment exposed to a major explosion and fire, based on API 579, Fitness-for-Service guidelines.On-site assistance with the implementation of API 580 Risk-Based Inspection Programs.On-site assistance with assessing the corrosion damage to 304SS piping in seawater cooling water service in Puerto Rico.

Expert may consult nationally and internationally, and is also local to the following cities: Houston, Texas - Pasadena, Texas - Beaumont, Texas - College Station, Texas - Baytown, Texas - Bryan, Texas - Sugar Land, Texas - Port Arthur, Texas - Galveston, Texas - Missouri City, Texas

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Education

Year Degree Subject Institution
Year: 1976 Degree: BS Subject: Metallurgical Engineering Institution: University of Alabama in Tuscaloosa

Work History

Years Employer Title Department Responsibilities
Years: 1990 to Present Employer: Undisclosed Title: President Department: Responsibilities: Responsible for client consulting projects.
Years: 2002 to 2005 Employer: RBI Consulting, L.L.C. Title: Principal Department: Engineering Responsibilities: Responsible for all engineering projects, including failure analysis, corrosion investigations and technical advisor on risk based inspection projects.
Years: 1988 to 1990 Employer: Bryant-Lee Associates, Houston, TX Title: Manager Department: Responsibilities: Manager of the Houston, TX office of Bryant-Lee Associates. Responsible for client development, and consulting projects.
Years: 1986 to 1988 Employer: Law Engineering Title: Manager Department: Metallurgical Engineering Responsibilities: Metallurgical Engineering Department Manager. Responsible for client development, NDE technican staff, and client consulting projects.
Years: 1980 to 1986 Employer: ARCO Chemical Company Title: Principal Metallurgical Engineer Department: Responsibilities: Responsible for materials technology, failure analysis and corrosion control for ARCO's Texas Gulf Coast chemical plants.
Years: 1976 to 1980 Employer: Texaco, Inc. Title: Metallurgical Engineer Department: Responsibilities: Responsible for failure analysis, corrosion investigations and materials selection for Texaco's worldwide operations.

Government Experience

Years Agency Role Description
Years: 2000 to Present Agency: The Chemical Safety and Hazard Investigation Board Role: Independent Consultant Description: Expert conducted research, an independent review of documents and provided opinions regarding the root cause of a fatality incident in a crude unit at a major petroleum refinery.
Years: 2012 to 2014 Agency: City of Richmond, CA Role: Consultant to the City of Richmond involving corrosion and materials selection issues in refineries Description:

International Experience

Years Country / Region Summary
Years: 1999 to 1999 Country / Region: Buenos Aires, Argentina Summary: Expert conducted a root cause failure analysis of failed type 304SS compression fittings associated with a high voltage electrical transmission towers and conducted a fitnesss-for-service evaluation of installed compression fittings containing forging flaws.
Years: 1991 to 1991 Country / Region: South Korea Summary: Audited pressure vessel fabrication shops in Korea to verify compliance with ASME Section VIII, Div. I Code requirements and owner specification requirements.
Years: 2013 to 2014 Country / Region: Cartegena, Columbia Summary: Supported a risk based inspection project for Ecopetrol as the designated subject matter expert (SME) in damage and corrosion mechanisms for refinery processes.
Years: 2010 to 2011 Country / Region: Kingdon of Saudi Arabia Summary: Consulted with a Saudia Arabian chemical company on various projects, including failure analysis of acetic acid piping, corrosion support on risk based inspection programs and corrosion support during a unit shutdown.
Years: 2012 to 2013 Country / Region: India Summary: Conducted corrosion workshops for an India Refiner in support of a risk based inspection (RBI) program as the subject matter expert (SME) for damage mechanisms in refinery processing units.

Career Accomplishments

Associations / Societies
Expert is an active member of NACE International, ASM International and ASTM.
Licenses / Certifications
Professional Engineer in Texas, NACE Materials Design/Selection Specialist, API 653 Aboveground Storage Tank Inspector, API 580 Supplemental Inspection Certification in Risk Based Inspection
Professional Appointments
Past Chairperson of the Houston section of NACE International and past Chairperson of the Houston Chapter of ASM International.
Publications and Patents Summary
Expert is the author and/or presenter of more than 33 papers concerning corrosion, failure analysis, risk based inspection, materials selection, storage tank inspections, coatings and fitness-for-service.

Additional Experience

Expert Witness Experience
He has been a consulting or testifying expert witness in more than 30 legal cases. Activities included research, giving depositions, laboratory analysis and trial testimony.
Training / Seminars
He has presented 3-day to week long courses in corrosion, materials, metallurgy failure analysis and risk based inspection.
Vendor Selection
Expert has experience in providing vendor services for steel, alloy products, valves, flanges, used process equipment, testing services, corrosion monitoring equipment, and inspection services.

Language Skills

Language Proficiency
Spanish Expert speaks and reads some Spanish.

Fields of Expertise

chemical process equipment corrosion failure, chemical process equipment selection, stainless steel corrosion, steel corrosion, storage tank corrosion, corrosion failure analysis, austenitic stainless steel corrosion, chemical process equipment evaluation, aqueous corrosion, concentration cell corrosion, ferrous metal corrosion, acidic corrosion, alkali corrosion, corrosion-resistant alloy, corrosion-resistant material, metal material selection, corrosion fatigue, materials failure analysis, metal failure analysis, root cause failure, corrosion control, corrosion monitoring, risk based inspection, remaining life assessment, equipment failure analysis, forensic materials failure analysis, carbon steel, carbon steel corrosion, corrosion, corrosion prevention, corrosion protection, corrosion resistance, corrosion-resistant metal, duplex stainless steel, embrittlement, failure analysis, fractography, heat exchanger failure, heat exchanger failure analysis, heat-resistant alloy, in-service materials failure analysis, industrial corrosion, localized corrosion, material degradation, materials failure, materials selection, mechanical integrity, metal alloy, metal alloy corrosion, metal corrosion, metal failure, metal testing, nonferrous metal failure analysis, rotating machinery failure analysis, stainless steel, stainless steel weld corrosion, steel failure analysis, oil pump, hazardous waste storage, tank storage, corrosion evaluation, ASME Section IX Code Welding, tank bottom corrosion, corrosion coupon, equipment specific maintenance, tank bottoms, chemical industry, chemical compatibility, acetic acid corrosion, corrosion rate, chromium plating material substitute, soil corrosion, chemical degradation, corrosion allowance, alloy design, paint selection, coating selection, corrosion detection device, dezincification, rust protection, rust-preventive coating material, rust prevention, corrosion test facility, electrochemical oxidation, chromium corrosion, oil tank corrosion, austenitic steel, alloy steel, bleach plant stainless steel corrosion, chemical process equipment failure, chemical process equipment, chromium steel, rubber failure analysis, service suitability testing, anti-corrosive coating failure analysis, brittle material fracture, ferrous metal corrosion chemistry, corrosion chemistry, corrosion testing, aboveground storage tank, alloy dissolution, forensic engineering, carbon-steel welding, high-temperature corrosion, martensitic stainless steel corrosion, ferritic stainless steel corrosion, corrosion measurement, nickel corrosion, iron corrosion, erosion-corrosion, nickel alloy corrosion, copper alloy corrosion, alloy corrosion, specific material corrosion, stress corrosion cracking, stress corrosion, storage tank, nickel alloy, alloy, galvanic corrosion, fretting corrosion, electrochemical corrosion, copper corrosion, bronze, brass, brass corrosion, boiler feedwater, austenitic stainless steel

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