Corrosion effects on a leakage steam control valve: analysis and risk assessment on the biodiesel plant case study

General surface erosion can be caused by the continuous exposure of metal surfaces to corrosive materials, resulting in further weight loss. This happened in the steam control valve, where continuous exposure to the steam flow rate resulted in erosion of the control valve wall. The purpose of this study is to discuss the causes of steam control valve failure due to corrosion in a biodiesel plant using the gravimetric and salt spray methods, based on the effects caused, and to review the safety risks and implication in more detail. Corrosion which occurred in the first year was 0.7321 mm/year, while corrosion which occurred in years 12 to 15 was relatively more stable at about 0.005 mm/year. Weight and metal losses during the first year were 45 g/year and 0.6052 mm/year, while those during the 14th to 15th years were relatively stable at about 4 g/years and 0.0630 mm/years. The results of the control valve salt spray chamber measurements are value obtained shows that higher NaCl concentration causes higher corrosion. In this observation, the highest value obtained was 0.3181 mm/year at 20% NaCl concentration, while the lowest value was 0.1548 mm/year at 5% NaCl concentration. A robust maintenance schedule helps identify early signs of wear and corrosion, allowing for timely intervention. Implementing a comprehensive maintenance and predictive programme will save time and reduce operating costs for a biodiesel plant.