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CORROSION CORROSION 101101
Why we are here• To discuss the problems of corrosion and learn about
corrosion control• To meet others and share thoughts, knowledge and
concerns• To see how to avoid failures, excessive costs and
other problems through corrosion control
Outline• Introduction–economics• Applications to various industries• Corrosion –what is it and what causes it
• Examples of corrosion problems
Outline• Methods of Corrosion Control
– Materials Selection– Coatings and Linings– Cathodic Protection– Inhibitors– Engineering Design– Monitoring and Maintenance
• NACE Resources
Introduction
• Problems in Recognizing Corrosion• Costs of Corrosion• Economics of Corrosion Control• Safety• Environmental Factors • Value of Corrosion Control
Problems In Recognizing Corrosion
• Not mobilized by public opinion• Not recognized as an engineering discipline• Not recognized as controllable
Cost of CorrosionTotal Direct Cost of Corrosion in the
U.S.B$276 / year = 3.1% of GDP
Source: Corrosion Cost and Preventative Strategies in the United States, September 2001, Report FHWA-RD-01-156
Summary of Costs per SectorCost of Corrosion per Analyzed Economic Sector, ($x billion)
$8.3$7.0
$0.3$7.0
$-$-
$5.0$36.0
$6.9$-
$23.4$2.7
$2.2$0.5$0.9$1.4
$0.1$3.7
$1.7$6.0
$1.1$2.1
$-$1.5
$20.0$0.1
1.00
Highway BridgesGas and Liquid Transm. PipelinesWaterways and PortsHazardous Materials StorageAirportsRailroadsGas DistributionDrinking Water and Sewer SystemsElectrical UtilitiesTelecommunicationMotor VehiclesShipsAircraftRailroad CarsHazardous Materials TransportOil and Gas Expl.and ProductionMiningPetroleum RefiningChem., Petrochem., Pharm.Pulp and PaperAgriculturalFood ProcessingElectronicsHome AppliancesDefenseNuclear Waste Storage
How much money is lost to corrosion annually in the USA?
It costs U.S. households, businesses, and government agencies more than $300 billion each year.
That’s $1,100 for every man, woman, and child in this country.
(These are direct costs but there are also indirect costs of corrosion.)
Direct Corrosion CostsExcessive Maintenance / Repair / ReplacementLost Production / DowntimeProduct ContaminationLoss of ProductLoss of Efficiency (Oversizing & Excess)Energy CostsAccidentsIncreased Capital Costs – OverdesignEnvironmental Cleanup – Fines
Indirect Corrosion CostsSafetyStructural CollapseLeaksFire / Toxic ReleasesProduct ContaminationFoods / Pharmaceuticals WaterConsumer ConfidenceLoss of RedundancyAppearance Increased Regulation
Costs are about 5% of U.S. GNP
• Costs add up to about $2,000 per person per year– $500 Billion in the USA– $58 Billion in Canada
• About 35% of this could be saved through better corrosion control
• % of GNP is about the same in other developed countries
Corrosion Affects You!
• Your Environment
• Your Company
• Your Job
• Your Safety
• Your Pocketbook
Economics of Corrosion Control
• Avoid excessive maintenance costs• Avoid unexpected shutdowns• Avoid financial losses and lawsuits
Economic Analyses• Long range costs of project vs. initial cost• Maintenance costs (operations) vs. capital
investment (new construction)• Return on investment is usually ten times the cost
Safety
• Safety is everybody’s business• Fire and explosions• Bridge collapses• Falls from corroded ladders or gratings• Machine parts• Automobile and aircraft parts
– arouses public opinion
Safety (cont)
• Loss of electrical grounding due to corrosion of connections
• Overheating of electrical contacts due to corrosion (fire hazard)
• Collapse of reinforced parking deck• Falling of building decorations and facia• Loss of fire protection from corroded piping
Environmental Factors• Leakage• Pollution of water and earth• Atmospheric corrosion and deterioration from acid
rain• Preservation of resources
Value of Corrosion Control• Preservation of materials and products• Gain desired product life• Avoid safety and environmental problems• Avoid financial losses• Avoid inconvenience to customers• Avoid shut downs and loss of production• Economic advantages of control over losses
Application to Various Industries
Application to Various Industries
• Pipelines• Underground Storage
Tanks• Industrial Plants• Power Generation• Transportation
• Marine • Waterworks• Petrochemical Plants• Pulp and Paper• Real Estate• Private Homes
Application to Various Industries
• Pipelines - transmission and distribution– Leak prevention– OPS rules (USA)– NEB rules (Canada)
Application to Various Industries
• Underground storage tanks– Pollution control– EPA and NEB rules
Application to Various Industries
• Industrial plants and manufacturing– Underground structures– Mechanical equipment– Process equipment– Fire protection, heating and cooling systems– Product liability – Customer satisfaction
Application to Various Industries
• Real Estate– Plumbing systems– Mechanical equipment– Air conditioning
Application to Various Industries
• Transportation– Safety and performance of vehicles, aircraft, etc.– Pipelines, trains, etc.
Application to Various Industries
• Power generation– Boilers– Condensers and heat exchangers– Underground structures– Nuclear reactors
Application to Various Industries
• Marine– Docks and wharfs
• saltwater• freshwater
– Ships– Offshore platforms and structures
• Environment• Safety
Application to Various Industries
• Water works– Transmission and distribution piping– Water storage tanks– Water and waste water treatment plants– Sewers
Application to Various Industries
• Chemical and petrochemical– Refineries– Marketing terminals– Aboveground Storage Tanks– Underground piping and Tanks– Product handling equipment– Safety of carriers - trucks, rail, ships
Application to Various Industries
• Pulp and paper– Reactors, clarifiers, etc.– Paper making machinery
Application to Various Industries
• Oil and gas• Production wells• Crude oil equipment• Offshore platforms• Treaters/Process Vessels• Storage Tanks
Application to Various Industries
• Private homes– Water heating tanks– Metal siding– Aluminum screens, doors, etc.– Steel garage doors– Appliances– Burglar and fire alarms
What is Corrosion?
Corrosion• Definition:
The destruction of a substance, usually a metal, or its properties because of a reaction with its surroundings environment).– The natural tendency of a refined metal to return to its
original state as an ore
Elements of a Corrosion Cell
CathodeAnode
ElectrolyteMetal Path
An Electrochemical Cell Must Have:
• Anode - where oxidation occurs• Cathode - where reduction occurs• Electrolyte - where ion migration occurs• Metallic path - where electrons migrate from the
anode to the cathode
Are all of these Corrosion?
Single Corrosion Cell
e-e- e-
e-e-e-e-
e-
e- e-
Fe++ Fe++
Fe++
Fe++
OH-
OH-
OH-
Fe(OH)2
Fe(OH)2
Fe(OH)2H+
H+
H+
H+
H+
H+
H+HH
H
CATHODICSITE
ANODIC SITE
Fe++Fe++e-
Microscopic View
The Corrosion Cell• Metallic corrosion is an “electrochemical reaction”
which involves :– a transfer of electrons– oxidation - loss of electrons (corrosion)– reduction - gain of electrons (protection)– migration of ions
ee
Cu Fe
ee
ee
Metallic Path
Cathode Anode
Electrolyte
Fe++
H+
H+
H+OH—
H+OH—
Actual Case Showing Ion and Electron Flow
e eStructure (Metallic Path)
EFe Fe++
2H+ + 2e H2H2O H+(OH)—+2e
H+ H+Fe++
Electrolyte
Practical CaseShowing Conventional Current Flow
Corrosion Current Electrolyte
(soil)
Cathode
E
Anode
Structure (metallic path)
Electrochemical ReactionsAnode: (Oxidation)
Fe Fe++ + 2e—
Cathode : (reduction) 2H+ + 2e— H2
3O2 + 6H2O + 12e– 12OH—
O2 + 4H+ + 4e— 2H2O
ElectrolyteH2O H+ + OH—
Fe ++
Fe ++
Fe++
Fe ++
Fe ++
Fe ++Fe ++
Fe++
Fe++
e-
e - e -
e-
e-e-
e-
e-e-
e-
e-
e-e-e-
e-
e -e- e-
ANODE
Oxidation Reaction
ELECTROLYTE
Anodic Process
Reduction Reaction
H+
e-
e -
e-
e-
e -e-
e - e-
e-
e-
e-e-
e-
e-e-
e-
e-
CATHODE H
H+
H+
H+
H+
H+
HH
H+H+
H+H+
H+H+
H+
HH
H
ELECTROLYTE
Cathodic Process
Why Does Corrosion Occur?
Corrosion is driven by the voltage difference between irregularities on the surface of the structure.
Forms of Corrosion
Forms of Corrosion• General Corrosion• Localized Corrosion• Galvanic Corrosion• Environmental Corrosion Cracking• Flow-assisted Corrosion• Intergranular Corrosion• Dealloying• Fretting• High-temperature Corrosion
General CorrosionCorrosion that proceeds more of less uniformlyover the exposed surface without appreciablelocalization of attack.
General Attack Corrosion
GeneralCorrosion
General Corrosion• Dissimilar surfaces• Dissimilar soils/electrolytes/environments• Dissimilar oxygen concentration• Dissimilar metal ion concentration
General Corrosion due to Dissimilar Surfaces
• Mill Scale• New–Old Pipe• Stressed Surfaces• Welded Sections (Heat Affected Zone)
Corrosion Caused by Dissimilarity of Surface Conditions
Scratches Caused by Pipe Wrench(Anode)
Threads Bright Metal (Anode)
Pipe(Cathode)
New—Old Pipe Cell
Old Pipe (cathode)
New Pipe (anode)
Old Pipe (cathode)
Different Stress
The portion of the metal under higher stress, (eg. cold worked) will be anodic to the portion of the metal at a lower stress level.
– High Stress Anode– Low Stress Cathode
Stress Corrosion
Pipe
Lower Stressed Area (cathode)
Higher Stressed Area (anode)
Lower Stressed Area (cathode)
Coupling
General Corrosion due to Dissimilar Electrolytes
In most cases, the metal immersed in the moreconductive solution will be the anode, and the metal immersed in the less conductive solution will be thecathode.
– More Conductive Anode– Less Conductive Cathode
General Corrosion due to Oxygen Concentration
• The metal immersed in the oxygen lean electrolyte will be the anode, and the metal immersed in the oxygen rich electrolyte will be the cathode.
–Oxygen lean Anode–Oxygen rich Cathode
Dissimilar Metal Ion Concentration
• Cathode–in saturated solution• Anode –in unsaturated solution
Corrosion Caused by Differential Aeration of Soil
Poor or No Aeration (anode)
Aerated Soil
Structure
Localized Corrosion• Pitting
A deep, narrow corrosive attack in a localized region which often causes rapid penetration of the substrate thickness.
• Crevice CorrosionA form of localized attack in which the site of the attack is an area where free access to the surrounding environment is restricted..
• Filiform CorrosionA special form of oxygen cell corrosion occurring beneath organic or metallic coatings on materials. The attack results in a fine network of random “threads” of corrosion product developed beneath the coating material.
PittingSeveral pits that became interconnected and still partially covered by corrosion product.
Individual Pit
Crevice Corrosion Mechanisms
Corrosion Deep Inside Crevice
Oxygen Concentration Cell CorrosionAnodic area inside crevice
Crevice Corrosion
Filiform Corrosion
Galvanic Corrosion
Corrosion due to the potential differencebetween metals.
Galvanic Corrosion
Galvanic SeriesPotassiumMagnesiumBerylliumAluminumZincChromiumIronNickelTinCopperSilverPlatinumGold
MostEnergy
Required
LeastEnergy
Required
Graphite-Zinc Battery
Protective casing
Electrolyte paste(ammonium
chlorideand zinc chloride)
Zinc
Separator
Negative terminal
Pitch SealAir Space
Carbon and manganesedioxide mixture
Carbon rod
Water Heater
Copper Water Service
Wat
erG
as
Steel Gas Service (Anode)
Gas Meter with no or shorted insulation
Environmental Corrosion Cracking
• Stress Corrosion CrackingA brittle failure mode in an otherwise ductile metal, resulting from the combined action of tensile stress and a specific corrosive environment.
• Hydrogen-Induced Cracking (HIC) Results from the combined action of a tensile stress and hydrogen in metal.
• Sulfide Stress Cracking (SSC)A type of hydrogen-induced cracking in which sulfide is the primary poison for
hydrogen evolution. Liquid Metal Embrittlement (LME)A decrease in the strength or ductility of a metal or alloy as a result of content with a liquid metal.
• Corrosion FatigueResults from the combined action of a cyclic tensile stress and and a corrosive environment.
Stress Corrosion Cracking
Stress Corrosion Cracking
SCC of Underground P/L
Corrosion Fatigue
A smoothed area that appears as if it were
peened is the result of the opening and closing of the
crack on each cycle
A crystalline appearing area, where the crack progresses too
fast for the peening effect.
The sharp tip (on each piece) resulting when the rod’s cross section is too
small to carry the load and the metal fails as a pure tensile stress..
Flow-Assisted Corrosion• Erosion-corrosion
Occurs when the velocity of the fluid is sufficient to remove protective films from the metal surface.
• Impingement CorrosionLocalized erosion-corrosion caused by turbulence or impinging flow.
• Cavitation CorrosionMechanical damage process caused by collapsing bubbles in a flowing liquid.
Erosion Corrosion
Cylinder Lining Cavitation
Impingement
Intergranular Corrosion
Corrosion due to the preferential attack at, or adjacent to, the grain boundaries of a metal.
Intergranular Corrosion
Dealloying
The corrosion process, in which one constituentof an alloy is removed preferentially, leaving analtered residual structure.
Dealloying
Fretting CorrosionFretting corrosion is defined as metal deteriorationcaused by repetitive slip at the interface between twosurfaces in contact.
Fretting
Fretting
High-Temperature Corrosion• A form of material degradation that occurs at
elevated temperatures. • Direct chemical reactions, rather than the reactions of
an electrochemical cell, are responsible for the deterioration of the metals.
High-Temperature Corrosion
Stray Current Corrosion• The flow of current, along a path other than the
intended path.
• Discharge of current to the environment results in metal loss (corrosion).
Stray Current Corrosion• Concern for rapid corrosion because of large currents
– Dynamic• Rail Transit• Mine Railroads• Direct current arc welding• Telluric currents
– Dynamic - changes with time• eg. DC Powered Rail Transit
– When train travels near a foreign structure, the foreign structure can pick up direct current.
– This direct current has to discharge back to the power source.– At point of discharge, large current - rapid corrosion!
Fluctuating Current Source
+Overhead Positive Feeder
Load Current Required to Operate Train
Moving Current Pickup Area
Current Discharge Area Due to Corrosion
Current Flowing Around High Resistance or Insulating Joint
DCSubstation
_
Tracks Negative Return
Stray Current Corrosion• Concern for rapid corrosion because of large currents
– Steady state• Cathodic interference• Hvdc transmission
– Steady state• eg. Foreign structure pick-up of current from cathodic protection
system.• At point of discharge, concentrated large current - RAPID
CORROSION!
Cathodic Protection Stray Current(Interference)
Interference (corrosive) current flowing through the
earth to return toprotected line
Protective Current picked up by Foreign
Line
Foreign or Affected Line
Protected Line
Cathodic Protection Installation Protective Current
Examples of Corrosion Problems
Copper Piping• Natural protection from oxide film• Deposit corrosion
– If contaminants deposit onto the copper surface, differential aeration cells are set up, and pit the surface
• Low concentrations of CaCo3 can actually assist in resisting corrosion because of film.
Copper Pipe• Natural protection from oxide film• Deposit corrosion from oxygen• Cold water attack
– Well water– Low velocity– Low hardness– pH less than 8.5
Copper Pipe• Cold Water Attack
– L.S.I. slightly (+) to strongly (-)– High oxygen and carbon dioxide content– High sulfates, chlorides and dissolved solids
• Flux corrosion• Erosion corrosion• Lack of reaming tube ends• Turbulence at partially open valves• Velocity• Electrolysis
Galvanized and Black Steel• Galvanic action with connected copper pipe• Copper ion deposition from copper pipe in system
causes pitting• Oxygen/deposit corrosion - tuburculation• Corrosion accelerates at higher temperatures,
generally >160°F
Boilers and Heat Exchanger Applications
• Dissolved oxygen• Corrosion fatigue• Caustic embrittlement• Caustic gouging/crater
corrosion• Acid corrosion
• Chelate attack• Hydrogen cracking• Scaling• Lay up procedures• Firebox attack from
humidity
Boilers/Heat Exchangers• Dissolved gases cause problems, especially oxygen
(use of oxygen scavengers such as hydrazine)• Corrosion accelerated by corrosion fatigue at
elevated temperatures and pressures.
Boilers/Heat ExchangersCaustic embrittlement is the intercrystalline cracking ofsteel, caused by a specific concentration of stress, andfree NaOH in the boiler water.
Boilers/Heat Exchangers• Caustic gouging occurs under porous deposits.
Extensive, general and severe• Acidic water (low pH) extremely corrosive• Chealant attack concentrates on areas of stress in
the boiler, and occurs when excess concentration of sodium salt is maintained over a period of time
Boilers/Heat Exchangers• Hydrogen cracking
– lower end of pH operation– high pressure (>1800 psi)– hydrogen absorbs into steel– reacts with carbon– molecule large, steel ruptures
• Scaling creates problems in deposit corrosion, plugs, flow, etc.
Effect of pH on Corrosion• Acids• Alkalis
Effect of Low pH on Corrosion(example: Iron attack by hydrochloric acid)
In the electrolyteHCl = H+ + Cl–
Anodic area on iron:
Fe = Fe++ + 2eCathodic area:2H+ + 2e = H2
Effect of High pH on Corrosion• Alkalis: Strong bases that produce OH- ions in water
– Particular problems for metals are KOH, NaOH, and NH4 OH– Nickel and nickel alloys best– “Caustic embrittlement”
• Oxidizing Salts– Increase conductivity of electrolyte– Increase corrosion rate
Methods of Corrosion Control
Methods of Corrosion Control
Materials SelectionCoatings and LiningsCathodic ProtectionWater TreatmentDesign
Metallurgy and Metal Behavior
• Different metals corrode differently due to their metallurgy
• Some effects– Steel (pitting)– Gray cast iron (graphitization)– Ductile iron (usually pitting, some graphitization)
• Stainless steel– Passivity due to oxide film– Susceptible to corrosion in various environments– Need to select the proper stainless for the
environment
Metallurgy and Metal Behavior
• Alloys– Corrosion as a unit– Selective attack
• Weathering Steel– Depends on alternate wetting and drying to develop oxide
film– Susceptible to corrosion in chloride or polluted atmosphere – Underground - behaves as carbon steel
Stainless Steels• Martensitic
– 12% – 17% Cr– minor other elements– moderate corrosion resistance in mild environments
• Ferritic– higher Cr composition than Martensitic (12% – 30%)– better corrosion resistance to high temperatures
Stainless Steels (cont)• Austenitic
– Cr: 17% – 25%– Ni: 9% – 10%– highly resistant to wet oxidizing environments
• Duplex– mixture of ferritic and austenitic– increased strength and corrosion resistance
Non Metallics• Concrete
– Freeze thaw cycle– Rebar corrosion– Attack by de-icing salts and acids– Hydrogen sulfide attack in sewers
• Plastics– UV attack– Thermal stresses and cracking– Stress cracks from some thermal insulation’s – Solvent attack
Corrosion of Concrete
Corrosion of Concrete
Non Metallics (cont)• FRP
– Creep– Delamination
• Other Concerns– Mechanical damage– Gnawing by animals
Fiberglass Material
Corrosion of FRP Plastic
Pipe
Summary of Materials Selection
• No one perfect material• Factors affecting choice:
– Corrosion resistance (metallurgical)
– Mechanical properties (metallurgical)
– Availability– Ease of
installation/fabrication
– Environmental– Operational issues– Cost: capital vs. long
term– Sometimes a finite life
with replacement is the most economical approach
Factors Affecting Corrosion Resistance of a Material
Environmental Environmental FactorsFactors
Corrosion Corrosion ResistanceResistance
Protective Protective Treatments
Metallurgical Factors Metallurgical Factors Resistance TreatmentsResistance
MechanicalMechanicalPropertiesProperties
Safety FactorsSafety Factors
ApplicationApplication
Methods of Corrosion Control
Materials SelectionCoatings and LiningsCathodic ProtectionWater TreatmentDesign
Functions and qualities of coatings
• Separate material from the environment• Provide good adhesion to the metal• Serve as primer for topcoats• Provide sacrificial protection to the metal• Resist abrasion, impact and soil stress• Hold an inhibitor at the metal surface• Resist water absorption• Prevent contamination• Protect against high temperature oxidation • Be safe to use• Be environmentally acceptable• Provide good electrical insulation for underground structures
Coating Considerations• Cost• Life expectancy• Recoating
– Cost– Effect on structure performance
• System approach is needed
Atmospheric Coatings• Sacrifical - galvanizing• Dielectric - barriers
– Oils– Phenolics– Acrylics– Alkyds– Vinyls– Epoxies– Urethanes
Hot dip Galvanizing
Underground Coatings• Holidays• Typical Materials
– Coal tar enamel– Asphalt enamel– Extruded polyethylene– Liquid epoxy– Fusion bonded epoxy– Mastics– Polyethylene and other cold applied tapes– Hot applied tapes - usually coal tar based
Process Coatings(Example: Water Storage Tank)
• Sometimes used– Recoating expense– Tank downtime
• Environmentally acceptable re. water standards• Usually combined with cathodic protection
– maintenance of proper cp levels– danger of disbonding from overprotection
Coating Application Considerations
• Surface preparation• Atmospheric conditions• Application techniques• Inspection
– Wet and dry film thickness– Electrical (holiday) inspection
Surface Preparation–Blasting
Coating Inspection
Holiday Detection
Methods of Corrosion Control
Materials SelectionCoatings and LiningsCathodic ProtectionWater TreatmentDesign
Cathodic Protection• Electrochemical theory• Polarize the cathodic sites on the structure to the
same potential as the anodic sites.
Microscopic View of a Corrosion CellMicroscopic View of a Corrosion Cell
AnodeCathode
Microscopic Corrosion Cell on the Surface of a Pipeline
Cathodic Protection on a Structure
(Macroscopic view)
Cathodic Protection on a Structure
(Macroscopic view)
AnodeCathode
Metallic Connection
Electrolyte
Cathodic Protection Anode
Cathodic ProtectionCurrent Applied
Conventional Current Theory
• Apply current to the surface of the metal• Overcome the corrosion current on the metal• The structure becomes the cathode of a new
corrosion cell• The new anode is allowed to corrode to protect the
structure• Coatings reduce the protective current
requirement• Protects the holidays
Types of Cathodic Protection
• Galvanic• Impressed Current
Galvanic Cathodic Protection• Galvanic (sacrificial anodes)
– Magnesium and zinc most common– Aluminum alloys used offshore– Typical uses
• Well coated structure• Electrically isolated structures• Facilities with low current requirements• Little flexibility, so current requirements need to be fairly
constant
Galvanic Anode Cathodic Protection SystemGalvanic Anode Cathodic Protection System
ANODEANODE
STRUCTURESTRUCTURE
CURRENTCURRENT
CURRENTCURRENT
Cast, Packaged and Extruded Magnesium Anodes
Tank with anode attached at bottom
Impressed Current Cathodic Protection
• Impressed Current– Rectifiers– Anodes
• High silicon iron• Graphite• Mixed metal oxide
Impressed Current SystemImpressed Current System
ANODEANODE
STRUCTURESTRUCTURE
CURRENTCURRENT
CU
RR
ENT
CU
RR
ENT
PowerSource
+-
CU
RR
ENT
CU
RR
ENT
Impressed Current Cathodic Protection
4Anodes
4 Power Source
4Wiring
Rectifier Unit Schematic
V
+-
A
-
+
AC Power Input
Step-DownTransformer
AdjustingTaps on
SecondaryWinding Rectifying Stacks
AC Breaker Switch
Current Shunt Output Ammeter
Output Voltmeter
To Structure To Anodes
Grounding
Housing
Rectifier Unit
Impressed Current Cathodic Protection(cont)
• Typical Uses– Large current requirements– Non-isolated structures– Flexible current output
• Concern with cathodic interference
Typical Application of Impressed Current Cathodic Protection
• Underground pipelines• Underground storage tanks• Bottoms of on grade storage tanks• Interiors of water storage tanks
Typical Application of Impressed Current Cathodic Protection (cont)
• Condenser and heat exchanger water boxes• Reinforced concrete• Doesn’t work in the atmosphere (Automobiles)
Methods of Corrosion Control
Materials SelectionCoating and LiningCathodic Protection
• Water TreatmentDesign
Water TreatmentChange of Water Characteristics
• Oxygen removal• Minor species removal• pH control• Scale Control• Addition of Corrosion Inhibitors
Corrosion InhibitorsA substance when added to an environment, decreasesthe rate of attack by the environment.
Corrosion Inhibitors• Inhibitors for protective films by:
– Adsorption– Formation of precipitates– Passive layer on metal surface
Corrosion Inhibitors• Five different classifications of Inhibitors
– Anodic– Cathodic– Ohmic– Precipitation– Vapor Phase
Inhibitors form films by:• adsorption• formation of precipitates• form passive layer on metal surface• Five different classifications of inhibitors:
Inhibitors (cont)• (i) Anodic
– increase anodic polarization (current density exceeds that required for passivation)
– can increase localized corrosion if entire surface not covered
– eg. Zinc ion compounds (ZnCl)• (ii) Cathodic
– increase cathodic polarization– slows the cathodic reaction– some cause precipitates– eg. Phosphate, nitrates
Inhibitors (cont)• (iii) Ohmic
– form a film on the metal surface– increases circuit resistance– eg, amines – not used in fresh/pure water– used in oil/gas/salt water
• (iv) Precipitation– create large precipitates that interfere with both
anodic and cathodic reactions– eg. Silicates, phosphates
Inhibitors (cont)
• (v) Vapor phase– compounds carried in the vapor phase of a system– upon contact with the metal, condense and
passivate– eg. ammonia
Cooling Water Applications• Langlier and Stability (Ryzner) Indices• Scaling or non-scaling properties of the water• Corrosive effect of oxygen
Water Handling Systems• Langlier Stability Index - Defines the conditions
(temperature and pH) under which CaCo3 is precipitated from water or dissolved in water.
• CaCo3 a major problem in water (hardness)• The solubility of most scales decreases with
increasing temperature.• Oxygen is extremely corrosive in closed elevated
pressure and temperature water systems.
Water Treatment & Inhibitors
• Once through Systems• Closed Loop Systems• Boiler Systems• Cooling Tower Systems• Heating and Chilled Water
– Biocides–slime control– Inhibitors –corrosion control– Good maintenance of closed loop systems to exclude air
Water Treatment–Once-through Systems
• Usually not economical to treat• pH adjustment• Chlorine residual
Water Treatment–Closed Loop Systems
• Nitrites and/or Molybdates• Good maintenance to exclude air
– Excessive leakage nullifies treatment
Water Treatment–Boiler Systems
• Boiler Feed Water• Boiler Water• Condensate
Water Treatment–Cooling Waters Systems
• Corrosion control–pH• Scale control–dispersants• Microbiological control–chlorine• Side stream filter
High-temperature CorrosionA form of material degradation that occurs at elevated temperatures. Direct chemical reactions, rather than the reactions of an electrochemical cell, are responsible for the deterioration of the metals.
High Temperature Corrosion
• Not “if”, but how fast a structure corrodes• Foundaries, flue gasses, etc.• Both general corrosion and pitting corrosion• Corrosion is not electrochemical in nature• Materials react to form oxides
High Temperature Corrosion
• Oxidation occurs from water vapor, hydrogen, hydrogen sulfide, ammonia, sulfur dioxide, chlorine, sulfur, carbon dioxide and oxygen
• Development of scales• Corrosion products
– solids– liquids– gases
Methods of Corrosion Control
Materials SelectionCoating and LiningCathodic ProtectionWater Treatment
• Design
Structure or Product Design• Corrosion control requires lead time like other parts of the
project• Corrosion control must be planned• Preconstruction corrosion surveys• Lowest initial cost design may be the most expensive in the long
run• Coordination among design, construction and other disciplines• Proper specifications addressing corrosion control
Design Considerations• Ease of painting• Ease of maintenance• Avoidance of traps where water will collect• Avoidance of crevices• Treatment of faying surfaces
Design Considerations (cont)
• Proper welding techniques - problems with stainless, eg., heat-affected zone (HAZ)
• Selection of proper materials for the job• Use of dissimilar metals• Mechanical system design• Underground structures
Design Considerations
CREVICETRAP FORLIQUIDS
CREVICE WELDS
BOLTBOLTORORRIVETRIVET
POOR BETTER BEST
Crevices
AVOID AVOID BETTER PREFERRED
Joining Details
Design ConsiderationsDESIRABLE SPECIAL ATTENTION
REQUIRED No radius
Enough distance for coating
Weld accessible
Radius
Weld not accessible for grinding
Not enough distance for coating
Design –DrainageWater/Debris
Tank Outlet for Drainage
Structural Member Orientation for Drainage
Avoid Preferred
Avoid Preferred
Design ConsiderationsJoining Dissimilar Metals
Pit (anode) Protective coating
Alloy (cathode)
Steel
Welding ConsiderationsSKIP WELDS
Skip weld
Welding ConsiderationsSKIP WELDS
Special attention requiredDesirable
Continuous weld Skip weld
Welding ConsiderationsRough
Flush
Smooth contour (as-welded or ground) for
coating
Undercut Rollover
Porosity
Smooth
Welding ConsiderationsFLANGED OUTLET
Sharp corner
Inside of vessel
Special attention required
Threads
Weld
Inside of vessel
2” Min.
Desirable Round corners
Threads in a collar
Threads on nipples
Angle stiffener
Desirable Special attention required
Inside of vessel Inside of
vessel
RIVETSpecial attention requiredDesirable
Grind smooth, round corners
Continuous fillet weld
Gap
Weld
Inside of vessel
Gap
Monitoring and Maintenance of Corrosion Protection
• Continuous operation is necessary for success• Regular inspections are needed• Coating
– Regular inspections– Programmed recoating as required
Monitoring and Maintenance of Corrosion Protection
• Cathodic Protection– Galvanic anodes - annual surveys– Impressed current
• Rectifier inspections• Annual surveys
– Regulatory requirements– NACE criteria for protection
• Inspections of water boxes, water storage tanks, etc.
Monitoring and Maintenance of Corrosion Prevention
• Water Treatment & Inhibition– Proper Levels
• Other Inspections• Visual• Ultrasonic• Coupons• Corrosion monitoring probes• Electrical resistance
• Record Keeping
Additional NACE Training• NACE International
– Courses for those involved in corrosion control
• Basic Corrosion• Cathodic Protection courses• Designing for Corrosion Control• Protective Coatings and Linings 1 and 2• Corrosion Control in the Refining Industry• NACE Coating Inspector Program• Marine Coating Inspection• Successful Coating and Lining of Concrete
NACE Certification• General Corrosion certifications• Cathodic Protection certifications• Coating Inspector certification
For additional information, visit the NACE website at www.nace.org or contact the NACE CertificationDepartment.
Other NACE Resources• COR•AB• Publications
– Materials Performance– Corrosion– Standards
• Technical Committee Reports• Books
Other NACE Activities
• Technical Practices committees• NACE annual conference• Area and Section meetings and conferences• Colleagues world wide
Other Resources• Short courses around the country• Assistance from manufacturers and consultants• Experience of other owners and operators
Summary• Corrosion control is everyone’s business• Management
– Costs– Concern over failures and replacements– Product Life– Safety
Summary (cont)• Purchasing
– Least expensive to begin with may be most costly in the end– Follow the company’s corrosion control specifications
• Sales– Prevent failures, service interruptions– Have a good product to sell
Summary (cont)• Customer Service
– Good relations with customer - customer satisfaction– Explain what company is doing about corrosion control– Provide good service to customers
• Specification Writers– Include corrosion control in specifications– Write through specifications
Summary (cont)• Design Engineers
– Materials selection– Life of the product– Environmental protection and safety– Long range economics of the design– Design corrosion control into new products
RememberRemember
Corrosion Control Corrosion Control Doesn’t Cost Doesn’t Cost ——
It Pays!It Pays!