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Corrosion Analysis: Understanding the Equipment

Posted November 05, 2014 1:00 AM by larhere

Back again. Today we'll discuss the third step in the corrosion evaluation/mitigation process

1. Identify the corrosion mechanism.

2. Understand the environment, both external and internal.

3. Understand the equipment - materials of construction, operating cycles, hours.....

4. Identify alternatives - materials, coatings, limiting operating envelope, changing the environment (water treatment, alternative lubricants/refrigerants, filter the air, etc.), redesign the machine (better drainage, eliminate contact of dissimilar metals, .....)

5. Implement change.

6. Monitor results.

3. Understand the equipment - materials of construction, operating cycles, hours…..

In the previous post in this series we discussed how important understanding the operating environment is when working to solve a corrosion problem, not surprisingly, it is just as important to understand the equipment which operates in that environment.

One of the challenges for a failure analyst working with a client to solve a corrosion problem is thoroughly understanding the equipment that is failing - what are the materials of construction, how are the materials processed, why were the materials selected, is there more than one supplier of materials or components, what is the typical duty cycle for the equipment, what are the extremes of the operating map, etc., etc., etc.?

A lot of these questions can be answered by reviewing engineering drawings and documentation, but much of this information is only available via the tribal knowledge of the people who work with, or on the equipment every day. Thus, it is crucial for design, manufacturing, service and purchasing personnel to share their tribal knowledge regarding how and why the equipment is designed and built the way it is with whoever is charged with analyzing the corrosion problem. Again, just like understanding the environment, the better we understand the equipment, the better and more robust and more economical will be the solutions that are found to address the corrosion problem.

Editor's Note: CR4 would like to thank PJ Sikorsky, GEA Consulting Associate, for contributing this blog entry.

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Guru

Join Date: Aug 2008
Location: England & Ireland
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#1

Re: Corrosion Analysis: Understanding the Equipment

11/05/2014 3:19 PM

Corrosion is an absolute curse. I get quite emotionally involved when I see once brand new shiny products corroding away. Products that may have cost you a lot - cars, air conditioning systems for example. Manufacturers are to blame. Seeing an A/C condenser turning to rust outside is unforgivable. It's all about being made down to a price, using mild steel and inadequate coating, no doubt. My wife recently bought a new electric bicycle - made in the Far East, of course. We left it uncovered one night. No rain but wet with dew the next day. Already the bolts holding the pannier were rusting. Unforgivable!

As for cars - at least they have improved a lot, but seeing important and desirable Classic Cars reduced to lacework by the dreaded "tin-worm" is disturbing. The marine and oil industries use cathodic protection with zinc or an impressed current. Why can this not be used on other products?

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Guru

Join Date: Aug 2014
Location: Port Macquarie N.S.W. Australia
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#2
In reply to #1

Re: Corrosion Analysis: Understanding the Equipment

11/05/2014 10:54 PM

I couldn't agree more.

My air conditioner outdoor unit required resurfacing within 12 months of new, no warranty on the cabinet.

One of my pet hates is the outboard motor manufacturers who insist on using mild steel plated nuts and bolts on their salt water series of motors.

Another is the pool pump industry which makes pumps with mild steel shafts even with the understanding that most pools are either salt or chlorine, both of which attack the shafting over time.

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Guru

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#3
In reply to #2

Re: Corrosion Analysis: Understanding the Equipment

11/06/2014 5:48 AM

Good examples of thoughtless construction methods by so-called engineers and the "throw away" world.

The expression: "Don't spoil the ship for a ha'p'orth of tar" comes to mind.

Translation: proverb Don't risk the failure of a large project by trying to economize on trivial things.

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Power-User

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#5
In reply to #3

Re: Corrosion Analysis: Understanding the Equipment

11/06/2014 12:41 PM

My preferred version is "penny wise, pound foolish".
No regional dialect required. I thought it was an actual ship being spoiled!

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Member

Join Date: Aug 2011
Posts: 8
#6
In reply to #1

Re: Corrosion Analysis: Understanding the Equipment

11/12/2014 9:42 AM

Good comments. Too often, manufacturers and consumers confuse price and cost and decisions are made based on lowest price, not on total cost. With that said, on to your question about using cathodic protection to address corrosion problems: for cathodic protection to work there needs to be a complete circuit for current to pass through. In marine or pipeline situations the ship hull, or the interior of the pipe are immersed in an electrolyte (water, seawater or whatever liquid the pipe is carrying) and electrical current can pass through the electrolyte, the sacrificial anode (often zinc) and the metal that is to be protected (the ship hull or the pipe). Unless that electrical circuit is there and continuous, cathodic protection won't work. Galvanized zinc coatings on steel do provide cathodic protection to the steel substrate on a localized level, but if ruptures in the coating get too large the cathodic protection of the coating breaks down.

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Guru
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#4

Re: Corrosion Analysis: Understanding the Equipment

11/06/2014 11:06 AM

An old time pipeline engineer once said " you never really own carbon steel, you just borrow it for a while".

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