Corrosion Survey

at

XYZ Mfg. Ltd., Khopoli

Maharashtra

Date of Survey: -
31/10/2019

--FROM--
Mr. Amit R. Nimbalkar
NACE - CIP Level 2 (Cert. No. 19751)
Technical Service
Nippon Paint India Pvt. Ltd.

Mumbai

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CONTENTS

1) Scope

2) Geographical & Environment

3) Assessment Methodology

4) Summary

5) Corrosion assessment report plant wise

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 Scope
Corrosion Survey of Pipe bridges & Shutters at XYZ plants and suggest a painting system for
maintenance.

Geographical & Environment

About XYZ Mfg Limited Geographical & Environment:-

The factory is in interior area of khalapur, khopoli. The area is not so polluted but highly humid.
Also receives very heavy rain during monsoon. This area is very hot during day & reduces
temperature at nights.
Due to differences in temperature during day and night, high humidity levels and heavy rains,
factory area is classified under corrosive area category C3 – medium as per ISO 12944-2.
Corrosivity of Environment:

Rural Urban Coastal Industrial Chemical Zone Avg. Humidity Other

Area Area Area Polluted
Area

Yes No Distance No No Average :70% to It was found

from sea 80% highly humid
App. 50 area, also the
Kilometres temperature
difference
between day
& night is very
high. During
monsoon,
receives very
heavy rain fall

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 Assessment Methodology.
To understand the corrosion audit test please note following methodology,

Namely two test Methods have been considered for Arriving at the Audit finding.

i) ASTM D 610- STD Test Method for Evaluating Degree of Rusting on Painted Steel Surface ii)
ASTM D 714- STD Test Method for Evaluating Degree of Blistering of Paints.

Both the above test methods talk of Visual Inspection Methods depending upon the Rusting and Blistering on
surfaces.
ASTM D 610 Chart.
Visual examples.
Rust Grade % of Surface Rusted
Spot (S) General (G)

10 Less than or equal to 0.01% None

9 Greater than 0.01% up to 0.03% 9-S 9 -G

8 Greater than 0.03% up to 0.1% 8–S 8-G

7 Greater than 0.1% up to 0.3% 7 -S 7-G

6 Greater than 0.3% up to 1.0% 6-S 6-G

5 Greater than 1.0% up to 3.0% 5-S 5-G

4 Greater than 3.0% up to 10% 4-S 4-G

3 Greater than 10% up to 16.0% 3-S 3-G

2 Greater than 16.0% up to 33% 2-S 2-G

1 Greater than 33% up to 50% 1-S 1-G

0 Greater than 50% None.

Rust Distribution Types:

S: Spot Rusting – Spot rusting occurs when the bulk of the rusting is concentrated in a few localized
areas of the painted surface. The visual examples depicting this type of rusting are labelled 9-S through
1- S.

G: General Rusting – General Rusting occurs when various size rust spots are randomly distributed
across the surfaces. The visual examples depicting this type of rusting are labelled 9-G through 1- G.

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 i) ASTM D 714.

Frequency: - Reference Standards have been selected for four steps in frequency at each step in size,
designated as follows:

Few: F Medium: M Medium Dense: MD Dense: D

A quantitative physical description of blistering would include the following characteristics determined by
actual count Size distribution in terms of menstruation units, Frequency of occurrence per unit area,
Pattern of distribution over the surface and Shape of blisters.

Few: F Medium: M Few: F Medium: M

Medium Dense: MD Dense: D Medium Dense: MD Dense: D

Blister Size No. 02 Blister Size No. 04

Few: F Medium: M Few: F Medium: M

Medium Dense: MD Dense: D Medium Dense: MD Dense: D

Blister Size No. 06 Blister Size No. 08

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 Summery

Company Name: XYZ Mfg. Ltd, Khalapur Plants

BELOW MENTIONED ARE THE AREA INSPECTED AT SITE;

1. Pipe Bridge near plant no. 4

2. Shutter – Plant no. 2

Preliminary observation and Information received

It was observed that pipe bridges are corroded and blistering of existing paint system started,
some places pitting is also observed.

On shutters – corrosion started all over and blistering of existing paint system started.

Corrosion assessment report plant wise

1. Pipe Bridge near plant no. 4

2. Shutter – Plant no 2

Exposure:
Heavy rain, high & low temperature & high Humidity

COATING DEFECTS & OBSERVATION:-

CORROSION-
PITTING BLISTERING RUSTING DETACHMENT SWEATING LOCALISED/
AREA SCATTERED
Pipe Approx.
Bridge D-4 G-2 Approx. 10% No Scattered
2%
Shutter
Approx.
M-6 S-8 Approx. 5% No Scattered
1%

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PHOTOS OF INSPECTED AREAS: -

Pipe bridge – Blistering D-4, Rusting G-2

Shutter- Blistering M-6, Rusting G-6

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 Proposal -
SURFACE PREPARATION: -

• We suggest to carry out the surface preparation as per ISO 12944 – St2 / St3 method.
• Remove any corrosion by means of power tool or hand tools, i.e. disc sander and
grinder or Emery papers no 80/100, Wire brushing, Chipping hammer.
• Oil or grease, salts, dirt’s, chalk marks and similar contaminants shall be removed as far as
possible, prior to surface preparation, using an appropriate method in accordance with ISO
12944-4.
• The area to be repaired/ repainted must be fresh water washed (LPWW) and dry.
• Clean loose dust or rust by solvent cleaning
• Make the surface dry before application of paint.
• Apply the paint as per paint specification.
• Coating shall not be applied when,
1. Relative humidity is above 85%
2. The surface temperature is less than 3°c above the dew point.

Paint Specification:
Pipe Bridge
Generic Description Nippon Product Shade %VS DFT

Surface tolerant epoxy mastic HI-PON 20-04 STE 80 – Grey 80 250

2 – 3 coats
Polyurethane Top Coat Nippothane 51-03 PU T/C – RAL 42 50
7004
1 coat

Shutters
Generic Description Nippon Product Shade %VS DFT

Surface tolerant epoxy mastic HI-PON 20-04 STE 80 – Grey 80 120

1 – 2 coats
Polyurethane Top Coat Nippothane 51-03 PU T/C RAL 42 50
7004
1 coat

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