ANACE [= THE CORROSION SOCIETY Basic Corrosion Course Chapter 1 Introductiontroducbon Definition of Corrosion “Corrosion isthe deterioration of a substance (usually 2 metal) or Its properties because of a reaction with its environment.” Basic Forms of Corrosion ‘There are many forms of corrosion. Some are frequently encountered in everyday life and on the job. Others require Specific combinations of materials and environments that are rarely encountered, Gaining an understanding of the mechanisms at work in these forms of eotrosion and hove te mechanisms result in the specific forms of corrosion is an important first step in controlling corrosicn, What we Understand, wo ean more easily contol In this course, we will find that all forms of eocosion, with the exception of some forms of high-temperature corrosion, ‘occur through the action of the electrochemical zell. We will find that this electrochemical cell can get in many ways, but that its general principles, once understood, can be applied to the understanding of most forms of eonrosion. We wil, find that many of the methods that are used to control corrosion involve intentional interruption of theetion ofthe tlectroctemica cells responsible for corrosion, In this course we will discuss many forms of corrosion, including the following: ‘© General Corrosion Localized Corrosion Pitting Corrosion = Crevice Corrosion = Filiform Corrosion ‘© Galvanie Corrosion Environmental Corrosion Cracking Corrosion Dealloying Frotting Cormsion High-Temperature Corrosion “Fase Goren Conse Bite anal SNAG reratina, 2000, ossrosucton Examples of Corrosion We will look at many practical examples of comosion that cecur during our cveryday lives and on the job. We will tiscuss the mechanisms that are active in the ination and propagation of the corrosion. The following are typical Examples of corrosion that we will describe, and learn how to.combat: ‘= Corroding Automobiles Uniform Corrosion of Carbon Steel Boiler Tubes Pitti of Copper Water Pipes { Pitsing Under Deposits in Carbon Steel Boiler Tubes, {Galvanic Corrosion of Copper-roduetion ‘These interruptions can result in reduced ineone for the plant, having great economic impact. In addition, there ean be substantial costs in the shutdown and startup of the system. Shutting down and starting @ fossil fuel power plant tan cost in excess of $500,000 when labor, fue, and other costs are considered. » Produet Contamination In many industries, contamination of product heeawer of corrosion products entering the product stream ean be ‘eirimental. This is particulaey true forthe food processing fand pharmaceutical industries, but it applies to many other systems as well. The direct cost of such contamiration isthe contaminated product's loss of value; contamination can also have indirect implications, to be diseussed further. WAGE Inematon 2000= Loss of Produet Loss of product due to leaks can have significant direct and indirect costs, The dircet costs include the value of the ‘rocluct itself, the cost of repair, and the asociated costs of | owetime, including shutdown and startup. However, ‘corrosion leaks can have other implications and zosts. AS we Shall discuss later, loss of materials ean cause collateral damage of greater effect than the cost of lost preduct. Leaks in plumbing in public and domestic buildings often results in collateral water damage many times greater tan the cost te repair or prevent the leak ‘¢ Loss of Effciency-Oversizing & Excess Energy Costs In many cases, substantial corrosion is anfiipated and portions of a system are oversized to accommodate the corrasion. In addition to the direct cost of excess material, Such oversizing ean have other direct economic effects. For example, if heat exchanger tubes are made thicker than necessary to accommodate corrosion, the exta thickness of the tube wall will reduce the efficiency of the heat exchanger, which can inerease fuel costs or reluce output Fouling of heat exchangers with corrosion froduets ean have similar effets on fuel costs and productivity Accidents Corrosion ean cause, and unfortunately has caused, severe accidents resulting in personal injury and boss of life. Corrosion-related accidents have both direct economic effects to cover the costs of these losses, and ather indirect ‘economic and social implications. For example, if plant or industry has a bad safety record because of corrosion, or any biter cause, the cost of insurance will be higher than if a ‘good safoty record has been maintained. + Increased Capital Costs-Overdesign [As described previously, addition of extra material to a system fo allow for corrosion can increase the capital cost of the system, Capital costs also include the inital costs of ther corrosion control measures, such as protective “Gavi Coven Cores Staten Wana ‘SNAGE rmernetone 2000Inreduction coatings, cathodie proteetion systems, and equipment for the injection of corrosion inhibitors into te system, ‘¢ Environmental Cleanup-Fines ‘The cost of environmental cleanup of product spills has increased greatly bocause of increased awareness oF the potential short- and long-term effects these spills can have fan the environment, Cleanup of most spills is now a legal requirement. Even ifthe company responsible forthe spill is zo longer the owner of the offending system, the company that owned the system at the time ofthe spill can be liable for the cost ofthe cleanup. If negligence was involved, fines ay be imposed on the system owners or system operators. “These fines are considerable and have exceeded $1,000,000. Indirect Consequences of Corrosion Safety Corrosion can cause, and unfortunately has caused, many ‘ecidents. Most accidents could have been avoided by the Proper application of corrosion control measures. Others could have een predicted and corrected before injury or loss of life, = Structural Collapse Fortunately, complete structural collapse due to corrosion is rare, but it does oecur. Stress corrosion cracking of stainless steel reinforcement in the conerete roof ofa swireming pool ‘caused collapse of the roof while the pool was in use, and several people were killed or injured, Corrosion ean also Feduice the resistance of structures to other natural forces, such as earthquakes. = Leaks Leaks in systems carying flammable or toxie materials are fan obvious safety hazard. Fire and explosions from corrosion leaks in underground natural was pipes are all too Frequent and avo je losses die 10 corrosion. Leaksresulting in fire and explosion are, however, mow frequently faused by third-party damage than by corrosion, ‘= Product Contamination Proxluct contamination ean also affeet safety, particulary if the contamination is not detected or its importance is not realized until after the products have been consumed. © Foods Contamination of foods through corrosion can occur during both production and storage. Before the toxic properties of Tead were appreciated, the contamination from corrosion of | lead solder on food cans caused many illnesses and deaths. ‘© Pharmaceuticals ‘Contamination of pharmaceuticals can cause not only loss of | product during» manuficture, but also premature Uterioration and loss of potency of the materials during storage = Water ‘Contamination of potable water by corrosion products from the’ distribution lines and other — plumbing-system ‘components is common. The contamination may simply be unsightly, as in the case of “red water” where relatively harmless levels of iron from corrosion of iron pipes causes unsightly staining in the water and on the visible surfaces of plumbing fixtures. High levels of iron can also be a health hhazand. Lead from the corrosion of lead piping and from the Teal solders that were formerly used in copper plumbing systems isa ¢eal and significant health hazard. In addition (0 the elimination of the lead through replacement of the lead ‘containing materials, water treatment to reduce the corrosion fof the lead and the subsequent release of lead into the water have been successful in mitigating this problem in some “Gas Corton Course Soden anal SNACE intraoral 2000 fansloodueon ‘© Consumer Confidence Corrosion ean bo related fo the marketability oF a product. Recent improvements in the corrosion resistance of automobiles, particularly with long-term guarantees against ristthrough, are now @ major selling feature. Even if the corrosion only results in unsightliness, a produc that has a reputation of retaining that “new look” will have greater sales appeal + Loss of Redundancy Where continuous processing ot supply of @ product is required, redundant systems are provided to ensure continuous operation, These systems are operated in parallel for one is used as a spare, Inthe frst case, corrosion in one of the parallel systems results in loss of this redundancy ‘unl repairs can be completed. In the second case. corrosion in the primary systom will cause loss of redundaney until the primary system is repaired. The worst-case scenario isin the Second case when corrosion occurs in the standoy system land remains undetected until corrosion, or other problems, in the primary system require the use of the secondary system, which cannot perform its finetion because of the corrosion damage that occurred during standby service. ¢ Appearance Corrosion, particularly the all-too-familiar red rust from cording ifon and steel, 18 unsightly even if does not interfere with system operation, Significant offot is taken simply to eliminate such unsightly corrosion siemply forthe aesthetic benefits. This also applics to industry, where the “good mneighbor” artimde is now more common, and where the appearance ofthe plant may be of considerabe value to stockholders Base Covoson Course Suen Narwat NAGE Inarnabonat 2000Jneducton © Increased Regulation Many aspects of corrosion control are now regulated. Laws are being enforced where corrosion damage has the potential to adversely affoct public health and safety. Legislation pertaining to corresion-related aspects regarding safe ‘operation of pipelines carrying hazardous liquids or ‘ammable gasses fsa good example of such regalations. Base Conan Cause SedontNarwal SNGE ntrtonal 2000 ‘ov