Preservation of Parts, Equipments and Assets

during Storage, WIP and Shipment using VpCI.

Presented by CR Venkatesh, Vertex Corrotech Solutions at
the CII-Corrosion Management Summit
Coimbatore, Sep 20, 2014

Copyright 2005, Cortec Corrosion Solutions India Private Limited. All rights

Corrosion Silent Killer !!

About 75,000 Crores of Rupees are lost
every year in India due to Corrosion
during manufacture, shipping and
storage
30 % of these is avoidable, related to the
failure to use the best practices and
products available

Areas where Industry faces

the problem
Storage
Work-in-Process
Domestic and Export Shipment
During operation & lay-up of Plant
and Equipment

Lets face the Truth!

Corrosion can neither be stopped nor
prevented!!!

What is the solution?

Protection
How?
by Shielding the Metal for a pre-defined duration
Under a given set of Conditions

Methods of Protection by
Shielding
Material Selection
Barrier Bag + Desiccant
Petroleum based RP Oils
Contact Inhibitors such as epoxy and grease
Use of Vapor Phase Corrosion Inhibitors

Vapor-Phase Corrosion
Inhibitors
Definition:
Organic Chemicals that vaporize
These vapors have corrosion inhibiting properties
They condition an enclosed atmosphere with a
protective vapor that condenses on all metal
surfaces, including recessed areas and cavities

How does VpCI work?

Metal

Enlarged view of metal

surface
VpCI vaporizes, ionizes and dissolves in the electrolyte (moisture)
These dissolved ions then seek the opposite pole of the metal
They find them, bond with them and settle on the metal surface
to form a
thin monomolecular protective film on the surface of 15-20
Angstroms thk
Migrates through air to condense on metal away from it, thus
reaches
recessed areas and cavities by itself
Works in the liquid, gaseous and interphase

H2 O

O2
VpCI molecule

VpCI

Metal

H2 S

 Light Blue: oxygen molecules

Dark Blue: water molecules
Black: VpCI

Metal

Contaminants

VpCI

Oxygen

VpCI

Water

VpCI

Metal

VpCI

VpCI

Different Carriers used for

liquid products
Solvent - Dry Film
Water - Dry Film
Oil
- Wet Film

Carrier does not protect metal. It only

transports the inhibitor to the metal.
It is the inhibitor that protects metal

3 Phase Action of VpCI

Inside a Pipe

Inside a closed
container

Industry expectations

Safety
Cleanliness
Surface Preparation
Removal and Cleaning prior to use
Disposal, reuse and recyclability
Reliability
Cost effective

Other Industry Issues and

Myths? on Preservation

Desiccants and de-humidifiers

Vacuumising and Nitrogen Filling
SS and higher metals do not corrode?
Raining inside the container
More the barriers and micron build up, better
the protection?
Protection during monsoon only?
Water carry over on metal during machi ning
Permanent protection?

VpCI Forms and Industry

Categories

Packaging including biodegradable and compostable plastics

Metal Working
Products for Electrical & Electronic Industry
For Process Industry, Water Treatment, Cooling Water
For the Defense and Steel Industries
Liquids, Coatings, Aerosols, Powders
Additives to oil, water, paint, ink, polymers, etc
Water-based cleaners/degreasers with flash rust protection
Rust Removers with flash rust protection
Products to protect rebar and concrete in construction industry

Packaging Products
Extruded PE Film, Woven fabric, Bio-degradable &
compostable film, with and without inhibitor,
Stretch, Shrink & Anti-static films, Coated, reinforced and
laminated paper, Linerboards, Impregnated Foam
Emitting devices, Tablets, Pouches and Powders that release
corrosion inhibiting vapors into the enclosure, etc
Common Principle : Ionic action between opposite poles
Application
: Wrap/ Insert and Seal
Protects
: Multi-metal
Protects up to
: 2 years - storage and shipment

Films and Bags

Some Popular Applications

Weaponry Protection and

Storage

Stretch Film

Video: Corpak VpCI Stretch Film

Shrink Film

31

32

Static Dissipative Film

Coated Paper

Reinforced Paper

Impregnated Foam and bio-based

non woven pad

Pouches and Tablets

Emitters for the Electrical and

Electronic Industry

Integrated Solution

Cocooning the equipment

Few more examples of cocooning

Biodegradable & Compostable

film with & without inhibitor

Oil based corrosion

inhibitor concentrates
Additive to lubricants, cutting oils and
hydraulic, stamping and drawing oils
For gear boxes, differentials, engines and equipment internals,
lubricating and hydraulic oil systems, etc.
During storage, operating and intermittent use
Effective for mineral and synthetic oils
Protects machinery, equipments & parts, Cold Rolled Steel Coils
and Sheets, stamped and pressed parts, etc.

Solvent based corrosion

inhibitor concentrate
Dry,Waxy Film protects CS, SS, CI, Cu &
Al. up to 2 years
Used in Moth balling of plant and
equipment
Protection of machinery and bi-metallic
components, during storage and export
Protection of turbine blades and
components, crank shafts, plates and pipes
in outdoor conditions, bi-metallic bearings,
etc.
Protection of Aircrafts and spares

Water based corrosion

inhibitor concentrates
Dry and clear film protects multi-metal
Protects spare parts, tubular parts, pumps, components,
castings & forgings during storage and export
Excellent in process metal protector
Additive to Standing water and rinse water systems
Can be added to water based coolants
Edge spray for coils and sheets stock
Fog void spaces, enclosures, packages, tanks & containers
Protects internal surfaces of equipments, parts and tools

Concentrates for Metal Working/

Machining/Cutting Operations

Mutli-functional corrosion inhibitor

Protects ferrous and non ferrous metal
Excellent lubricant and coolant properties
Resistant to rancid attack by bacteria

High Performance Coatings

with inhibitor
Water borne coatings that leave a dry and semi-dry film
Can be used as Primer/Top Coat. However
compatibility with other coatings must be checked
Suitable for outdoor uncovered structures and
equipments, including marine and in acidic
atmospheres
Some of them work even in immersed conditions

Rust Converters
Unique water-based formulation converts
the surface rust into a protective primer
Suitable for rusty or poorly prepared steel
Can be top coated with solvent and water
based coatings
Low VOC, High salt spray rating
Works in presence of acid fumes
Ideal for marine and outdoor applications,
including immersed, even sea water

Inhibitors for preservation in

the Process Industry

Corrosion inhibiting Powders

For dry and wet applications
Its unique VCI action can protect metal in all three
phases ; viz., Liquid phase, Inter phase and Gaseous
phase.
For protecting internal surfaces of Pipes, Vessels,
Compressors and other enclosed surfaces, etc. during
storage and shipment
Additive to water used in closed circuit cooling
systems.
Additive to standing water & hydro test water

Application of Powder inside

Pipes and Vessels

Water based cleaners and

degreasers with inhibitor
Cleans hydrocarbon deposits, grease, drawing and buffing
compounds,and mill and machinery oils
Dilutable with water increases economy
Inhibitor present prevents flash rusting, while it cleans
Nontoxic, non-hazardous, nitrite free, cost-effective
Used via dipping tank, cleaning equipments, washing or
spraying systems

Water based Rust Removers with

inhibitor in liquid, gel & powder forms
Removes rust, cleans and protects against flash
corrosion
Specific product removes paint
Hard on rust but mild on metal
Adhesion promoter. Top paintable.

Clean, Preserve, Protect

Program that can
incorporate liquids and
packaging

Migrating Corrosion Inhibitors for

the Construction Industry
To protect rebar in concrete against
corrosion
For new concrete: MCI Admixtures to
concrete, to be added before casting.
For repair and rehabilitation of existing
structures: MCI Surface coatings and
related products to prevent further corrosion
of rebar.
Also coatings for rebar during storage

Few Applications of VpCIs in the

Industry
Bulk packaging of automotive components
in crates lined with VpCI film
Storage of service parts in VpCI films and
bags
Install VpCI emitting devices into
electrical, electronic and telecomm
equipments for protection during transit as
well as in service

Few VpCI Applications

(continued)
Preserve military assets in a readiness state
outdoors (and indoors) by adding VpCI to all
functional fluids and then simply wrapping in
VpCI shrink film
By adding VpCI additives to existing coolants
or by using VpCI - based Cutting Fluids,
secondary dips in RP Oil can be eliminated
because the protection is now built-in to the
machining

Few VpCI Applications

(continued)
Semi finished parts are protected against
work-in-process corrosion by exposing
them to VpCIs. Parts need not be
cleaned or prepared for the next
operation
Rusted parts and equipments can be
salvaged by using rust removers and
cleaners containing VpCI

Few VpCI Applications

(continued)

Fog heat exchangers with VpCI powder

or liquid to eliminate subsequent shipping
and storage corrosion problems
Spray or coat valve flanges and stems
with outdoor VpCI coatings for extended
protection
Boost the protection of lubricating oils
with VpCI additives for multi metal
systems.

Few VpCI Applications

(continued)
Three phase protection for gear box
internals during storage and service by
using VpCI additive to the existing oil
Protect tank bottom plates by injecting
VpCI powders or liquids under the tank
Protect metal under insulation by injecting
migrating VpCIs at predetermined
intervals

Few VpCI Applications

(continued)
Use VpCIs as additive to hydrotest fluid to
protect internal surfaces even after the fluid is
drained off
Protection of coils, sheets and sections
produced in a steel plant
Repair and Protection of structural steel,
equipments and pipelines
Protect rebar in concrete as well as during
storage at open sites

FAQs on VpCI
Is VpCI safe?
Yes, it is safe to humans and the environment
Is it expensive?
No, it is cost effective
Is it user friendly?
Yes, it can be used in a variety of friendly and
convenient ways

FAQs on VpCI (contd)

How does VpCI differ from
traditional methods and coatings?
While others try to keep the moisture
and environment away from the metal
by creating a barrier/shield and thus
protect, VpCIs protect metal in the
presence of moisture

FAQs on VpCI
Is skill required for proper use of VpCI?
As VpCI works by itself once it the right VpCI is
deployed at the right place and in the right dosage.
However application knowledge will help
How to choose the right VpCI?
This is dictated by the application and the customer
expectations. If in doubt, ASK the VpCI expert

THANK YOU

QUESTIONS?

For further details, contact

Vertex Corrotech Solutions, Coimbatore
crvenkatesh@vrpmarketing.com
OR
Cortec Corrosion Solutions India, Bangalore
pk.mathew@cortec-india.com