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8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 128SUCCESS STORIES OPEN HOUSE SEMINARS
3 SEPTEMBER 2012
The smallest componentmust be reliable
Surface treatment
laboratoryOffshore
corrosivity
8132019 Corrnew Nr 3 LR
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editorial
Swerea KIMAB is partner to industryuniversities and public bodies in ap-plied research and problem-solvingWe ocus on materials development
the manuacture and use o construction mate-
rials or demanding applications within fieldssuch as energy transport inrastructure andprocess industries
EXPENDITURE ON MAINTENANCE repairs andbreakdowns caused by corrosion is a majorcost or society today With our three labora-tories across Sweden and France we are oneo Europersquos leading corrosion institutes withcutting-edge competence in materials selec-tion design and protection methods or avoid-ing corrosion problems
MAJOR INVESTMENTS WITHIN several researchfields are a contributory actor behind oursuccess We have initiated a new member-ship programme within oil and gas in whichor example we perorm combined testingo corrosion and mechanical properties in ahydrogen sulphide environment ndash a highly ag-gressive environment that is present during theextraction process or oil and gas
ANOTHER MAJOR INVESTMENT is the establish-
ment o a virtual laboratory in which materialand component manuacturing processes andsystems can be described using 983091D modellingand simulation techniques Our in-house ex-perimental resources enable us also to establishhigh quality input data and to veriy experi-mentally the results that are obtained
Relocation to Kista
UNIVERSITY COLLABORATION IS important tous ndash and in particular our collaboration withKH Royal Institute o echnology in SwedenWith KH Maumllardalen University and theSwerea Group we are participating in XPRES
the national strategic investment with theaim o creating an internationally recognisedresearch and educational environment withinthe field o advanced production techniques
OUR EXPANDING OPERATIONS as well as ourFrench subsidiary (Institut de la Corrosion)and extensive participation in European RFCSprojects - or which we act as coordina-tor or six o the projects - has enabled usto have access to an increasing networkwithin the field o materials and corrosion
research
THE BUSINESS MODEL o developingcutting-edge skills to enable us to offerqualified support to customers and our983090983088983088 member companies has been suc-cessul We can look back on growth o983093983088 per cent over the past our years Inorder to manage continued expansionthe development o our laboratoriesin France is continuing and duringthe spring o 983090983088983089983090 we moved to new
and modern acilities in Kista northo Stockholm with larger capacity orexperimental operations
Staffan SoumlderbergManaging Director
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Editors Tomas Hult tomashultswerease Margaretha Soumlnnergaard sonnergaardswerease
Advisory Board Eva Johansson Sweden Bertil Sandberg SwedenJohan Tidblad Sweden Dominique Thierry FrancePrinting EO GrafiskaCover Nuclear reactor Oskarshamn 3 (Photo OKG)Corrosion News is published by Swerea KIMAB and Institut de la Corrosion
SubscriptionsSwerea KIMABCorrosion NewsPO-Box 983095983088983092983095SE-983089983094983092 983088983095 Kista Swedencorrosionnewsswereasewwwswereakimabse
Corrosion News All rights reserved No part of this publication may bereproduced in any form by any electronic or mechanical means withoutpermission in writing from Swerea KIMAB
14
4
CORROSION NEWS 3 | 2012 3
12
20
Swerea KIMAB conduct a study of the properties and condition of PVDFpiping systems that had been used to transport hydrofluoric acid hydro-chloric acid and nitric acid for nearly 983091983088 years in a steel pickling plant
Through a newly started joint industry project Swerea KIMAB is aimingto help companies gain more knowledge about the corrosion rates ontheir offshore assets and the coatings systems in use
A nuclear power station cancontain some fairly aggressiveenvironments for materials and itis vital to avoid material failures
An automated corrosion monitoringsystem was applied for assessmentof the corrosivity towards carbon steeland zinc in a accelerated corrosion test
Nearly 983091983088 years in use and still going strong 983092
Why do reinforcement bars rust in concrete 983096
New developments in the classification ofcorrosivity of atmospheres 983089983088
Meeting of ISOTC 983089983093983094 in Paris in June 983090983088983089983090 983089983089
Offshore corrosivity 983089983090
The smallest component must be reliable 983089983092The right fuel and temperature keep the steam up 983089983094
Proper material choice for corrosive environments 983089983097
Institut de la Corrosion ndash 983089983088th anniversary 983089983097
Application of automated corrosion sensors 983090983088
BIOCOR Oil amp Gas 983090983090
Surface treatment laboratory 983090983092
Paints and linings for steel and related alloysstructures in atmosphere and in immersion 983090983094
8132019 Corrnew Nr 3 LR
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CORROSION NEWS 3 | 20124
In addition to corrosion resistancethe long-term behavior o the mate-rial was examined in an extensiveseries o tests Te testing included
visual and microscopic studies mi-crotome cuts thermal analyses me-chanical tests and an assessment o theresidual stress For evaluation purposesthe acquired data was compared withthat o a actory-new PVDF pipe romGF Piping Systems Furthermore thecondition o the socket welds was exam-
ined and the usion work done on the
983091983088-year-old pipes was also appraisedIn steel pickling piping systems are
under extreme stress because o theaggressive media which need to betransported through them Tat is whymany metals are not even considered inthe planning phase since they are notresistant to highly concentrated acidsIn terms o metals only a ew preciousmetals (gold platinum) high-alloysteels or special nonerrous alloys aresuitable or this specific application
area In contrast PVC-U- PVC-C- or
PVDF pipes exhibit very good resist-ance to suluric acid hydrofluoric acidor hydrochloric acid
From 983089983097983095983096 Sandvik Materials ech-nology utilized three parallel PVDF pip-ing systems rom GF Piping Systems toconvey concentrated hydrofluoric acid(wt 983095983089ndash983095983093983077) nitric acid (wt 983094983096983077) andsuluric acid (wt 983097983094983077) In December983090983088983088983095 the nitric acid and hydrofluoricacid pipelines were taken out o servicebut not disassembled Te suluric acid
pipeline had already been shut down
Early 983090983088983088983096 the steel pickling plant Sandvik Materials Technology in Sweden closed downits operations Swerea KIMAB took advantage of the plant shut-down to conduct a studyof the properties and condition of PVDF piping systems that had been used to transporthydrofluoric acid hydrochloric acid and nitric acid for nearly 983091983088 years The purpose of thetests was to gain knowledge of the actual corrosion condition as well as the probability ofcorrosion on joints in plastic piping systems after a lengthy period of use
Nearly 30 years in useand still going strongPVDF plastic piping systems are free of corrosion brittleness and cracking
BY HANS-JOumlRG SOMMER
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CORROSION NEWS 3 | 2012 5
ten years earlier but was only disman-tled in 983090983088983088983096 along with the others
Te PVDF pipes were installedoutdoors and depending on the season
were exposed to temperatures rangingrom -983090983088 degC to +983092983088 degC Te pressureload reached 983090ndash983091 bar several times dailyTe pipelines in the steel pickling plantwere manuactured o Syge PVDF ma-terial by GF Piping Systems and joined
via socket usion Syge is requentlyused or chemicals distribution due toits excellent chemical resistance Sygeis ree o additives dyes or stabilizingagents
Te pressure rating o the PVDF pipesis 983089983094 bar (PN983089983094) or a diameter o 983092983088mm and a wall thickness o 983090983093 mmBeore the pipes were removed SwereaKIMAB took ten meters o pipe mate-rial including usion joints and bendsper pipeline or the test procedures
Visual and microscopic testingIn the visual inspection PVDF pipesthrough which hydrofluoric or suluricacid was conducted showed no signso corrosion ie no visible suracedamage no blistering or debonding
no swelling Te only noticeable effectwas a light brown discoloration o thehydrofluoric and suluric acid pipesTe discoloration was spread consist-ently over the length o the pipelinewhereas the acid permeation o suluricacid reached a depth o 983088983090 mm Tediscoloration was caused by a chemicalreaction o the acids with the polymersOn the other hand pipelines that wereexposed to nitric acid did not exhibitany discoloration Te microscopic tests
did not show any signs o corrosioneither
Thermal analysisTe melting point and crystallizationtest conducted on the basis o dynamicdifferential calorimetry (DSC) showedthat there was no significant differ-ence between spot samples taken romthe interior o the pipe and the mainbody o the test pipe Te crystallinityalso revealed no degeneration o the
polymer chains Tis indicates that thePVDF material had not been weakened
by the contact with acid over a period o983090983088ndash983091983088 years just as there were no differ-ences detected between pipes installedindoors and outdoors
Mechanical testingTe tensile stress tests done at roomtemperature on all three PVDF pipesand the new pipe uncovered no majordifferences in the mechanical proper-ties Tese results coincide with the re-sults rom the thermal analysis and themicrotome examination according towhich there was no or merely a minimaldegeneration o the PVDF pipes used inthis application
Impact resistance was tested in aroom o which the temperature cor-responded to the guidelines o ISOnorm 983089983095983097 Six test specimens were takenrom each o the three pipes None othe specimens showed any brittlenessbehavior in the impact resistance test
Inspection of fusion jointsWhen inspecting the old usion jointsthe question also arose as to the qualityo usion welds with old pipe materialIn other words how saely can material
which has been penetrated with acid be
used in case o maintenance and repairwork
Respective sections rom the threePVDF pipes were sent to a company
which specializes in acid technologyTeir findings turned out to be similarlypositive or all three pipe sections withIR butt usion joints the usion qualitywas consistently good with slight pres-sure Only on the hydrofluoric samplewas there a bit o blistering in the usionarea
In the socket usion joints used on thehydrofluoric and nitric acid pipes nofissuring was detected Fissures werehowever ound in all the examinedsocket usion joints which had beenexposed to suluric acid It is a knownact that socket usion causes such e -ects Te examined fissures were up totwo millimeters deep and although theyweakened the components to a certainextent they never represented a saetyrisk even at an operating pressure o983090ndash983091 bar over a period o 983090983088 years Anadditional method which contributesto the saety o pipe systems used toconvey aggressive media is BCF (beadand crevice-ree) usion developed
by GF Piping Systems Tis low-stress
After more than thirty years of use the PVDF plastic pipes are still intact They are only slightlydiscolored by the corrosive acids that under high pressure pass through them
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CORROSION NEWS 3 | 20126
jointing technique is highly appreciated by proes-sionals and has stood the test o time in a multitudeo applications
Additionally a ront discoloration 983094983093 mm deep
was noted on the socket joints in the hydrofluoricacid application Assuming that this is a sign opermeation it is possible to calculate an averagepermeation o 983089983090 mm a year (according to Fickrsquos lawo diffusion)
Generally however the socket usion method hasproven reliable in manuacturing piping systemsthat are or example used to convey hydrofluoric ornitric acid
ConclusionTe extensive testing perormed by Swerea KIMABshowed that PVDF pipes rom GF Piping Systemsstill have excellent resistance to corrosion even un-der the harshest conditions and afer more than 983090983088years o use Other than a slight discoloration o thepipe material no other signs o corrosion fissuringor brittleness were determined on the pipes exam-ined Moreover the microtome cuts o the pipe wallsrevealed no indication o local material brittleness
Since chemicals at certain temperatures or pres-sures can cause macromolecular chains to split offor separate it was necessary to test the molecularstructure o the pipes even i there was no signifi-cant degeneration o the material during the utiliza-
tion periodTe mechanical properties o the pipes were not
altered during the course o use Tis result coin-cides with the results o the thermal analysis accord-ing to which there was no significant or substantialdegeneration
On the basis o the test results Swerea KIMABgenerally recommends socket usion as the preerredusion process or PVDF pipes
Assuming that the operating conditions wouldhave remained consistent with those during the pre-
vious 983090983088ndash983091983088 years the creep behavior data lead us to
conclude that the examined pipes would have beensuitable or a much longer period o use with a saetyactor o 983090983096 or higher
The investigated pipes was taken from Sandvik Materials
Technologys steel pickling plant
FACTS
THE AUTHOR HANS-JOumlRG SOMMER is head of Chem-icalMechanical Support and Claims at Georg Fischer
GF Piping Systems Schaffhausen Switzerland
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CORROSION NEWS 3 | 2012 7
in short
NURIA FUERTES began her PhD thesisin April 983090983088983089983090 on ldquoUse of localised electro-chemical techniques for studying stresscorrosion cracking of stainless steelsrdquoSwerea KIMAB recently purchased aScanning Vibrating Electrode Technique(SVET) which will be used in the projectto perform in-situ observations of cracknucleation and growth during stress
corrosion Other applications of this tech-nique include investigation of pitting cor-rosion galvanic corrosion and corrosionresistance of coatings Nuria has workedat Swerea KIMAB since June 983090983088983089983088 inthe research group Metallic Materials inCorrosive Environments
ContactNuacuteria Fuertesnuriafuertesswerease
IN A LETTER to the board of the Swedish
Metallographic Institute on 983090983088 December983089983097983092983093 Carl Benedicks assigned ownershipof his books off-prints and journals to theInstitute Benedicks was the founder of theMetallographic Institute (Swerea KIMAB)From 983089983097983090983089 when the MetallographicInstitute was founded and for fifteen yearsafter that he was its director
The collection ranges over six centuriesand comprises metallurgy mineralogy andmining but also general chemistry physicsand reference works of a historical natureThe majority of the collection consists of
prints from the period of hand printing upto the end of the 983089983097th century These books
are the most valuable in terms of cultural
history and science as well as in financialterms
An example of an interesting book isVanoccio Biringucciorsquos ldquoDe la Pirotechniardquo(983089983093983092983088) which is one of the classic bookswithin the science of mining Another clas-sic is Georg Agricolarsquos ldquoDe Re MetallicardquoMost editions of this title are included buttwo are of particular interest The Italianwork ldquoLrsquoarte de Metallirdquo (983089983093983094983091) which isprobably not held by any other library inSweden The second edition which is alsoin the collection was translated by Herbert
Clark Hoover and his wife Hoover laterbecame President of the United States but
was a qualified mining engineer In addition
to the translation of the book the Hoovercouple have added valuable commentsS
The Benedicks collection contains manyof the more important publications onSwedish mining All books by ldquothe father ofthe Swedish mining industryrdquo Sven Rinmanare included in the collection for example
Most of the Benedicks collection of booksare now stored in the Hagstroumlmer Librarya medico-historical research library andmuseum of books in Stockholm Sweden
Contact
Louise Parnefjordlouiseparnefjordswerease
The Benedicks collection
NEW MEMBER CONSORTIA
Surface Technology
AT SWEREA KIMAB we are now initiating the much-requested membership pro-gramme MRC Surface Technology In its first stage the programme will focus onsurface treatment systems increased understanding concerning corrosion protec-tion and other functional properties of surfaces Joint projects are going to be runwithin surface properties surface analysis and different types of surface treatmentAs well as the properties of surfaces in finished products understanding process-critical parameters will also be included to ensure that selected applications obtainthe very best surface treatments Swerea KIMAB has many years of experienceconcerning surfaces and now in collaboration with interested companies we willbe concentrating on developing current and future requirements within the field
Do not hesitate to contact us for further information about the programme orabout surface technology ideas in general
ContactJohan Nordstroumlm johannordstromswerease
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CORROSION NEWS 3 | 20128
Why do reinforcementbars rust in concrete
BY JOHAN AHLSTROumlM
Reinforcement bars cast in concretenormally have a very low rate of corro-sion The low corrosion rate is due tothe concretersquos high alkalinity the pHvalue in concrete is about 983089983090ndash983089983091Corrosion can occur in environmentswhere chlorides are present which aretransported through the concrete tothe reinforcement bar surface andbreak down the steelrsquos passivity Manytests have been made to determinethe chloride concentration thresholdvalue on the reinforcement bar sur-face that is required to initiate corro-sion The distribution in the resultsfrom these tests is quite wide and canprobably be explained by differentexperimental methods having beenused as well as different externalenvironmental factors
CORROSION NEWS 3 | 20128
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CORROSION NEWS 3 | 2012 9
Tere is a critical chloride thresholdwhich dictates steel corrosion rate oreach quality o concrete Te corrosionrate is largely determined by the con-
cretersquos moisture content Te moisturecontent affects the concretersquos resistiv-ity and transport o both oxygen andchlorides Te time it takes or chloridesto be transported to the reinorcementbar surace where corrosion beginsis called the initialisation period Apropagation stage begins thereafer seefigure Concrete with high moisturecontent has relatively low resistivity andslow transport o oxygen Te propaga-tion rate is consequently low even i thechloride concentration is significantlyhigher than the chloride threshold val-ue Concrete with low moisture contentexhibits rapid transport o oxygen andhigh resistivity which produces a lowrate o corrosion as well At a specificmoisture interval however the transporto oxygen can be high at the same timeas resistivity is low which produces ahigh corrosion rate It is at this specificmoisture interval that the chloridethreshold values should be determined
Te corrosion rate or steel in water-
saturated concrete constructions isusually low due to slow transporto oxygen to the reinorcement barsurace However i the reinorcementbars are in contact with a more noblematerial the corrosion rate can showa marked increase Te magnitude othe galvanic effects or steel in concreteare determined by among other thingschloride and the oxygen concentrationI the chloride concentration is low thereinorcement bar can maintain passiv-
ity despite electrical contact with a morenoble material and the rate o corrosionwill thus be low In one case sacrificialanodes o aluminum were installedto protect the reinorcement bars in aconcrete construction or transportingseawater Te reinorcement bars wereunintentionally in electrical contactwith pumps made o stainless steel andthe sacrificial anodes rapidly deteriorat-ed Te stainless steel pumps probablytook up a large portion o the protective
current compared with the reinorce-ment bars Tere is thereore a risk that
the reinorcement bars were not beingsufficiently protected by the sacrificialanodes
On this basis a PhD project has beeninitiated to investigate how the moisturecontent in concrete affects the chloridethreshold values as well as to inves-tigate the risk or galvanic corrosion
o steel in concrete Te PhD projectencompasses experimental methodsor determining the chloride threshold
values modeling o corrosion processesand field studies o concrete construc-tions situated in seawater
Application of the resultsTe purpose o the project is to surveyin detail which actors interact inchloride-initialized reinorcement barcorrosion and to establish relevant
threshold values or these Increasedunderstanding and clearer limit valuesor chloride-initialized reinorcementbar corrosion enable more reliable as-sessments o condition
Project informationTe PhD project will be conductedthrough collaboration between SwereaKIMAB and the Faculty o Engineering
at Lund University (LH) Te projectis co-financed by the Elorsk Kaumlrnkrafconcrete programme SBUFrsquos develop-ment und and Swerea KIMAB
ContactJohan Ahlstroumlm
johanahlstroumlmswerease
Schematic diagram of corrosion process for steel in concrete
Test configuration for determining moisture-
contentrsquos effects on the corrosion chloridevalue
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CORROSION NEWS 3 | 201210
The international standards ISO 983097983090983090983091-983097983090983090983094 arethe original source for the corrosivity categoriesC983089ndashC983093 used for the classification of the corro-
sivity of atmospheric environments thus serv-ing as a basis for the choice of corrosionprotection systems for many different indus-trial applications Revised versions of thesestandards were issued in the beginning of983090983088983089983090 including the addition of a new corro-sivity category CX and improved proce-dures for estimating corrosivity categories
A SYSTEM FOR CLASSIFICATION oatmospheric corrosivity is helpul orthe selection o materials and protectionagainst corrosion or estimating thelietime o coatings and materials andcan also serve as a guide when choos-ing appropriate corrosion tests Tecorrosivity categories C983089ndashC983093 are wellaccepted and used when selecting struc-tural metals protective coatings andhave been incorporated in other norma-
tive and guidance documents through-out the world Te system was originallydeveloped in the 983089983097983096983088s and the previous
version o ISO 983097983090983090983091 was dated 983089983097983097983090Tis article gives an overview o thenew versions issued in the beginning o983090983088983089983090 starting with a description o thescientific field work underpinning thestandards
Field exposure programsEven though the standards ISO 983097983090983090983091-
983097983090983090983094 are well accepted they have alsobeen the subject o some criticism Tis
was mainly related to the part o thestandard that describes procedures orestimating corrosivity categories basedon environmental data as opposed tothe more reliable way to determine thecorrosivity category by exposure ostandard specimens Tis was realizedearly and due to the act that the first
versions o the standards were based toa great extent on data rom the temper-ate region
Tereore the ISOCORRAG exposureprogram was initiated It was carriedout by nations involved in the standard-ization work and included 983093983091 test sites in983089983091 countries on our continents It wasconducted during an eight-year period983089983097983096983092ndash983089983097983097983093 and included six subsequentone-year exposures and long-termexposures or 983090 983092 and 983096 years Te datarom this exposure program orm thecore o the data used in the revision oISO 983097983090983090983091 (one-year data) and ISO 983097983090983090983092
(long term data) and has been summa-rized in ldquoISOCORRAG ndash International
Exposure ProgramrdquoISOCORRAG International
Atmospheric Exposure Program Sum-mary o Results Editors Sheldon WDean Dagmar Knotkova KaterinaKreislova ASM
Te MICA exposure program wasorganized and carried out in 983089983097983096983096ndash983089983097983097983090by 983089983092 Iberoamerican countries andcovered 983095983090 test sites Since the MICAprogram more or less ully adopted the
methodology or the ISOCORRAGprogram and in addition covered addi-tional climatic conditions it was naturalto create a common database used orderiving improved ways o estimatingcorrosivity categories based on environ-mental data
Classification determination andestimation (ISO 9223)Corrosion rates exceeding the upperlimit o category C983093 ia 983090983088983088 microm a-983089 or
carbon steel were previously consid-ered out o the scope o the standard
BY JOHAN TIDBLAD AND KATERINA KREI SLOVA
New developments in the
classification of corrosivityof atmospheres
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CORROSION NEWS 3 | 2012 11
During the analysis o the data rom theISOCORRAG and MICA programs itwas realized that several marine sites insubtropicaltropical regions had values
above the upper limit o C983093 Since theseare natural environments that should becovered by the standard a new categoryCX have been added with upper limit983095983088983088 microm a-983089 or carbon steel reerringto specific marine and marineindus-trial environments typically in a warmclimate
Dose-response unctions ie unc-tions giving an estimate o the corrosionrate based on environmental param-eters have been developed or the ISO983097983090983090983091 metals carbon steel zinc copperand aluminum based on measuredannual values o temperature relativehumidity SO983090 concentrationdeposi-tion and chloride deposition Tis isa significant improvement comparedto the previous standard in terms oreliability o predicted corrosivitycategories Even so the standard givesan important distinction between thedetermination (typical error 983093983077) o thecorrosivity category by exposure o
standard specimens and the estimation(typical error 983093983088983077) o the corrosiv -ity category based on environmentalparameters Furthermore the effect o
clean and acid rain was considered atan early stage but could not be includedin the dose-response unctions despitetheir importance or atmosphericcorrosion Tese new unctions are anintegral part o the KorrField databaseand prediction program developed bySwerea KIMAB
Guiding values for the corrosivitycategories (ISO 9224)Te newly issued ISO 983097983090983090983092 providesinstructions or predicting corrosionattack afer extended and long-term ex-posures Detailed ormulas are providedor carbon steel zinc copper and alu-minium and in addition specific criteriato be taken into account or alloyingelements in weathering steels and alloyso zinc copper and aluminium
Measurement of environmentalparameters (ISO 9225)Description o measurements o
environmental parameters ocus ontemperature relative humidity SO983090and salinity since these are given in thedose-response unctions New methods
are considered including or examplepassive samplers or pollutants andconversion actors are given between se-lected pollution measurement methodsTe methodologies to measure envi-ronmental parameters are now similarto those described in ISO 983089983089983096983092983092 whichdeals with classification o low corrosiv-ity o indoor atmospheres
Evaluation of standard specimens(ISO 9226)In the previous version o the standardit was possible to evaluate corrosioneither by exposing flat standard speci-mens or by exposing special wire helixspecimens Since the analysis showedthat they are not equivalent it is nowonly possible to determine the corrosiv-ity category by flat standard specimens
ContactJohan TidbladJohantidbladswerease
About 983093983088 experts romnine countries (Aus-tralia China CzechRepublic France
Germany Japan Korea Swedenand UK) participated the week o983089983089ndash983089983093 June 983090983088983089983090 at the meeting o
ISOC 983089983093983094 Corrosion o met-als and alloys and its 983089983091 workinggroups Te meeting was held atEspace la Rocheoucauld in ParisFrance and was hosted by AFNORthe French standardization bodyTe chairman o the committee isGoumlran Engstroumlm Swerea KIMABand the secretariat is at CMISI inChina
Read more about the results romthe working groups at httpwww
swereaseenStart983090983090Working-AreasovrigtStandardisation
Meeting of ISOTC 156 in Paris in June 2012
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CORROSION NEWS 3 | 201212
CORROSION ON OFFSHORE INSTALLATIONS requires almostconstant maintenance in order to keep structural membersand saety critical elements fit or purpose On board anoffshore installation the corrosivity varies depending on the
height rom sea level and wind direction as well as otherenvironmental effects such as temperature Many companieschoose to repair degraded coatings on the bases o prequalifi-cation tests carried out onshore or in the laboratory and alsoplan maintenance using corrosion rate data rom estimationsor again rom onshore or lab tests Swerea KIMAB is aimingto help companies gain more knowledge about the corrosionrates on their offshore assets and the coatings systems in use
Trough a newly started joint industry project (JIP) SwereaKIMAB is looking at these aspects in which samples o
various materials and coating systems will be placed offshoreand subsequently analysed in order to build up a picture o
corrosivity and coating system effectiveness It is envisionedthat the JIP will be made up o oil and gas operators their
service companies coating manuacturers as well as materialsand equipment manuacturers Te data obtained rom theexperiments will be used by specialists (designers and main-tenance teams) and this will allow them to better understand
the conditions in which their equipment and materials aredesigned to be used Materials and paint companies couldalso have access to unique testing environments that wouldallow them to prove existing products or trial developmentproducts
Tere is a particular requirement to improve the mainte-nance o coatings on offshore installations in the North Seacurrently Te Health and Saety Executive (HSE) in the UKare in the midst o their KP983092 (Key Programme 983092) projectwhich looks at the procedures used by asset owners in regardsto saety and operability In the previous project KP983091 coatingmaintenance (or abric maintenance as it is known in the
industry) was ound to be an area that required significantimprovement Te problem with this type o maintenance is
Offshore corrosivityBY ANDREW GORDON amp MARTIN JOumlNSSON
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CORROSION NEWS 3 | 2012 13
that it requires avourable weather condi-tions and with restrictions on bed spaceor example the logistics o such workbecomes very difficult to manage
Prequalification tests in the environ-mentWith an accurate picture o which areaso an installation corrode aster or sloweroperators can plan their maintenance moreeffectively ensuring resources are allocatedwhere they are most needed as well as al-lowing them to deer maintenance activitiesi required Te selection and use o coatingsystems can be tailored more effectively bycarrying out the prequalification tests inthe environment in which they will be usedrather than just in accelerated laboratorytests or onshore exposures
Swerea KIMAB has a long history oconducting research into materials andcorrosion having successully completedsimilar studies or inrastructure and auto-motive companies Te data obtained hashelped populate the Korrfield database andenabled companies to select materials moreeffectively or the environments in whichthey operate Te previous studies involvedplacing samples in very hostile environ-
ments such as on the underside o heavygood vehicles and so provides SwereaKIMAB with the expertise or ensuringsamples are saely exposed and easy toevaluate
Focussed on oil and gas operatorsTe first round o meetings with companieshas been completed and has been ocussedon oil and gas operators based in AberdeenUK However the aim is to encompass asmany participants as possible in order to
generate a data set that will be useul notonly to current installations in the NorthSea but also to new projects and otherregions o the world I you are a paint com-pany materials manuacturer equipmentmanuacturer or have an influence on theuse andor maintenance o materials usedin the offshore environment this projectcould be o benefit to you Please eel ree toget in contact i you wish to learn more
Contact
andrewgordonSwereasemartinjonssonswerease
Maintenance scheduling should take into account known degradation ratesof materials and coating systems in operating environments
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CORROSION NEWS 3 | 201214
BY MARIA AringSLUND
A nuclear power station can contain some fairly aggressiveenvironments for materials and it is vital in these environ-ments to try and avoid material failures Thomas Blomfeldtof Swerea KIMAB keeps a check on the condition of thepolymer materials at nuclear sites
RISKS IN NUCLEAR POWER stations areofen associated with meltdowns like atChernobyl or last year at Fukushima -a nightmare scenario that is thankullya rare occurrence However even smallequipment ailures can result in bigproblems or the operators such as pro-duction losses or injury to personnelFor that reason saety and reliability areparamount and this philosophy filtersdown to every component in the system
including nuts bolts and gasketsldquoTe saety margins specified by the
nuclear power station owners have beenset or very good reasons At the sametime or financial reasons they do notwant to replace materials unnecessarilyrdquosays Tomas Blomeldt who has thetask o determining the remaining ser-
vice lie o a rubber joint or exampleSwerea KIMAB has several teams
working on inspecting different typeso material Tomas specialises inpolymers both as an expert at Swerea
KIMAB and as a research scientist 983096983088per cent o his working hours involve
inspecting and evaluating samplesrom nuclear power stations Tomasis a requent visitor at Swedenrsquos threenuclear power stations this year he hasinspected seven out o the total o tenreactors
rdquoPlastic and rubber may not bewhat you first think o when you see anuclear power station However thereare large quantities o polymers thereIn a reactor building the cables alone
correspond to the street lighting systemo a medium-sized Swedish town In ad-
The smallest componentmust be reliable
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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editorial
Swerea KIMAB is partner to industryuniversities and public bodies in ap-plied research and problem-solvingWe ocus on materials development
the manuacture and use o construction mate-
rials or demanding applications within fieldssuch as energy transport inrastructure andprocess industries
EXPENDITURE ON MAINTENANCE repairs andbreakdowns caused by corrosion is a majorcost or society today With our three labora-tories across Sweden and France we are oneo Europersquos leading corrosion institutes withcutting-edge competence in materials selec-tion design and protection methods or avoid-ing corrosion problems
MAJOR INVESTMENTS WITHIN several researchfields are a contributory actor behind oursuccess We have initiated a new member-ship programme within oil and gas in whichor example we perorm combined testingo corrosion and mechanical properties in ahydrogen sulphide environment ndash a highly ag-gressive environment that is present during theextraction process or oil and gas
ANOTHER MAJOR INVESTMENT is the establish-
ment o a virtual laboratory in which materialand component manuacturing processes andsystems can be described using 983091D modellingand simulation techniques Our in-house ex-perimental resources enable us also to establishhigh quality input data and to veriy experi-mentally the results that are obtained
Relocation to Kista
UNIVERSITY COLLABORATION IS important tous ndash and in particular our collaboration withKH Royal Institute o echnology in SwedenWith KH Maumllardalen University and theSwerea Group we are participating in XPRES
the national strategic investment with theaim o creating an internationally recognisedresearch and educational environment withinthe field o advanced production techniques
OUR EXPANDING OPERATIONS as well as ourFrench subsidiary (Institut de la Corrosion)and extensive participation in European RFCSprojects - or which we act as coordina-tor or six o the projects - has enabled usto have access to an increasing networkwithin the field o materials and corrosion
research
THE BUSINESS MODEL o developingcutting-edge skills to enable us to offerqualified support to customers and our983090983088983088 member companies has been suc-cessul We can look back on growth o983093983088 per cent over the past our years Inorder to manage continued expansionthe development o our laboratoriesin France is continuing and duringthe spring o 983090983088983089983090 we moved to new
and modern acilities in Kista northo Stockholm with larger capacity orexperimental operations
Staffan SoumlderbergManaging Director
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Editors Tomas Hult tomashultswerease Margaretha Soumlnnergaard sonnergaardswerease
Advisory Board Eva Johansson Sweden Bertil Sandberg SwedenJohan Tidblad Sweden Dominique Thierry FrancePrinting EO GrafiskaCover Nuclear reactor Oskarshamn 3 (Photo OKG)Corrosion News is published by Swerea KIMAB and Institut de la Corrosion
SubscriptionsSwerea KIMABCorrosion NewsPO-Box 983095983088983092983095SE-983089983094983092 983088983095 Kista Swedencorrosionnewsswereasewwwswereakimabse
Corrosion News All rights reserved No part of this publication may bereproduced in any form by any electronic or mechanical means withoutpermission in writing from Swerea KIMAB
14
4
CORROSION NEWS 3 | 2012 3
12
20
Swerea KIMAB conduct a study of the properties and condition of PVDFpiping systems that had been used to transport hydrofluoric acid hydro-chloric acid and nitric acid for nearly 983091983088 years in a steel pickling plant
Through a newly started joint industry project Swerea KIMAB is aimingto help companies gain more knowledge about the corrosion rates ontheir offshore assets and the coatings systems in use
A nuclear power station cancontain some fairly aggressiveenvironments for materials and itis vital to avoid material failures
An automated corrosion monitoringsystem was applied for assessmentof the corrosivity towards carbon steeland zinc in a accelerated corrosion test
Nearly 983091983088 years in use and still going strong 983092
Why do reinforcement bars rust in concrete 983096
New developments in the classification ofcorrosivity of atmospheres 983089983088
Meeting of ISOTC 983089983093983094 in Paris in June 983090983088983089983090 983089983089
Offshore corrosivity 983089983090
The smallest component must be reliable 983089983092The right fuel and temperature keep the steam up 983089983094
Proper material choice for corrosive environments 983089983097
Institut de la Corrosion ndash 983089983088th anniversary 983089983097
Application of automated corrosion sensors 983090983088
BIOCOR Oil amp Gas 983090983090
Surface treatment laboratory 983090983092
Paints and linings for steel and related alloysstructures in atmosphere and in immersion 983090983094
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CORROSION NEWS 3 | 20124
In addition to corrosion resistancethe long-term behavior o the mate-rial was examined in an extensiveseries o tests Te testing included
visual and microscopic studies mi-crotome cuts thermal analyses me-chanical tests and an assessment o theresidual stress For evaluation purposesthe acquired data was compared withthat o a actory-new PVDF pipe romGF Piping Systems Furthermore thecondition o the socket welds was exam-
ined and the usion work done on the
983091983088-year-old pipes was also appraisedIn steel pickling piping systems are
under extreme stress because o theaggressive media which need to betransported through them Tat is whymany metals are not even considered inthe planning phase since they are notresistant to highly concentrated acidsIn terms o metals only a ew preciousmetals (gold platinum) high-alloysteels or special nonerrous alloys aresuitable or this specific application
area In contrast PVC-U- PVC-C- or
PVDF pipes exhibit very good resist-ance to suluric acid hydrofluoric acidor hydrochloric acid
From 983089983097983095983096 Sandvik Materials ech-nology utilized three parallel PVDF pip-ing systems rom GF Piping Systems toconvey concentrated hydrofluoric acid(wt 983095983089ndash983095983093983077) nitric acid (wt 983094983096983077) andsuluric acid (wt 983097983094983077) In December983090983088983088983095 the nitric acid and hydrofluoricacid pipelines were taken out o servicebut not disassembled Te suluric acid
pipeline had already been shut down
Early 983090983088983088983096 the steel pickling plant Sandvik Materials Technology in Sweden closed downits operations Swerea KIMAB took advantage of the plant shut-down to conduct a studyof the properties and condition of PVDF piping systems that had been used to transporthydrofluoric acid hydrochloric acid and nitric acid for nearly 983091983088 years The purpose of thetests was to gain knowledge of the actual corrosion condition as well as the probability ofcorrosion on joints in plastic piping systems after a lengthy period of use
Nearly 30 years in useand still going strongPVDF plastic piping systems are free of corrosion brittleness and cracking
BY HANS-JOumlRG SOMMER
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CORROSION NEWS 3 | 2012 5
ten years earlier but was only disman-tled in 983090983088983088983096 along with the others
Te PVDF pipes were installedoutdoors and depending on the season
were exposed to temperatures rangingrom -983090983088 degC to +983092983088 degC Te pressureload reached 983090ndash983091 bar several times dailyTe pipelines in the steel pickling plantwere manuactured o Syge PVDF ma-terial by GF Piping Systems and joined
via socket usion Syge is requentlyused or chemicals distribution due toits excellent chemical resistance Sygeis ree o additives dyes or stabilizingagents
Te pressure rating o the PVDF pipesis 983089983094 bar (PN983089983094) or a diameter o 983092983088mm and a wall thickness o 983090983093 mmBeore the pipes were removed SwereaKIMAB took ten meters o pipe mate-rial including usion joints and bendsper pipeline or the test procedures
Visual and microscopic testingIn the visual inspection PVDF pipesthrough which hydrofluoric or suluricacid was conducted showed no signso corrosion ie no visible suracedamage no blistering or debonding
no swelling Te only noticeable effectwas a light brown discoloration o thehydrofluoric and suluric acid pipesTe discoloration was spread consist-ently over the length o the pipelinewhereas the acid permeation o suluricacid reached a depth o 983088983090 mm Tediscoloration was caused by a chemicalreaction o the acids with the polymersOn the other hand pipelines that wereexposed to nitric acid did not exhibitany discoloration Te microscopic tests
did not show any signs o corrosioneither
Thermal analysisTe melting point and crystallizationtest conducted on the basis o dynamicdifferential calorimetry (DSC) showedthat there was no significant differ-ence between spot samples taken romthe interior o the pipe and the mainbody o the test pipe Te crystallinityalso revealed no degeneration o the
polymer chains Tis indicates that thePVDF material had not been weakened
by the contact with acid over a period o983090983088ndash983091983088 years just as there were no differ-ences detected between pipes installedindoors and outdoors
Mechanical testingTe tensile stress tests done at roomtemperature on all three PVDF pipesand the new pipe uncovered no majordifferences in the mechanical proper-ties Tese results coincide with the re-sults rom the thermal analysis and themicrotome examination according towhich there was no or merely a minimaldegeneration o the PVDF pipes used inthis application
Impact resistance was tested in aroom o which the temperature cor-responded to the guidelines o ISOnorm 983089983095983097 Six test specimens were takenrom each o the three pipes None othe specimens showed any brittlenessbehavior in the impact resistance test
Inspection of fusion jointsWhen inspecting the old usion jointsthe question also arose as to the qualityo usion welds with old pipe materialIn other words how saely can material
which has been penetrated with acid be
used in case o maintenance and repairwork
Respective sections rom the threePVDF pipes were sent to a company
which specializes in acid technologyTeir findings turned out to be similarlypositive or all three pipe sections withIR butt usion joints the usion qualitywas consistently good with slight pres-sure Only on the hydrofluoric samplewas there a bit o blistering in the usionarea
In the socket usion joints used on thehydrofluoric and nitric acid pipes nofissuring was detected Fissures werehowever ound in all the examinedsocket usion joints which had beenexposed to suluric acid It is a knownact that socket usion causes such e -ects Te examined fissures were up totwo millimeters deep and although theyweakened the components to a certainextent they never represented a saetyrisk even at an operating pressure o983090ndash983091 bar over a period o 983090983088 years Anadditional method which contributesto the saety o pipe systems used toconvey aggressive media is BCF (beadand crevice-ree) usion developed
by GF Piping Systems Tis low-stress
After more than thirty years of use the PVDF plastic pipes are still intact They are only slightlydiscolored by the corrosive acids that under high pressure pass through them
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CORROSION NEWS 3 | 20126
jointing technique is highly appreciated by proes-sionals and has stood the test o time in a multitudeo applications
Additionally a ront discoloration 983094983093 mm deep
was noted on the socket joints in the hydrofluoricacid application Assuming that this is a sign opermeation it is possible to calculate an averagepermeation o 983089983090 mm a year (according to Fickrsquos lawo diffusion)
Generally however the socket usion method hasproven reliable in manuacturing piping systemsthat are or example used to convey hydrofluoric ornitric acid
ConclusionTe extensive testing perormed by Swerea KIMABshowed that PVDF pipes rom GF Piping Systemsstill have excellent resistance to corrosion even un-der the harshest conditions and afer more than 983090983088years o use Other than a slight discoloration o thepipe material no other signs o corrosion fissuringor brittleness were determined on the pipes exam-ined Moreover the microtome cuts o the pipe wallsrevealed no indication o local material brittleness
Since chemicals at certain temperatures or pres-sures can cause macromolecular chains to split offor separate it was necessary to test the molecularstructure o the pipes even i there was no signifi-cant degeneration o the material during the utiliza-
tion periodTe mechanical properties o the pipes were not
altered during the course o use Tis result coin-cides with the results o the thermal analysis accord-ing to which there was no significant or substantialdegeneration
On the basis o the test results Swerea KIMABgenerally recommends socket usion as the preerredusion process or PVDF pipes
Assuming that the operating conditions wouldhave remained consistent with those during the pre-
vious 983090983088ndash983091983088 years the creep behavior data lead us to
conclude that the examined pipes would have beensuitable or a much longer period o use with a saetyactor o 983090983096 or higher
The investigated pipes was taken from Sandvik Materials
Technologys steel pickling plant
FACTS
THE AUTHOR HANS-JOumlRG SOMMER is head of Chem-icalMechanical Support and Claims at Georg Fischer
GF Piping Systems Schaffhausen Switzerland
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CORROSION NEWS 3 | 2012 7
in short
NURIA FUERTES began her PhD thesisin April 983090983088983089983090 on ldquoUse of localised electro-chemical techniques for studying stresscorrosion cracking of stainless steelsrdquoSwerea KIMAB recently purchased aScanning Vibrating Electrode Technique(SVET) which will be used in the projectto perform in-situ observations of cracknucleation and growth during stress
corrosion Other applications of this tech-nique include investigation of pitting cor-rosion galvanic corrosion and corrosionresistance of coatings Nuria has workedat Swerea KIMAB since June 983090983088983089983088 inthe research group Metallic Materials inCorrosive Environments
ContactNuacuteria Fuertesnuriafuertesswerease
IN A LETTER to the board of the Swedish
Metallographic Institute on 983090983088 December983089983097983092983093 Carl Benedicks assigned ownershipof his books off-prints and journals to theInstitute Benedicks was the founder of theMetallographic Institute (Swerea KIMAB)From 983089983097983090983089 when the MetallographicInstitute was founded and for fifteen yearsafter that he was its director
The collection ranges over six centuriesand comprises metallurgy mineralogy andmining but also general chemistry physicsand reference works of a historical natureThe majority of the collection consists of
prints from the period of hand printing upto the end of the 983089983097th century These books
are the most valuable in terms of cultural
history and science as well as in financialterms
An example of an interesting book isVanoccio Biringucciorsquos ldquoDe la Pirotechniardquo(983089983093983092983088) which is one of the classic bookswithin the science of mining Another clas-sic is Georg Agricolarsquos ldquoDe Re MetallicardquoMost editions of this title are included buttwo are of particular interest The Italianwork ldquoLrsquoarte de Metallirdquo (983089983093983094983091) which isprobably not held by any other library inSweden The second edition which is alsoin the collection was translated by Herbert
Clark Hoover and his wife Hoover laterbecame President of the United States but
was a qualified mining engineer In addition
to the translation of the book the Hoovercouple have added valuable commentsS
The Benedicks collection contains manyof the more important publications onSwedish mining All books by ldquothe father ofthe Swedish mining industryrdquo Sven Rinmanare included in the collection for example
Most of the Benedicks collection of booksare now stored in the Hagstroumlmer Librarya medico-historical research library andmuseum of books in Stockholm Sweden
Contact
Louise Parnefjordlouiseparnefjordswerease
The Benedicks collection
NEW MEMBER CONSORTIA
Surface Technology
AT SWEREA KIMAB we are now initiating the much-requested membership pro-gramme MRC Surface Technology In its first stage the programme will focus onsurface treatment systems increased understanding concerning corrosion protec-tion and other functional properties of surfaces Joint projects are going to be runwithin surface properties surface analysis and different types of surface treatmentAs well as the properties of surfaces in finished products understanding process-critical parameters will also be included to ensure that selected applications obtainthe very best surface treatments Swerea KIMAB has many years of experienceconcerning surfaces and now in collaboration with interested companies we willbe concentrating on developing current and future requirements within the field
Do not hesitate to contact us for further information about the programme orabout surface technology ideas in general
ContactJohan Nordstroumlm johannordstromswerease
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CORROSION NEWS 3 | 20128
Why do reinforcementbars rust in concrete
BY JOHAN AHLSTROumlM
Reinforcement bars cast in concretenormally have a very low rate of corro-sion The low corrosion rate is due tothe concretersquos high alkalinity the pHvalue in concrete is about 983089983090ndash983089983091Corrosion can occur in environmentswhere chlorides are present which aretransported through the concrete tothe reinforcement bar surface andbreak down the steelrsquos passivity Manytests have been made to determinethe chloride concentration thresholdvalue on the reinforcement bar sur-face that is required to initiate corro-sion The distribution in the resultsfrom these tests is quite wide and canprobably be explained by differentexperimental methods having beenused as well as different externalenvironmental factors
CORROSION NEWS 3 | 20128
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CORROSION NEWS 3 | 2012 9
Tere is a critical chloride thresholdwhich dictates steel corrosion rate oreach quality o concrete Te corrosionrate is largely determined by the con-
cretersquos moisture content Te moisturecontent affects the concretersquos resistiv-ity and transport o both oxygen andchlorides Te time it takes or chloridesto be transported to the reinorcementbar surace where corrosion beginsis called the initialisation period Apropagation stage begins thereafer seefigure Concrete with high moisturecontent has relatively low resistivity andslow transport o oxygen Te propaga-tion rate is consequently low even i thechloride concentration is significantlyhigher than the chloride threshold val-ue Concrete with low moisture contentexhibits rapid transport o oxygen andhigh resistivity which produces a lowrate o corrosion as well At a specificmoisture interval however the transporto oxygen can be high at the same timeas resistivity is low which produces ahigh corrosion rate It is at this specificmoisture interval that the chloridethreshold values should be determined
Te corrosion rate or steel in water-
saturated concrete constructions isusually low due to slow transporto oxygen to the reinorcement barsurace However i the reinorcementbars are in contact with a more noblematerial the corrosion rate can showa marked increase Te magnitude othe galvanic effects or steel in concreteare determined by among other thingschloride and the oxygen concentrationI the chloride concentration is low thereinorcement bar can maintain passiv-
ity despite electrical contact with a morenoble material and the rate o corrosionwill thus be low In one case sacrificialanodes o aluminum were installedto protect the reinorcement bars in aconcrete construction or transportingseawater Te reinorcement bars wereunintentionally in electrical contactwith pumps made o stainless steel andthe sacrificial anodes rapidly deteriorat-ed Te stainless steel pumps probablytook up a large portion o the protective
current compared with the reinorce-ment bars Tere is thereore a risk that
the reinorcement bars were not beingsufficiently protected by the sacrificialanodes
On this basis a PhD project has beeninitiated to investigate how the moisturecontent in concrete affects the chloridethreshold values as well as to inves-tigate the risk or galvanic corrosion
o steel in concrete Te PhD projectencompasses experimental methodsor determining the chloride threshold
values modeling o corrosion processesand field studies o concrete construc-tions situated in seawater
Application of the resultsTe purpose o the project is to surveyin detail which actors interact inchloride-initialized reinorcement barcorrosion and to establish relevant
threshold values or these Increasedunderstanding and clearer limit valuesor chloride-initialized reinorcementbar corrosion enable more reliable as-sessments o condition
Project informationTe PhD project will be conductedthrough collaboration between SwereaKIMAB and the Faculty o Engineering
at Lund University (LH) Te projectis co-financed by the Elorsk Kaumlrnkrafconcrete programme SBUFrsquos develop-ment und and Swerea KIMAB
ContactJohan Ahlstroumlm
johanahlstroumlmswerease
Schematic diagram of corrosion process for steel in concrete
Test configuration for determining moisture-
contentrsquos effects on the corrosion chloridevalue
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CORROSION NEWS 3 | 201210
The international standards ISO 983097983090983090983091-983097983090983090983094 arethe original source for the corrosivity categoriesC983089ndashC983093 used for the classification of the corro-
sivity of atmospheric environments thus serv-ing as a basis for the choice of corrosionprotection systems for many different indus-trial applications Revised versions of thesestandards were issued in the beginning of983090983088983089983090 including the addition of a new corro-sivity category CX and improved proce-dures for estimating corrosivity categories
A SYSTEM FOR CLASSIFICATION oatmospheric corrosivity is helpul orthe selection o materials and protectionagainst corrosion or estimating thelietime o coatings and materials andcan also serve as a guide when choos-ing appropriate corrosion tests Tecorrosivity categories C983089ndashC983093 are wellaccepted and used when selecting struc-tural metals protective coatings andhave been incorporated in other norma-
tive and guidance documents through-out the world Te system was originallydeveloped in the 983089983097983096983088s and the previous
version o ISO 983097983090983090983091 was dated 983089983097983097983090Tis article gives an overview o thenew versions issued in the beginning o983090983088983089983090 starting with a description o thescientific field work underpinning thestandards
Field exposure programsEven though the standards ISO 983097983090983090983091-
983097983090983090983094 are well accepted they have alsobeen the subject o some criticism Tis
was mainly related to the part o thestandard that describes procedures orestimating corrosivity categories basedon environmental data as opposed tothe more reliable way to determine thecorrosivity category by exposure ostandard specimens Tis was realizedearly and due to the act that the first
versions o the standards were based toa great extent on data rom the temper-ate region
Tereore the ISOCORRAG exposureprogram was initiated It was carriedout by nations involved in the standard-ization work and included 983093983091 test sites in983089983091 countries on our continents It wasconducted during an eight-year period983089983097983096983092ndash983089983097983097983093 and included six subsequentone-year exposures and long-termexposures or 983090 983092 and 983096 years Te datarom this exposure program orm thecore o the data used in the revision oISO 983097983090983090983091 (one-year data) and ISO 983097983090983090983092
(long term data) and has been summa-rized in ldquoISOCORRAG ndash International
Exposure ProgramrdquoISOCORRAG International
Atmospheric Exposure Program Sum-mary o Results Editors Sheldon WDean Dagmar Knotkova KaterinaKreislova ASM
Te MICA exposure program wasorganized and carried out in 983089983097983096983096ndash983089983097983097983090by 983089983092 Iberoamerican countries andcovered 983095983090 test sites Since the MICAprogram more or less ully adopted the
methodology or the ISOCORRAGprogram and in addition covered addi-tional climatic conditions it was naturalto create a common database used orderiving improved ways o estimatingcorrosivity categories based on environ-mental data
Classification determination andestimation (ISO 9223)Corrosion rates exceeding the upperlimit o category C983093 ia 983090983088983088 microm a-983089 or
carbon steel were previously consid-ered out o the scope o the standard
BY JOHAN TIDBLAD AND KATERINA KREI SLOVA
New developments in the
classification of corrosivityof atmospheres
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CORROSION NEWS 3 | 2012 11
During the analysis o the data rom theISOCORRAG and MICA programs itwas realized that several marine sites insubtropicaltropical regions had values
above the upper limit o C983093 Since theseare natural environments that should becovered by the standard a new categoryCX have been added with upper limit983095983088983088 microm a-983089 or carbon steel reerringto specific marine and marineindus-trial environments typically in a warmclimate
Dose-response unctions ie unc-tions giving an estimate o the corrosionrate based on environmental param-eters have been developed or the ISO983097983090983090983091 metals carbon steel zinc copperand aluminum based on measuredannual values o temperature relativehumidity SO983090 concentrationdeposi-tion and chloride deposition Tis isa significant improvement comparedto the previous standard in terms oreliability o predicted corrosivitycategories Even so the standard givesan important distinction between thedetermination (typical error 983093983077) o thecorrosivity category by exposure o
standard specimens and the estimation(typical error 983093983088983077) o the corrosiv -ity category based on environmentalparameters Furthermore the effect o
clean and acid rain was considered atan early stage but could not be includedin the dose-response unctions despitetheir importance or atmosphericcorrosion Tese new unctions are anintegral part o the KorrField databaseand prediction program developed bySwerea KIMAB
Guiding values for the corrosivitycategories (ISO 9224)Te newly issued ISO 983097983090983090983092 providesinstructions or predicting corrosionattack afer extended and long-term ex-posures Detailed ormulas are providedor carbon steel zinc copper and alu-minium and in addition specific criteriato be taken into account or alloyingelements in weathering steels and alloyso zinc copper and aluminium
Measurement of environmentalparameters (ISO 9225)Description o measurements o
environmental parameters ocus ontemperature relative humidity SO983090and salinity since these are given in thedose-response unctions New methods
are considered including or examplepassive samplers or pollutants andconversion actors are given between se-lected pollution measurement methodsTe methodologies to measure envi-ronmental parameters are now similarto those described in ISO 983089983089983096983092983092 whichdeals with classification o low corrosiv-ity o indoor atmospheres
Evaluation of standard specimens(ISO 9226)In the previous version o the standardit was possible to evaluate corrosioneither by exposing flat standard speci-mens or by exposing special wire helixspecimens Since the analysis showedthat they are not equivalent it is nowonly possible to determine the corrosiv-ity category by flat standard specimens
ContactJohan TidbladJohantidbladswerease
About 983093983088 experts romnine countries (Aus-tralia China CzechRepublic France
Germany Japan Korea Swedenand UK) participated the week o983089983089ndash983089983093 June 983090983088983089983090 at the meeting o
ISOC 983089983093983094 Corrosion o met-als and alloys and its 983089983091 workinggroups Te meeting was held atEspace la Rocheoucauld in ParisFrance and was hosted by AFNORthe French standardization bodyTe chairman o the committee isGoumlran Engstroumlm Swerea KIMABand the secretariat is at CMISI inChina
Read more about the results romthe working groups at httpwww
swereaseenStart983090983090Working-AreasovrigtStandardisation
Meeting of ISOTC 156 in Paris in June 2012
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CORROSION NEWS 3 | 201212
CORROSION ON OFFSHORE INSTALLATIONS requires almostconstant maintenance in order to keep structural membersand saety critical elements fit or purpose On board anoffshore installation the corrosivity varies depending on the
height rom sea level and wind direction as well as otherenvironmental effects such as temperature Many companieschoose to repair degraded coatings on the bases o prequalifi-cation tests carried out onshore or in the laboratory and alsoplan maintenance using corrosion rate data rom estimationsor again rom onshore or lab tests Swerea KIMAB is aimingto help companies gain more knowledge about the corrosionrates on their offshore assets and the coatings systems in use
Trough a newly started joint industry project (JIP) SwereaKIMAB is looking at these aspects in which samples o
various materials and coating systems will be placed offshoreand subsequently analysed in order to build up a picture o
corrosivity and coating system effectiveness It is envisionedthat the JIP will be made up o oil and gas operators their
service companies coating manuacturers as well as materialsand equipment manuacturers Te data obtained rom theexperiments will be used by specialists (designers and main-tenance teams) and this will allow them to better understand
the conditions in which their equipment and materials aredesigned to be used Materials and paint companies couldalso have access to unique testing environments that wouldallow them to prove existing products or trial developmentproducts
Tere is a particular requirement to improve the mainte-nance o coatings on offshore installations in the North Seacurrently Te Health and Saety Executive (HSE) in the UKare in the midst o their KP983092 (Key Programme 983092) projectwhich looks at the procedures used by asset owners in regardsto saety and operability In the previous project KP983091 coatingmaintenance (or abric maintenance as it is known in the
industry) was ound to be an area that required significantimprovement Te problem with this type o maintenance is
Offshore corrosivityBY ANDREW GORDON amp MARTIN JOumlNSSON
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CORROSION NEWS 3 | 2012 13
that it requires avourable weather condi-tions and with restrictions on bed spaceor example the logistics o such workbecomes very difficult to manage
Prequalification tests in the environ-mentWith an accurate picture o which areaso an installation corrode aster or sloweroperators can plan their maintenance moreeffectively ensuring resources are allocatedwhere they are most needed as well as al-lowing them to deer maintenance activitiesi required Te selection and use o coatingsystems can be tailored more effectively bycarrying out the prequalification tests inthe environment in which they will be usedrather than just in accelerated laboratorytests or onshore exposures
Swerea KIMAB has a long history oconducting research into materials andcorrosion having successully completedsimilar studies or inrastructure and auto-motive companies Te data obtained hashelped populate the Korrfield database andenabled companies to select materials moreeffectively or the environments in whichthey operate Te previous studies involvedplacing samples in very hostile environ-
ments such as on the underside o heavygood vehicles and so provides SwereaKIMAB with the expertise or ensuringsamples are saely exposed and easy toevaluate
Focussed on oil and gas operatorsTe first round o meetings with companieshas been completed and has been ocussedon oil and gas operators based in AberdeenUK However the aim is to encompass asmany participants as possible in order to
generate a data set that will be useul notonly to current installations in the NorthSea but also to new projects and otherregions o the world I you are a paint com-pany materials manuacturer equipmentmanuacturer or have an influence on theuse andor maintenance o materials usedin the offshore environment this projectcould be o benefit to you Please eel ree toget in contact i you wish to learn more
Contact
andrewgordonSwereasemartinjonssonswerease
Maintenance scheduling should take into account known degradation ratesof materials and coating systems in operating environments
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CORROSION NEWS 3 | 201214
BY MARIA AringSLUND
A nuclear power station can contain some fairly aggressiveenvironments for materials and it is vital in these environ-ments to try and avoid material failures Thomas Blomfeldtof Swerea KIMAB keeps a check on the condition of thepolymer materials at nuclear sites
RISKS IN NUCLEAR POWER stations areofen associated with meltdowns like atChernobyl or last year at Fukushima -a nightmare scenario that is thankullya rare occurrence However even smallequipment ailures can result in bigproblems or the operators such as pro-duction losses or injury to personnelFor that reason saety and reliability areparamount and this philosophy filtersdown to every component in the system
including nuts bolts and gasketsldquoTe saety margins specified by the
nuclear power station owners have beenset or very good reasons At the sametime or financial reasons they do notwant to replace materials unnecessarilyrdquosays Tomas Blomeldt who has thetask o determining the remaining ser-
vice lie o a rubber joint or exampleSwerea KIMAB has several teams
working on inspecting different typeso material Tomas specialises inpolymers both as an expert at Swerea
KIMAB and as a research scientist 983096983088per cent o his working hours involve
inspecting and evaluating samplesrom nuclear power stations Tomasis a requent visitor at Swedenrsquos threenuclear power stations this year he hasinspected seven out o the total o tenreactors
rdquoPlastic and rubber may not bewhat you first think o when you see anuclear power station However thereare large quantities o polymers thereIn a reactor building the cables alone
correspond to the street lighting systemo a medium-sized Swedish town In ad-
The smallest componentmust be reliable
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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Editors Tomas Hult tomashultswerease Margaretha Soumlnnergaard sonnergaardswerease
Advisory Board Eva Johansson Sweden Bertil Sandberg SwedenJohan Tidblad Sweden Dominique Thierry FrancePrinting EO GrafiskaCover Nuclear reactor Oskarshamn 3 (Photo OKG)Corrosion News is published by Swerea KIMAB and Institut de la Corrosion
SubscriptionsSwerea KIMABCorrosion NewsPO-Box 983095983088983092983095SE-983089983094983092 983088983095 Kista Swedencorrosionnewsswereasewwwswereakimabse
Corrosion News All rights reserved No part of this publication may bereproduced in any form by any electronic or mechanical means withoutpermission in writing from Swerea KIMAB
14
4
CORROSION NEWS 3 | 2012 3
12
20
Swerea KIMAB conduct a study of the properties and condition of PVDFpiping systems that had been used to transport hydrofluoric acid hydro-chloric acid and nitric acid for nearly 983091983088 years in a steel pickling plant
Through a newly started joint industry project Swerea KIMAB is aimingto help companies gain more knowledge about the corrosion rates ontheir offshore assets and the coatings systems in use
A nuclear power station cancontain some fairly aggressiveenvironments for materials and itis vital to avoid material failures
An automated corrosion monitoringsystem was applied for assessmentof the corrosivity towards carbon steeland zinc in a accelerated corrosion test
Nearly 983091983088 years in use and still going strong 983092
Why do reinforcement bars rust in concrete 983096
New developments in the classification ofcorrosivity of atmospheres 983089983088
Meeting of ISOTC 983089983093983094 in Paris in June 983090983088983089983090 983089983089
Offshore corrosivity 983089983090
The smallest component must be reliable 983089983092The right fuel and temperature keep the steam up 983089983094
Proper material choice for corrosive environments 983089983097
Institut de la Corrosion ndash 983089983088th anniversary 983089983097
Application of automated corrosion sensors 983090983088
BIOCOR Oil amp Gas 983090983090
Surface treatment laboratory 983090983092
Paints and linings for steel and related alloysstructures in atmosphere and in immersion 983090983094
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CORROSION NEWS 3 | 20124
In addition to corrosion resistancethe long-term behavior o the mate-rial was examined in an extensiveseries o tests Te testing included
visual and microscopic studies mi-crotome cuts thermal analyses me-chanical tests and an assessment o theresidual stress For evaluation purposesthe acquired data was compared withthat o a actory-new PVDF pipe romGF Piping Systems Furthermore thecondition o the socket welds was exam-
ined and the usion work done on the
983091983088-year-old pipes was also appraisedIn steel pickling piping systems are
under extreme stress because o theaggressive media which need to betransported through them Tat is whymany metals are not even considered inthe planning phase since they are notresistant to highly concentrated acidsIn terms o metals only a ew preciousmetals (gold platinum) high-alloysteels or special nonerrous alloys aresuitable or this specific application
area In contrast PVC-U- PVC-C- or
PVDF pipes exhibit very good resist-ance to suluric acid hydrofluoric acidor hydrochloric acid
From 983089983097983095983096 Sandvik Materials ech-nology utilized three parallel PVDF pip-ing systems rom GF Piping Systems toconvey concentrated hydrofluoric acid(wt 983095983089ndash983095983093983077) nitric acid (wt 983094983096983077) andsuluric acid (wt 983097983094983077) In December983090983088983088983095 the nitric acid and hydrofluoricacid pipelines were taken out o servicebut not disassembled Te suluric acid
pipeline had already been shut down
Early 983090983088983088983096 the steel pickling plant Sandvik Materials Technology in Sweden closed downits operations Swerea KIMAB took advantage of the plant shut-down to conduct a studyof the properties and condition of PVDF piping systems that had been used to transporthydrofluoric acid hydrochloric acid and nitric acid for nearly 983091983088 years The purpose of thetests was to gain knowledge of the actual corrosion condition as well as the probability ofcorrosion on joints in plastic piping systems after a lengthy period of use
Nearly 30 years in useand still going strongPVDF plastic piping systems are free of corrosion brittleness and cracking
BY HANS-JOumlRG SOMMER
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CORROSION NEWS 3 | 2012 5
ten years earlier but was only disman-tled in 983090983088983088983096 along with the others
Te PVDF pipes were installedoutdoors and depending on the season
were exposed to temperatures rangingrom -983090983088 degC to +983092983088 degC Te pressureload reached 983090ndash983091 bar several times dailyTe pipelines in the steel pickling plantwere manuactured o Syge PVDF ma-terial by GF Piping Systems and joined
via socket usion Syge is requentlyused or chemicals distribution due toits excellent chemical resistance Sygeis ree o additives dyes or stabilizingagents
Te pressure rating o the PVDF pipesis 983089983094 bar (PN983089983094) or a diameter o 983092983088mm and a wall thickness o 983090983093 mmBeore the pipes were removed SwereaKIMAB took ten meters o pipe mate-rial including usion joints and bendsper pipeline or the test procedures
Visual and microscopic testingIn the visual inspection PVDF pipesthrough which hydrofluoric or suluricacid was conducted showed no signso corrosion ie no visible suracedamage no blistering or debonding
no swelling Te only noticeable effectwas a light brown discoloration o thehydrofluoric and suluric acid pipesTe discoloration was spread consist-ently over the length o the pipelinewhereas the acid permeation o suluricacid reached a depth o 983088983090 mm Tediscoloration was caused by a chemicalreaction o the acids with the polymersOn the other hand pipelines that wereexposed to nitric acid did not exhibitany discoloration Te microscopic tests
did not show any signs o corrosioneither
Thermal analysisTe melting point and crystallizationtest conducted on the basis o dynamicdifferential calorimetry (DSC) showedthat there was no significant differ-ence between spot samples taken romthe interior o the pipe and the mainbody o the test pipe Te crystallinityalso revealed no degeneration o the
polymer chains Tis indicates that thePVDF material had not been weakened
by the contact with acid over a period o983090983088ndash983091983088 years just as there were no differ-ences detected between pipes installedindoors and outdoors
Mechanical testingTe tensile stress tests done at roomtemperature on all three PVDF pipesand the new pipe uncovered no majordifferences in the mechanical proper-ties Tese results coincide with the re-sults rom the thermal analysis and themicrotome examination according towhich there was no or merely a minimaldegeneration o the PVDF pipes used inthis application
Impact resistance was tested in aroom o which the temperature cor-responded to the guidelines o ISOnorm 983089983095983097 Six test specimens were takenrom each o the three pipes None othe specimens showed any brittlenessbehavior in the impact resistance test
Inspection of fusion jointsWhen inspecting the old usion jointsthe question also arose as to the qualityo usion welds with old pipe materialIn other words how saely can material
which has been penetrated with acid be
used in case o maintenance and repairwork
Respective sections rom the threePVDF pipes were sent to a company
which specializes in acid technologyTeir findings turned out to be similarlypositive or all three pipe sections withIR butt usion joints the usion qualitywas consistently good with slight pres-sure Only on the hydrofluoric samplewas there a bit o blistering in the usionarea
In the socket usion joints used on thehydrofluoric and nitric acid pipes nofissuring was detected Fissures werehowever ound in all the examinedsocket usion joints which had beenexposed to suluric acid It is a knownact that socket usion causes such e -ects Te examined fissures were up totwo millimeters deep and although theyweakened the components to a certainextent they never represented a saetyrisk even at an operating pressure o983090ndash983091 bar over a period o 983090983088 years Anadditional method which contributesto the saety o pipe systems used toconvey aggressive media is BCF (beadand crevice-ree) usion developed
by GF Piping Systems Tis low-stress
After more than thirty years of use the PVDF plastic pipes are still intact They are only slightlydiscolored by the corrosive acids that under high pressure pass through them
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CORROSION NEWS 3 | 20126
jointing technique is highly appreciated by proes-sionals and has stood the test o time in a multitudeo applications
Additionally a ront discoloration 983094983093 mm deep
was noted on the socket joints in the hydrofluoricacid application Assuming that this is a sign opermeation it is possible to calculate an averagepermeation o 983089983090 mm a year (according to Fickrsquos lawo diffusion)
Generally however the socket usion method hasproven reliable in manuacturing piping systemsthat are or example used to convey hydrofluoric ornitric acid
ConclusionTe extensive testing perormed by Swerea KIMABshowed that PVDF pipes rom GF Piping Systemsstill have excellent resistance to corrosion even un-der the harshest conditions and afer more than 983090983088years o use Other than a slight discoloration o thepipe material no other signs o corrosion fissuringor brittleness were determined on the pipes exam-ined Moreover the microtome cuts o the pipe wallsrevealed no indication o local material brittleness
Since chemicals at certain temperatures or pres-sures can cause macromolecular chains to split offor separate it was necessary to test the molecularstructure o the pipes even i there was no signifi-cant degeneration o the material during the utiliza-
tion periodTe mechanical properties o the pipes were not
altered during the course o use Tis result coin-cides with the results o the thermal analysis accord-ing to which there was no significant or substantialdegeneration
On the basis o the test results Swerea KIMABgenerally recommends socket usion as the preerredusion process or PVDF pipes
Assuming that the operating conditions wouldhave remained consistent with those during the pre-
vious 983090983088ndash983091983088 years the creep behavior data lead us to
conclude that the examined pipes would have beensuitable or a much longer period o use with a saetyactor o 983090983096 or higher
The investigated pipes was taken from Sandvik Materials
Technologys steel pickling plant
FACTS
THE AUTHOR HANS-JOumlRG SOMMER is head of Chem-icalMechanical Support and Claims at Georg Fischer
GF Piping Systems Schaffhausen Switzerland
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CORROSION NEWS 3 | 2012 7
in short
NURIA FUERTES began her PhD thesisin April 983090983088983089983090 on ldquoUse of localised electro-chemical techniques for studying stresscorrosion cracking of stainless steelsrdquoSwerea KIMAB recently purchased aScanning Vibrating Electrode Technique(SVET) which will be used in the projectto perform in-situ observations of cracknucleation and growth during stress
corrosion Other applications of this tech-nique include investigation of pitting cor-rosion galvanic corrosion and corrosionresistance of coatings Nuria has workedat Swerea KIMAB since June 983090983088983089983088 inthe research group Metallic Materials inCorrosive Environments
ContactNuacuteria Fuertesnuriafuertesswerease
IN A LETTER to the board of the Swedish
Metallographic Institute on 983090983088 December983089983097983092983093 Carl Benedicks assigned ownershipof his books off-prints and journals to theInstitute Benedicks was the founder of theMetallographic Institute (Swerea KIMAB)From 983089983097983090983089 when the MetallographicInstitute was founded and for fifteen yearsafter that he was its director
The collection ranges over six centuriesand comprises metallurgy mineralogy andmining but also general chemistry physicsand reference works of a historical natureThe majority of the collection consists of
prints from the period of hand printing upto the end of the 983089983097th century These books
are the most valuable in terms of cultural
history and science as well as in financialterms
An example of an interesting book isVanoccio Biringucciorsquos ldquoDe la Pirotechniardquo(983089983093983092983088) which is one of the classic bookswithin the science of mining Another clas-sic is Georg Agricolarsquos ldquoDe Re MetallicardquoMost editions of this title are included buttwo are of particular interest The Italianwork ldquoLrsquoarte de Metallirdquo (983089983093983094983091) which isprobably not held by any other library inSweden The second edition which is alsoin the collection was translated by Herbert
Clark Hoover and his wife Hoover laterbecame President of the United States but
was a qualified mining engineer In addition
to the translation of the book the Hoovercouple have added valuable commentsS
The Benedicks collection contains manyof the more important publications onSwedish mining All books by ldquothe father ofthe Swedish mining industryrdquo Sven Rinmanare included in the collection for example
Most of the Benedicks collection of booksare now stored in the Hagstroumlmer Librarya medico-historical research library andmuseum of books in Stockholm Sweden
Contact
Louise Parnefjordlouiseparnefjordswerease
The Benedicks collection
NEW MEMBER CONSORTIA
Surface Technology
AT SWEREA KIMAB we are now initiating the much-requested membership pro-gramme MRC Surface Technology In its first stage the programme will focus onsurface treatment systems increased understanding concerning corrosion protec-tion and other functional properties of surfaces Joint projects are going to be runwithin surface properties surface analysis and different types of surface treatmentAs well as the properties of surfaces in finished products understanding process-critical parameters will also be included to ensure that selected applications obtainthe very best surface treatments Swerea KIMAB has many years of experienceconcerning surfaces and now in collaboration with interested companies we willbe concentrating on developing current and future requirements within the field
Do not hesitate to contact us for further information about the programme orabout surface technology ideas in general
ContactJohan Nordstroumlm johannordstromswerease
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CORROSION NEWS 3 | 20128
Why do reinforcementbars rust in concrete
BY JOHAN AHLSTROumlM
Reinforcement bars cast in concretenormally have a very low rate of corro-sion The low corrosion rate is due tothe concretersquos high alkalinity the pHvalue in concrete is about 983089983090ndash983089983091Corrosion can occur in environmentswhere chlorides are present which aretransported through the concrete tothe reinforcement bar surface andbreak down the steelrsquos passivity Manytests have been made to determinethe chloride concentration thresholdvalue on the reinforcement bar sur-face that is required to initiate corro-sion The distribution in the resultsfrom these tests is quite wide and canprobably be explained by differentexperimental methods having beenused as well as different externalenvironmental factors
CORROSION NEWS 3 | 20128
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CORROSION NEWS 3 | 2012 9
Tere is a critical chloride thresholdwhich dictates steel corrosion rate oreach quality o concrete Te corrosionrate is largely determined by the con-
cretersquos moisture content Te moisturecontent affects the concretersquos resistiv-ity and transport o both oxygen andchlorides Te time it takes or chloridesto be transported to the reinorcementbar surace where corrosion beginsis called the initialisation period Apropagation stage begins thereafer seefigure Concrete with high moisturecontent has relatively low resistivity andslow transport o oxygen Te propaga-tion rate is consequently low even i thechloride concentration is significantlyhigher than the chloride threshold val-ue Concrete with low moisture contentexhibits rapid transport o oxygen andhigh resistivity which produces a lowrate o corrosion as well At a specificmoisture interval however the transporto oxygen can be high at the same timeas resistivity is low which produces ahigh corrosion rate It is at this specificmoisture interval that the chloridethreshold values should be determined
Te corrosion rate or steel in water-
saturated concrete constructions isusually low due to slow transporto oxygen to the reinorcement barsurace However i the reinorcementbars are in contact with a more noblematerial the corrosion rate can showa marked increase Te magnitude othe galvanic effects or steel in concreteare determined by among other thingschloride and the oxygen concentrationI the chloride concentration is low thereinorcement bar can maintain passiv-
ity despite electrical contact with a morenoble material and the rate o corrosionwill thus be low In one case sacrificialanodes o aluminum were installedto protect the reinorcement bars in aconcrete construction or transportingseawater Te reinorcement bars wereunintentionally in electrical contactwith pumps made o stainless steel andthe sacrificial anodes rapidly deteriorat-ed Te stainless steel pumps probablytook up a large portion o the protective
current compared with the reinorce-ment bars Tere is thereore a risk that
the reinorcement bars were not beingsufficiently protected by the sacrificialanodes
On this basis a PhD project has beeninitiated to investigate how the moisturecontent in concrete affects the chloridethreshold values as well as to inves-tigate the risk or galvanic corrosion
o steel in concrete Te PhD projectencompasses experimental methodsor determining the chloride threshold
values modeling o corrosion processesand field studies o concrete construc-tions situated in seawater
Application of the resultsTe purpose o the project is to surveyin detail which actors interact inchloride-initialized reinorcement barcorrosion and to establish relevant
threshold values or these Increasedunderstanding and clearer limit valuesor chloride-initialized reinorcementbar corrosion enable more reliable as-sessments o condition
Project informationTe PhD project will be conductedthrough collaboration between SwereaKIMAB and the Faculty o Engineering
at Lund University (LH) Te projectis co-financed by the Elorsk Kaumlrnkrafconcrete programme SBUFrsquos develop-ment und and Swerea KIMAB
ContactJohan Ahlstroumlm
johanahlstroumlmswerease
Schematic diagram of corrosion process for steel in concrete
Test configuration for determining moisture-
contentrsquos effects on the corrosion chloridevalue
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CORROSION NEWS 3 | 201210
The international standards ISO 983097983090983090983091-983097983090983090983094 arethe original source for the corrosivity categoriesC983089ndashC983093 used for the classification of the corro-
sivity of atmospheric environments thus serv-ing as a basis for the choice of corrosionprotection systems for many different indus-trial applications Revised versions of thesestandards were issued in the beginning of983090983088983089983090 including the addition of a new corro-sivity category CX and improved proce-dures for estimating corrosivity categories
A SYSTEM FOR CLASSIFICATION oatmospheric corrosivity is helpul orthe selection o materials and protectionagainst corrosion or estimating thelietime o coatings and materials andcan also serve as a guide when choos-ing appropriate corrosion tests Tecorrosivity categories C983089ndashC983093 are wellaccepted and used when selecting struc-tural metals protective coatings andhave been incorporated in other norma-
tive and guidance documents through-out the world Te system was originallydeveloped in the 983089983097983096983088s and the previous
version o ISO 983097983090983090983091 was dated 983089983097983097983090Tis article gives an overview o thenew versions issued in the beginning o983090983088983089983090 starting with a description o thescientific field work underpinning thestandards
Field exposure programsEven though the standards ISO 983097983090983090983091-
983097983090983090983094 are well accepted they have alsobeen the subject o some criticism Tis
was mainly related to the part o thestandard that describes procedures orestimating corrosivity categories basedon environmental data as opposed tothe more reliable way to determine thecorrosivity category by exposure ostandard specimens Tis was realizedearly and due to the act that the first
versions o the standards were based toa great extent on data rom the temper-ate region
Tereore the ISOCORRAG exposureprogram was initiated It was carriedout by nations involved in the standard-ization work and included 983093983091 test sites in983089983091 countries on our continents It wasconducted during an eight-year period983089983097983096983092ndash983089983097983097983093 and included six subsequentone-year exposures and long-termexposures or 983090 983092 and 983096 years Te datarom this exposure program orm thecore o the data used in the revision oISO 983097983090983090983091 (one-year data) and ISO 983097983090983090983092
(long term data) and has been summa-rized in ldquoISOCORRAG ndash International
Exposure ProgramrdquoISOCORRAG International
Atmospheric Exposure Program Sum-mary o Results Editors Sheldon WDean Dagmar Knotkova KaterinaKreislova ASM
Te MICA exposure program wasorganized and carried out in 983089983097983096983096ndash983089983097983097983090by 983089983092 Iberoamerican countries andcovered 983095983090 test sites Since the MICAprogram more or less ully adopted the
methodology or the ISOCORRAGprogram and in addition covered addi-tional climatic conditions it was naturalto create a common database used orderiving improved ways o estimatingcorrosivity categories based on environ-mental data
Classification determination andestimation (ISO 9223)Corrosion rates exceeding the upperlimit o category C983093 ia 983090983088983088 microm a-983089 or
carbon steel were previously consid-ered out o the scope o the standard
BY JOHAN TIDBLAD AND KATERINA KREI SLOVA
New developments in the
classification of corrosivityof atmospheres
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CORROSION NEWS 3 | 2012 11
During the analysis o the data rom theISOCORRAG and MICA programs itwas realized that several marine sites insubtropicaltropical regions had values
above the upper limit o C983093 Since theseare natural environments that should becovered by the standard a new categoryCX have been added with upper limit983095983088983088 microm a-983089 or carbon steel reerringto specific marine and marineindus-trial environments typically in a warmclimate
Dose-response unctions ie unc-tions giving an estimate o the corrosionrate based on environmental param-eters have been developed or the ISO983097983090983090983091 metals carbon steel zinc copperand aluminum based on measuredannual values o temperature relativehumidity SO983090 concentrationdeposi-tion and chloride deposition Tis isa significant improvement comparedto the previous standard in terms oreliability o predicted corrosivitycategories Even so the standard givesan important distinction between thedetermination (typical error 983093983077) o thecorrosivity category by exposure o
standard specimens and the estimation(typical error 983093983088983077) o the corrosiv -ity category based on environmentalparameters Furthermore the effect o
clean and acid rain was considered atan early stage but could not be includedin the dose-response unctions despitetheir importance or atmosphericcorrosion Tese new unctions are anintegral part o the KorrField databaseand prediction program developed bySwerea KIMAB
Guiding values for the corrosivitycategories (ISO 9224)Te newly issued ISO 983097983090983090983092 providesinstructions or predicting corrosionattack afer extended and long-term ex-posures Detailed ormulas are providedor carbon steel zinc copper and alu-minium and in addition specific criteriato be taken into account or alloyingelements in weathering steels and alloyso zinc copper and aluminium
Measurement of environmentalparameters (ISO 9225)Description o measurements o
environmental parameters ocus ontemperature relative humidity SO983090and salinity since these are given in thedose-response unctions New methods
are considered including or examplepassive samplers or pollutants andconversion actors are given between se-lected pollution measurement methodsTe methodologies to measure envi-ronmental parameters are now similarto those described in ISO 983089983089983096983092983092 whichdeals with classification o low corrosiv-ity o indoor atmospheres
Evaluation of standard specimens(ISO 9226)In the previous version o the standardit was possible to evaluate corrosioneither by exposing flat standard speci-mens or by exposing special wire helixspecimens Since the analysis showedthat they are not equivalent it is nowonly possible to determine the corrosiv-ity category by flat standard specimens
ContactJohan TidbladJohantidbladswerease
About 983093983088 experts romnine countries (Aus-tralia China CzechRepublic France
Germany Japan Korea Swedenand UK) participated the week o983089983089ndash983089983093 June 983090983088983089983090 at the meeting o
ISOC 983089983093983094 Corrosion o met-als and alloys and its 983089983091 workinggroups Te meeting was held atEspace la Rocheoucauld in ParisFrance and was hosted by AFNORthe French standardization bodyTe chairman o the committee isGoumlran Engstroumlm Swerea KIMABand the secretariat is at CMISI inChina
Read more about the results romthe working groups at httpwww
swereaseenStart983090983090Working-AreasovrigtStandardisation
Meeting of ISOTC 156 in Paris in June 2012
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CORROSION NEWS 3 | 201212
CORROSION ON OFFSHORE INSTALLATIONS requires almostconstant maintenance in order to keep structural membersand saety critical elements fit or purpose On board anoffshore installation the corrosivity varies depending on the
height rom sea level and wind direction as well as otherenvironmental effects such as temperature Many companieschoose to repair degraded coatings on the bases o prequalifi-cation tests carried out onshore or in the laboratory and alsoplan maintenance using corrosion rate data rom estimationsor again rom onshore or lab tests Swerea KIMAB is aimingto help companies gain more knowledge about the corrosionrates on their offshore assets and the coatings systems in use
Trough a newly started joint industry project (JIP) SwereaKIMAB is looking at these aspects in which samples o
various materials and coating systems will be placed offshoreand subsequently analysed in order to build up a picture o
corrosivity and coating system effectiveness It is envisionedthat the JIP will be made up o oil and gas operators their
service companies coating manuacturers as well as materialsand equipment manuacturers Te data obtained rom theexperiments will be used by specialists (designers and main-tenance teams) and this will allow them to better understand
the conditions in which their equipment and materials aredesigned to be used Materials and paint companies couldalso have access to unique testing environments that wouldallow them to prove existing products or trial developmentproducts
Tere is a particular requirement to improve the mainte-nance o coatings on offshore installations in the North Seacurrently Te Health and Saety Executive (HSE) in the UKare in the midst o their KP983092 (Key Programme 983092) projectwhich looks at the procedures used by asset owners in regardsto saety and operability In the previous project KP983091 coatingmaintenance (or abric maintenance as it is known in the
industry) was ound to be an area that required significantimprovement Te problem with this type o maintenance is
Offshore corrosivityBY ANDREW GORDON amp MARTIN JOumlNSSON
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CORROSION NEWS 3 | 2012 13
that it requires avourable weather condi-tions and with restrictions on bed spaceor example the logistics o such workbecomes very difficult to manage
Prequalification tests in the environ-mentWith an accurate picture o which areaso an installation corrode aster or sloweroperators can plan their maintenance moreeffectively ensuring resources are allocatedwhere they are most needed as well as al-lowing them to deer maintenance activitiesi required Te selection and use o coatingsystems can be tailored more effectively bycarrying out the prequalification tests inthe environment in which they will be usedrather than just in accelerated laboratorytests or onshore exposures
Swerea KIMAB has a long history oconducting research into materials andcorrosion having successully completedsimilar studies or inrastructure and auto-motive companies Te data obtained hashelped populate the Korrfield database andenabled companies to select materials moreeffectively or the environments in whichthey operate Te previous studies involvedplacing samples in very hostile environ-
ments such as on the underside o heavygood vehicles and so provides SwereaKIMAB with the expertise or ensuringsamples are saely exposed and easy toevaluate
Focussed on oil and gas operatorsTe first round o meetings with companieshas been completed and has been ocussedon oil and gas operators based in AberdeenUK However the aim is to encompass asmany participants as possible in order to
generate a data set that will be useul notonly to current installations in the NorthSea but also to new projects and otherregions o the world I you are a paint com-pany materials manuacturer equipmentmanuacturer or have an influence on theuse andor maintenance o materials usedin the offshore environment this projectcould be o benefit to you Please eel ree toget in contact i you wish to learn more
Contact
andrewgordonSwereasemartinjonssonswerease
Maintenance scheduling should take into account known degradation ratesof materials and coating systems in operating environments
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CORROSION NEWS 3 | 201214
BY MARIA AringSLUND
A nuclear power station can contain some fairly aggressiveenvironments for materials and it is vital in these environ-ments to try and avoid material failures Thomas Blomfeldtof Swerea KIMAB keeps a check on the condition of thepolymer materials at nuclear sites
RISKS IN NUCLEAR POWER stations areofen associated with meltdowns like atChernobyl or last year at Fukushima -a nightmare scenario that is thankullya rare occurrence However even smallequipment ailures can result in bigproblems or the operators such as pro-duction losses or injury to personnelFor that reason saety and reliability areparamount and this philosophy filtersdown to every component in the system
including nuts bolts and gasketsldquoTe saety margins specified by the
nuclear power station owners have beenset or very good reasons At the sametime or financial reasons they do notwant to replace materials unnecessarilyrdquosays Tomas Blomeldt who has thetask o determining the remaining ser-
vice lie o a rubber joint or exampleSwerea KIMAB has several teams
working on inspecting different typeso material Tomas specialises inpolymers both as an expert at Swerea
KIMAB and as a research scientist 983096983088per cent o his working hours involve
inspecting and evaluating samplesrom nuclear power stations Tomasis a requent visitor at Swedenrsquos threenuclear power stations this year he hasinspected seven out o the total o tenreactors
rdquoPlastic and rubber may not bewhat you first think o when you see anuclear power station However thereare large quantities o polymers thereIn a reactor building the cables alone
correspond to the street lighting systemo a medium-sized Swedish town In ad-
The smallest componentmust be reliable
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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CORROSION NEWS 3 | 20124
In addition to corrosion resistancethe long-term behavior o the mate-rial was examined in an extensiveseries o tests Te testing included
visual and microscopic studies mi-crotome cuts thermal analyses me-chanical tests and an assessment o theresidual stress For evaluation purposesthe acquired data was compared withthat o a actory-new PVDF pipe romGF Piping Systems Furthermore thecondition o the socket welds was exam-
ined and the usion work done on the
983091983088-year-old pipes was also appraisedIn steel pickling piping systems are
under extreme stress because o theaggressive media which need to betransported through them Tat is whymany metals are not even considered inthe planning phase since they are notresistant to highly concentrated acidsIn terms o metals only a ew preciousmetals (gold platinum) high-alloysteels or special nonerrous alloys aresuitable or this specific application
area In contrast PVC-U- PVC-C- or
PVDF pipes exhibit very good resist-ance to suluric acid hydrofluoric acidor hydrochloric acid
From 983089983097983095983096 Sandvik Materials ech-nology utilized three parallel PVDF pip-ing systems rom GF Piping Systems toconvey concentrated hydrofluoric acid(wt 983095983089ndash983095983093983077) nitric acid (wt 983094983096983077) andsuluric acid (wt 983097983094983077) In December983090983088983088983095 the nitric acid and hydrofluoricacid pipelines were taken out o servicebut not disassembled Te suluric acid
pipeline had already been shut down
Early 983090983088983088983096 the steel pickling plant Sandvik Materials Technology in Sweden closed downits operations Swerea KIMAB took advantage of the plant shut-down to conduct a studyof the properties and condition of PVDF piping systems that had been used to transporthydrofluoric acid hydrochloric acid and nitric acid for nearly 983091983088 years The purpose of thetests was to gain knowledge of the actual corrosion condition as well as the probability ofcorrosion on joints in plastic piping systems after a lengthy period of use
Nearly 30 years in useand still going strongPVDF plastic piping systems are free of corrosion brittleness and cracking
BY HANS-JOumlRG SOMMER
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CORROSION NEWS 3 | 2012 5
ten years earlier but was only disman-tled in 983090983088983088983096 along with the others
Te PVDF pipes were installedoutdoors and depending on the season
were exposed to temperatures rangingrom -983090983088 degC to +983092983088 degC Te pressureload reached 983090ndash983091 bar several times dailyTe pipelines in the steel pickling plantwere manuactured o Syge PVDF ma-terial by GF Piping Systems and joined
via socket usion Syge is requentlyused or chemicals distribution due toits excellent chemical resistance Sygeis ree o additives dyes or stabilizingagents
Te pressure rating o the PVDF pipesis 983089983094 bar (PN983089983094) or a diameter o 983092983088mm and a wall thickness o 983090983093 mmBeore the pipes were removed SwereaKIMAB took ten meters o pipe mate-rial including usion joints and bendsper pipeline or the test procedures
Visual and microscopic testingIn the visual inspection PVDF pipesthrough which hydrofluoric or suluricacid was conducted showed no signso corrosion ie no visible suracedamage no blistering or debonding
no swelling Te only noticeable effectwas a light brown discoloration o thehydrofluoric and suluric acid pipesTe discoloration was spread consist-ently over the length o the pipelinewhereas the acid permeation o suluricacid reached a depth o 983088983090 mm Tediscoloration was caused by a chemicalreaction o the acids with the polymersOn the other hand pipelines that wereexposed to nitric acid did not exhibitany discoloration Te microscopic tests
did not show any signs o corrosioneither
Thermal analysisTe melting point and crystallizationtest conducted on the basis o dynamicdifferential calorimetry (DSC) showedthat there was no significant differ-ence between spot samples taken romthe interior o the pipe and the mainbody o the test pipe Te crystallinityalso revealed no degeneration o the
polymer chains Tis indicates that thePVDF material had not been weakened
by the contact with acid over a period o983090983088ndash983091983088 years just as there were no differ-ences detected between pipes installedindoors and outdoors
Mechanical testingTe tensile stress tests done at roomtemperature on all three PVDF pipesand the new pipe uncovered no majordifferences in the mechanical proper-ties Tese results coincide with the re-sults rom the thermal analysis and themicrotome examination according towhich there was no or merely a minimaldegeneration o the PVDF pipes used inthis application
Impact resistance was tested in aroom o which the temperature cor-responded to the guidelines o ISOnorm 983089983095983097 Six test specimens were takenrom each o the three pipes None othe specimens showed any brittlenessbehavior in the impact resistance test
Inspection of fusion jointsWhen inspecting the old usion jointsthe question also arose as to the qualityo usion welds with old pipe materialIn other words how saely can material
which has been penetrated with acid be
used in case o maintenance and repairwork
Respective sections rom the threePVDF pipes were sent to a company
which specializes in acid technologyTeir findings turned out to be similarlypositive or all three pipe sections withIR butt usion joints the usion qualitywas consistently good with slight pres-sure Only on the hydrofluoric samplewas there a bit o blistering in the usionarea
In the socket usion joints used on thehydrofluoric and nitric acid pipes nofissuring was detected Fissures werehowever ound in all the examinedsocket usion joints which had beenexposed to suluric acid It is a knownact that socket usion causes such e -ects Te examined fissures were up totwo millimeters deep and although theyweakened the components to a certainextent they never represented a saetyrisk even at an operating pressure o983090ndash983091 bar over a period o 983090983088 years Anadditional method which contributesto the saety o pipe systems used toconvey aggressive media is BCF (beadand crevice-ree) usion developed
by GF Piping Systems Tis low-stress
After more than thirty years of use the PVDF plastic pipes are still intact They are only slightlydiscolored by the corrosive acids that under high pressure pass through them
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CORROSION NEWS 3 | 20126
jointing technique is highly appreciated by proes-sionals and has stood the test o time in a multitudeo applications
Additionally a ront discoloration 983094983093 mm deep
was noted on the socket joints in the hydrofluoricacid application Assuming that this is a sign opermeation it is possible to calculate an averagepermeation o 983089983090 mm a year (according to Fickrsquos lawo diffusion)
Generally however the socket usion method hasproven reliable in manuacturing piping systemsthat are or example used to convey hydrofluoric ornitric acid
ConclusionTe extensive testing perormed by Swerea KIMABshowed that PVDF pipes rom GF Piping Systemsstill have excellent resistance to corrosion even un-der the harshest conditions and afer more than 983090983088years o use Other than a slight discoloration o thepipe material no other signs o corrosion fissuringor brittleness were determined on the pipes exam-ined Moreover the microtome cuts o the pipe wallsrevealed no indication o local material brittleness
Since chemicals at certain temperatures or pres-sures can cause macromolecular chains to split offor separate it was necessary to test the molecularstructure o the pipes even i there was no signifi-cant degeneration o the material during the utiliza-
tion periodTe mechanical properties o the pipes were not
altered during the course o use Tis result coin-cides with the results o the thermal analysis accord-ing to which there was no significant or substantialdegeneration
On the basis o the test results Swerea KIMABgenerally recommends socket usion as the preerredusion process or PVDF pipes
Assuming that the operating conditions wouldhave remained consistent with those during the pre-
vious 983090983088ndash983091983088 years the creep behavior data lead us to
conclude that the examined pipes would have beensuitable or a much longer period o use with a saetyactor o 983090983096 or higher
The investigated pipes was taken from Sandvik Materials
Technologys steel pickling plant
FACTS
THE AUTHOR HANS-JOumlRG SOMMER is head of Chem-icalMechanical Support and Claims at Georg Fischer
GF Piping Systems Schaffhausen Switzerland
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CORROSION NEWS 3 | 2012 7
in short
NURIA FUERTES began her PhD thesisin April 983090983088983089983090 on ldquoUse of localised electro-chemical techniques for studying stresscorrosion cracking of stainless steelsrdquoSwerea KIMAB recently purchased aScanning Vibrating Electrode Technique(SVET) which will be used in the projectto perform in-situ observations of cracknucleation and growth during stress
corrosion Other applications of this tech-nique include investigation of pitting cor-rosion galvanic corrosion and corrosionresistance of coatings Nuria has workedat Swerea KIMAB since June 983090983088983089983088 inthe research group Metallic Materials inCorrosive Environments
ContactNuacuteria Fuertesnuriafuertesswerease
IN A LETTER to the board of the Swedish
Metallographic Institute on 983090983088 December983089983097983092983093 Carl Benedicks assigned ownershipof his books off-prints and journals to theInstitute Benedicks was the founder of theMetallographic Institute (Swerea KIMAB)From 983089983097983090983089 when the MetallographicInstitute was founded and for fifteen yearsafter that he was its director
The collection ranges over six centuriesand comprises metallurgy mineralogy andmining but also general chemistry physicsand reference works of a historical natureThe majority of the collection consists of
prints from the period of hand printing upto the end of the 983089983097th century These books
are the most valuable in terms of cultural
history and science as well as in financialterms
An example of an interesting book isVanoccio Biringucciorsquos ldquoDe la Pirotechniardquo(983089983093983092983088) which is one of the classic bookswithin the science of mining Another clas-sic is Georg Agricolarsquos ldquoDe Re MetallicardquoMost editions of this title are included buttwo are of particular interest The Italianwork ldquoLrsquoarte de Metallirdquo (983089983093983094983091) which isprobably not held by any other library inSweden The second edition which is alsoin the collection was translated by Herbert
Clark Hoover and his wife Hoover laterbecame President of the United States but
was a qualified mining engineer In addition
to the translation of the book the Hoovercouple have added valuable commentsS
The Benedicks collection contains manyof the more important publications onSwedish mining All books by ldquothe father ofthe Swedish mining industryrdquo Sven Rinmanare included in the collection for example
Most of the Benedicks collection of booksare now stored in the Hagstroumlmer Librarya medico-historical research library andmuseum of books in Stockholm Sweden
Contact
Louise Parnefjordlouiseparnefjordswerease
The Benedicks collection
NEW MEMBER CONSORTIA
Surface Technology
AT SWEREA KIMAB we are now initiating the much-requested membership pro-gramme MRC Surface Technology In its first stage the programme will focus onsurface treatment systems increased understanding concerning corrosion protec-tion and other functional properties of surfaces Joint projects are going to be runwithin surface properties surface analysis and different types of surface treatmentAs well as the properties of surfaces in finished products understanding process-critical parameters will also be included to ensure that selected applications obtainthe very best surface treatments Swerea KIMAB has many years of experienceconcerning surfaces and now in collaboration with interested companies we willbe concentrating on developing current and future requirements within the field
Do not hesitate to contact us for further information about the programme orabout surface technology ideas in general
ContactJohan Nordstroumlm johannordstromswerease
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CORROSION NEWS 3 | 20128
Why do reinforcementbars rust in concrete
BY JOHAN AHLSTROumlM
Reinforcement bars cast in concretenormally have a very low rate of corro-sion The low corrosion rate is due tothe concretersquos high alkalinity the pHvalue in concrete is about 983089983090ndash983089983091Corrosion can occur in environmentswhere chlorides are present which aretransported through the concrete tothe reinforcement bar surface andbreak down the steelrsquos passivity Manytests have been made to determinethe chloride concentration thresholdvalue on the reinforcement bar sur-face that is required to initiate corro-sion The distribution in the resultsfrom these tests is quite wide and canprobably be explained by differentexperimental methods having beenused as well as different externalenvironmental factors
CORROSION NEWS 3 | 20128
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CORROSION NEWS 3 | 2012 9
Tere is a critical chloride thresholdwhich dictates steel corrosion rate oreach quality o concrete Te corrosionrate is largely determined by the con-
cretersquos moisture content Te moisturecontent affects the concretersquos resistiv-ity and transport o both oxygen andchlorides Te time it takes or chloridesto be transported to the reinorcementbar surace where corrosion beginsis called the initialisation period Apropagation stage begins thereafer seefigure Concrete with high moisturecontent has relatively low resistivity andslow transport o oxygen Te propaga-tion rate is consequently low even i thechloride concentration is significantlyhigher than the chloride threshold val-ue Concrete with low moisture contentexhibits rapid transport o oxygen andhigh resistivity which produces a lowrate o corrosion as well At a specificmoisture interval however the transporto oxygen can be high at the same timeas resistivity is low which produces ahigh corrosion rate It is at this specificmoisture interval that the chloridethreshold values should be determined
Te corrosion rate or steel in water-
saturated concrete constructions isusually low due to slow transporto oxygen to the reinorcement barsurace However i the reinorcementbars are in contact with a more noblematerial the corrosion rate can showa marked increase Te magnitude othe galvanic effects or steel in concreteare determined by among other thingschloride and the oxygen concentrationI the chloride concentration is low thereinorcement bar can maintain passiv-
ity despite electrical contact with a morenoble material and the rate o corrosionwill thus be low In one case sacrificialanodes o aluminum were installedto protect the reinorcement bars in aconcrete construction or transportingseawater Te reinorcement bars wereunintentionally in electrical contactwith pumps made o stainless steel andthe sacrificial anodes rapidly deteriorat-ed Te stainless steel pumps probablytook up a large portion o the protective
current compared with the reinorce-ment bars Tere is thereore a risk that
the reinorcement bars were not beingsufficiently protected by the sacrificialanodes
On this basis a PhD project has beeninitiated to investigate how the moisturecontent in concrete affects the chloridethreshold values as well as to inves-tigate the risk or galvanic corrosion
o steel in concrete Te PhD projectencompasses experimental methodsor determining the chloride threshold
values modeling o corrosion processesand field studies o concrete construc-tions situated in seawater
Application of the resultsTe purpose o the project is to surveyin detail which actors interact inchloride-initialized reinorcement barcorrosion and to establish relevant
threshold values or these Increasedunderstanding and clearer limit valuesor chloride-initialized reinorcementbar corrosion enable more reliable as-sessments o condition
Project informationTe PhD project will be conductedthrough collaboration between SwereaKIMAB and the Faculty o Engineering
at Lund University (LH) Te projectis co-financed by the Elorsk Kaumlrnkrafconcrete programme SBUFrsquos develop-ment und and Swerea KIMAB
ContactJohan Ahlstroumlm
johanahlstroumlmswerease
Schematic diagram of corrosion process for steel in concrete
Test configuration for determining moisture-
contentrsquos effects on the corrosion chloridevalue
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CORROSION NEWS 3 | 201210
The international standards ISO 983097983090983090983091-983097983090983090983094 arethe original source for the corrosivity categoriesC983089ndashC983093 used for the classification of the corro-
sivity of atmospheric environments thus serv-ing as a basis for the choice of corrosionprotection systems for many different indus-trial applications Revised versions of thesestandards were issued in the beginning of983090983088983089983090 including the addition of a new corro-sivity category CX and improved proce-dures for estimating corrosivity categories
A SYSTEM FOR CLASSIFICATION oatmospheric corrosivity is helpul orthe selection o materials and protectionagainst corrosion or estimating thelietime o coatings and materials andcan also serve as a guide when choos-ing appropriate corrosion tests Tecorrosivity categories C983089ndashC983093 are wellaccepted and used when selecting struc-tural metals protective coatings andhave been incorporated in other norma-
tive and guidance documents through-out the world Te system was originallydeveloped in the 983089983097983096983088s and the previous
version o ISO 983097983090983090983091 was dated 983089983097983097983090Tis article gives an overview o thenew versions issued in the beginning o983090983088983089983090 starting with a description o thescientific field work underpinning thestandards
Field exposure programsEven though the standards ISO 983097983090983090983091-
983097983090983090983094 are well accepted they have alsobeen the subject o some criticism Tis
was mainly related to the part o thestandard that describes procedures orestimating corrosivity categories basedon environmental data as opposed tothe more reliable way to determine thecorrosivity category by exposure ostandard specimens Tis was realizedearly and due to the act that the first
versions o the standards were based toa great extent on data rom the temper-ate region
Tereore the ISOCORRAG exposureprogram was initiated It was carriedout by nations involved in the standard-ization work and included 983093983091 test sites in983089983091 countries on our continents It wasconducted during an eight-year period983089983097983096983092ndash983089983097983097983093 and included six subsequentone-year exposures and long-termexposures or 983090 983092 and 983096 years Te datarom this exposure program orm thecore o the data used in the revision oISO 983097983090983090983091 (one-year data) and ISO 983097983090983090983092
(long term data) and has been summa-rized in ldquoISOCORRAG ndash International
Exposure ProgramrdquoISOCORRAG International
Atmospheric Exposure Program Sum-mary o Results Editors Sheldon WDean Dagmar Knotkova KaterinaKreislova ASM
Te MICA exposure program wasorganized and carried out in 983089983097983096983096ndash983089983097983097983090by 983089983092 Iberoamerican countries andcovered 983095983090 test sites Since the MICAprogram more or less ully adopted the
methodology or the ISOCORRAGprogram and in addition covered addi-tional climatic conditions it was naturalto create a common database used orderiving improved ways o estimatingcorrosivity categories based on environ-mental data
Classification determination andestimation (ISO 9223)Corrosion rates exceeding the upperlimit o category C983093 ia 983090983088983088 microm a-983089 or
carbon steel were previously consid-ered out o the scope o the standard
BY JOHAN TIDBLAD AND KATERINA KREI SLOVA
New developments in the
classification of corrosivityof atmospheres
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CORROSION NEWS 3 | 2012 11
During the analysis o the data rom theISOCORRAG and MICA programs itwas realized that several marine sites insubtropicaltropical regions had values
above the upper limit o C983093 Since theseare natural environments that should becovered by the standard a new categoryCX have been added with upper limit983095983088983088 microm a-983089 or carbon steel reerringto specific marine and marineindus-trial environments typically in a warmclimate
Dose-response unctions ie unc-tions giving an estimate o the corrosionrate based on environmental param-eters have been developed or the ISO983097983090983090983091 metals carbon steel zinc copperand aluminum based on measuredannual values o temperature relativehumidity SO983090 concentrationdeposi-tion and chloride deposition Tis isa significant improvement comparedto the previous standard in terms oreliability o predicted corrosivitycategories Even so the standard givesan important distinction between thedetermination (typical error 983093983077) o thecorrosivity category by exposure o
standard specimens and the estimation(typical error 983093983088983077) o the corrosiv -ity category based on environmentalparameters Furthermore the effect o
clean and acid rain was considered atan early stage but could not be includedin the dose-response unctions despitetheir importance or atmosphericcorrosion Tese new unctions are anintegral part o the KorrField databaseand prediction program developed bySwerea KIMAB
Guiding values for the corrosivitycategories (ISO 9224)Te newly issued ISO 983097983090983090983092 providesinstructions or predicting corrosionattack afer extended and long-term ex-posures Detailed ormulas are providedor carbon steel zinc copper and alu-minium and in addition specific criteriato be taken into account or alloyingelements in weathering steels and alloyso zinc copper and aluminium
Measurement of environmentalparameters (ISO 9225)Description o measurements o
environmental parameters ocus ontemperature relative humidity SO983090and salinity since these are given in thedose-response unctions New methods
are considered including or examplepassive samplers or pollutants andconversion actors are given between se-lected pollution measurement methodsTe methodologies to measure envi-ronmental parameters are now similarto those described in ISO 983089983089983096983092983092 whichdeals with classification o low corrosiv-ity o indoor atmospheres
Evaluation of standard specimens(ISO 9226)In the previous version o the standardit was possible to evaluate corrosioneither by exposing flat standard speci-mens or by exposing special wire helixspecimens Since the analysis showedthat they are not equivalent it is nowonly possible to determine the corrosiv-ity category by flat standard specimens
ContactJohan TidbladJohantidbladswerease
About 983093983088 experts romnine countries (Aus-tralia China CzechRepublic France
Germany Japan Korea Swedenand UK) participated the week o983089983089ndash983089983093 June 983090983088983089983090 at the meeting o
ISOC 983089983093983094 Corrosion o met-als and alloys and its 983089983091 workinggroups Te meeting was held atEspace la Rocheoucauld in ParisFrance and was hosted by AFNORthe French standardization bodyTe chairman o the committee isGoumlran Engstroumlm Swerea KIMABand the secretariat is at CMISI inChina
Read more about the results romthe working groups at httpwww
swereaseenStart983090983090Working-AreasovrigtStandardisation
Meeting of ISOTC 156 in Paris in June 2012
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CORROSION NEWS 3 | 201212
CORROSION ON OFFSHORE INSTALLATIONS requires almostconstant maintenance in order to keep structural membersand saety critical elements fit or purpose On board anoffshore installation the corrosivity varies depending on the
height rom sea level and wind direction as well as otherenvironmental effects such as temperature Many companieschoose to repair degraded coatings on the bases o prequalifi-cation tests carried out onshore or in the laboratory and alsoplan maintenance using corrosion rate data rom estimationsor again rom onshore or lab tests Swerea KIMAB is aimingto help companies gain more knowledge about the corrosionrates on their offshore assets and the coatings systems in use
Trough a newly started joint industry project (JIP) SwereaKIMAB is looking at these aspects in which samples o
various materials and coating systems will be placed offshoreand subsequently analysed in order to build up a picture o
corrosivity and coating system effectiveness It is envisionedthat the JIP will be made up o oil and gas operators their
service companies coating manuacturers as well as materialsand equipment manuacturers Te data obtained rom theexperiments will be used by specialists (designers and main-tenance teams) and this will allow them to better understand
the conditions in which their equipment and materials aredesigned to be used Materials and paint companies couldalso have access to unique testing environments that wouldallow them to prove existing products or trial developmentproducts
Tere is a particular requirement to improve the mainte-nance o coatings on offshore installations in the North Seacurrently Te Health and Saety Executive (HSE) in the UKare in the midst o their KP983092 (Key Programme 983092) projectwhich looks at the procedures used by asset owners in regardsto saety and operability In the previous project KP983091 coatingmaintenance (or abric maintenance as it is known in the
industry) was ound to be an area that required significantimprovement Te problem with this type o maintenance is
Offshore corrosivityBY ANDREW GORDON amp MARTIN JOumlNSSON
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CORROSION NEWS 3 | 2012 13
that it requires avourable weather condi-tions and with restrictions on bed spaceor example the logistics o such workbecomes very difficult to manage
Prequalification tests in the environ-mentWith an accurate picture o which areaso an installation corrode aster or sloweroperators can plan their maintenance moreeffectively ensuring resources are allocatedwhere they are most needed as well as al-lowing them to deer maintenance activitiesi required Te selection and use o coatingsystems can be tailored more effectively bycarrying out the prequalification tests inthe environment in which they will be usedrather than just in accelerated laboratorytests or onshore exposures
Swerea KIMAB has a long history oconducting research into materials andcorrosion having successully completedsimilar studies or inrastructure and auto-motive companies Te data obtained hashelped populate the Korrfield database andenabled companies to select materials moreeffectively or the environments in whichthey operate Te previous studies involvedplacing samples in very hostile environ-
ments such as on the underside o heavygood vehicles and so provides SwereaKIMAB with the expertise or ensuringsamples are saely exposed and easy toevaluate
Focussed on oil and gas operatorsTe first round o meetings with companieshas been completed and has been ocussedon oil and gas operators based in AberdeenUK However the aim is to encompass asmany participants as possible in order to
generate a data set that will be useul notonly to current installations in the NorthSea but also to new projects and otherregions o the world I you are a paint com-pany materials manuacturer equipmentmanuacturer or have an influence on theuse andor maintenance o materials usedin the offshore environment this projectcould be o benefit to you Please eel ree toget in contact i you wish to learn more
Contact
andrewgordonSwereasemartinjonssonswerease
Maintenance scheduling should take into account known degradation ratesof materials and coating systems in operating environments
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CORROSION NEWS 3 | 201214
BY MARIA AringSLUND
A nuclear power station can contain some fairly aggressiveenvironments for materials and it is vital in these environ-ments to try and avoid material failures Thomas Blomfeldtof Swerea KIMAB keeps a check on the condition of thepolymer materials at nuclear sites
RISKS IN NUCLEAR POWER stations areofen associated with meltdowns like atChernobyl or last year at Fukushima -a nightmare scenario that is thankullya rare occurrence However even smallequipment ailures can result in bigproblems or the operators such as pro-duction losses or injury to personnelFor that reason saety and reliability areparamount and this philosophy filtersdown to every component in the system
including nuts bolts and gasketsldquoTe saety margins specified by the
nuclear power station owners have beenset or very good reasons At the sametime or financial reasons they do notwant to replace materials unnecessarilyrdquosays Tomas Blomeldt who has thetask o determining the remaining ser-
vice lie o a rubber joint or exampleSwerea KIMAB has several teams
working on inspecting different typeso material Tomas specialises inpolymers both as an expert at Swerea
KIMAB and as a research scientist 983096983088per cent o his working hours involve
inspecting and evaluating samplesrom nuclear power stations Tomasis a requent visitor at Swedenrsquos threenuclear power stations this year he hasinspected seven out o the total o tenreactors
rdquoPlastic and rubber may not bewhat you first think o when you see anuclear power station However thereare large quantities o polymers thereIn a reactor building the cables alone
correspond to the street lighting systemo a medium-sized Swedish town In ad-
The smallest componentmust be reliable
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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CORROSION NEWS 3 | 2012 5
ten years earlier but was only disman-tled in 983090983088983088983096 along with the others
Te PVDF pipes were installedoutdoors and depending on the season
were exposed to temperatures rangingrom -983090983088 degC to +983092983088 degC Te pressureload reached 983090ndash983091 bar several times dailyTe pipelines in the steel pickling plantwere manuactured o Syge PVDF ma-terial by GF Piping Systems and joined
via socket usion Syge is requentlyused or chemicals distribution due toits excellent chemical resistance Sygeis ree o additives dyes or stabilizingagents
Te pressure rating o the PVDF pipesis 983089983094 bar (PN983089983094) or a diameter o 983092983088mm and a wall thickness o 983090983093 mmBeore the pipes were removed SwereaKIMAB took ten meters o pipe mate-rial including usion joints and bendsper pipeline or the test procedures
Visual and microscopic testingIn the visual inspection PVDF pipesthrough which hydrofluoric or suluricacid was conducted showed no signso corrosion ie no visible suracedamage no blistering or debonding
no swelling Te only noticeable effectwas a light brown discoloration o thehydrofluoric and suluric acid pipesTe discoloration was spread consist-ently over the length o the pipelinewhereas the acid permeation o suluricacid reached a depth o 983088983090 mm Tediscoloration was caused by a chemicalreaction o the acids with the polymersOn the other hand pipelines that wereexposed to nitric acid did not exhibitany discoloration Te microscopic tests
did not show any signs o corrosioneither
Thermal analysisTe melting point and crystallizationtest conducted on the basis o dynamicdifferential calorimetry (DSC) showedthat there was no significant differ-ence between spot samples taken romthe interior o the pipe and the mainbody o the test pipe Te crystallinityalso revealed no degeneration o the
polymer chains Tis indicates that thePVDF material had not been weakened
by the contact with acid over a period o983090983088ndash983091983088 years just as there were no differ-ences detected between pipes installedindoors and outdoors
Mechanical testingTe tensile stress tests done at roomtemperature on all three PVDF pipesand the new pipe uncovered no majordifferences in the mechanical proper-ties Tese results coincide with the re-sults rom the thermal analysis and themicrotome examination according towhich there was no or merely a minimaldegeneration o the PVDF pipes used inthis application
Impact resistance was tested in aroom o which the temperature cor-responded to the guidelines o ISOnorm 983089983095983097 Six test specimens were takenrom each o the three pipes None othe specimens showed any brittlenessbehavior in the impact resistance test
Inspection of fusion jointsWhen inspecting the old usion jointsthe question also arose as to the qualityo usion welds with old pipe materialIn other words how saely can material
which has been penetrated with acid be
used in case o maintenance and repairwork
Respective sections rom the threePVDF pipes were sent to a company
which specializes in acid technologyTeir findings turned out to be similarlypositive or all three pipe sections withIR butt usion joints the usion qualitywas consistently good with slight pres-sure Only on the hydrofluoric samplewas there a bit o blistering in the usionarea
In the socket usion joints used on thehydrofluoric and nitric acid pipes nofissuring was detected Fissures werehowever ound in all the examinedsocket usion joints which had beenexposed to suluric acid It is a knownact that socket usion causes such e -ects Te examined fissures were up totwo millimeters deep and although theyweakened the components to a certainextent they never represented a saetyrisk even at an operating pressure o983090ndash983091 bar over a period o 983090983088 years Anadditional method which contributesto the saety o pipe systems used toconvey aggressive media is BCF (beadand crevice-ree) usion developed
by GF Piping Systems Tis low-stress
After more than thirty years of use the PVDF plastic pipes are still intact They are only slightlydiscolored by the corrosive acids that under high pressure pass through them
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CORROSION NEWS 3 | 20126
jointing technique is highly appreciated by proes-sionals and has stood the test o time in a multitudeo applications
Additionally a ront discoloration 983094983093 mm deep
was noted on the socket joints in the hydrofluoricacid application Assuming that this is a sign opermeation it is possible to calculate an averagepermeation o 983089983090 mm a year (according to Fickrsquos lawo diffusion)
Generally however the socket usion method hasproven reliable in manuacturing piping systemsthat are or example used to convey hydrofluoric ornitric acid
ConclusionTe extensive testing perormed by Swerea KIMABshowed that PVDF pipes rom GF Piping Systemsstill have excellent resistance to corrosion even un-der the harshest conditions and afer more than 983090983088years o use Other than a slight discoloration o thepipe material no other signs o corrosion fissuringor brittleness were determined on the pipes exam-ined Moreover the microtome cuts o the pipe wallsrevealed no indication o local material brittleness
Since chemicals at certain temperatures or pres-sures can cause macromolecular chains to split offor separate it was necessary to test the molecularstructure o the pipes even i there was no signifi-cant degeneration o the material during the utiliza-
tion periodTe mechanical properties o the pipes were not
altered during the course o use Tis result coin-cides with the results o the thermal analysis accord-ing to which there was no significant or substantialdegeneration
On the basis o the test results Swerea KIMABgenerally recommends socket usion as the preerredusion process or PVDF pipes
Assuming that the operating conditions wouldhave remained consistent with those during the pre-
vious 983090983088ndash983091983088 years the creep behavior data lead us to
conclude that the examined pipes would have beensuitable or a much longer period o use with a saetyactor o 983090983096 or higher
The investigated pipes was taken from Sandvik Materials
Technologys steel pickling plant
FACTS
THE AUTHOR HANS-JOumlRG SOMMER is head of Chem-icalMechanical Support and Claims at Georg Fischer
GF Piping Systems Schaffhausen Switzerland
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CORROSION NEWS 3 | 2012 7
in short
NURIA FUERTES began her PhD thesisin April 983090983088983089983090 on ldquoUse of localised electro-chemical techniques for studying stresscorrosion cracking of stainless steelsrdquoSwerea KIMAB recently purchased aScanning Vibrating Electrode Technique(SVET) which will be used in the projectto perform in-situ observations of cracknucleation and growth during stress
corrosion Other applications of this tech-nique include investigation of pitting cor-rosion galvanic corrosion and corrosionresistance of coatings Nuria has workedat Swerea KIMAB since June 983090983088983089983088 inthe research group Metallic Materials inCorrosive Environments
ContactNuacuteria Fuertesnuriafuertesswerease
IN A LETTER to the board of the Swedish
Metallographic Institute on 983090983088 December983089983097983092983093 Carl Benedicks assigned ownershipof his books off-prints and journals to theInstitute Benedicks was the founder of theMetallographic Institute (Swerea KIMAB)From 983089983097983090983089 when the MetallographicInstitute was founded and for fifteen yearsafter that he was its director
The collection ranges over six centuriesand comprises metallurgy mineralogy andmining but also general chemistry physicsand reference works of a historical natureThe majority of the collection consists of
prints from the period of hand printing upto the end of the 983089983097th century These books
are the most valuable in terms of cultural
history and science as well as in financialterms
An example of an interesting book isVanoccio Biringucciorsquos ldquoDe la Pirotechniardquo(983089983093983092983088) which is one of the classic bookswithin the science of mining Another clas-sic is Georg Agricolarsquos ldquoDe Re MetallicardquoMost editions of this title are included buttwo are of particular interest The Italianwork ldquoLrsquoarte de Metallirdquo (983089983093983094983091) which isprobably not held by any other library inSweden The second edition which is alsoin the collection was translated by Herbert
Clark Hoover and his wife Hoover laterbecame President of the United States but
was a qualified mining engineer In addition
to the translation of the book the Hoovercouple have added valuable commentsS
The Benedicks collection contains manyof the more important publications onSwedish mining All books by ldquothe father ofthe Swedish mining industryrdquo Sven Rinmanare included in the collection for example
Most of the Benedicks collection of booksare now stored in the Hagstroumlmer Librarya medico-historical research library andmuseum of books in Stockholm Sweden
Contact
Louise Parnefjordlouiseparnefjordswerease
The Benedicks collection
NEW MEMBER CONSORTIA
Surface Technology
AT SWEREA KIMAB we are now initiating the much-requested membership pro-gramme MRC Surface Technology In its first stage the programme will focus onsurface treatment systems increased understanding concerning corrosion protec-tion and other functional properties of surfaces Joint projects are going to be runwithin surface properties surface analysis and different types of surface treatmentAs well as the properties of surfaces in finished products understanding process-critical parameters will also be included to ensure that selected applications obtainthe very best surface treatments Swerea KIMAB has many years of experienceconcerning surfaces and now in collaboration with interested companies we willbe concentrating on developing current and future requirements within the field
Do not hesitate to contact us for further information about the programme orabout surface technology ideas in general
ContactJohan Nordstroumlm johannordstromswerease
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CORROSION NEWS 3 | 20128
Why do reinforcementbars rust in concrete
BY JOHAN AHLSTROumlM
Reinforcement bars cast in concretenormally have a very low rate of corro-sion The low corrosion rate is due tothe concretersquos high alkalinity the pHvalue in concrete is about 983089983090ndash983089983091Corrosion can occur in environmentswhere chlorides are present which aretransported through the concrete tothe reinforcement bar surface andbreak down the steelrsquos passivity Manytests have been made to determinethe chloride concentration thresholdvalue on the reinforcement bar sur-face that is required to initiate corro-sion The distribution in the resultsfrom these tests is quite wide and canprobably be explained by differentexperimental methods having beenused as well as different externalenvironmental factors
CORROSION NEWS 3 | 20128
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CORROSION NEWS 3 | 2012 9
Tere is a critical chloride thresholdwhich dictates steel corrosion rate oreach quality o concrete Te corrosionrate is largely determined by the con-
cretersquos moisture content Te moisturecontent affects the concretersquos resistiv-ity and transport o both oxygen andchlorides Te time it takes or chloridesto be transported to the reinorcementbar surace where corrosion beginsis called the initialisation period Apropagation stage begins thereafer seefigure Concrete with high moisturecontent has relatively low resistivity andslow transport o oxygen Te propaga-tion rate is consequently low even i thechloride concentration is significantlyhigher than the chloride threshold val-ue Concrete with low moisture contentexhibits rapid transport o oxygen andhigh resistivity which produces a lowrate o corrosion as well At a specificmoisture interval however the transporto oxygen can be high at the same timeas resistivity is low which produces ahigh corrosion rate It is at this specificmoisture interval that the chloridethreshold values should be determined
Te corrosion rate or steel in water-
saturated concrete constructions isusually low due to slow transporto oxygen to the reinorcement barsurace However i the reinorcementbars are in contact with a more noblematerial the corrosion rate can showa marked increase Te magnitude othe galvanic effects or steel in concreteare determined by among other thingschloride and the oxygen concentrationI the chloride concentration is low thereinorcement bar can maintain passiv-
ity despite electrical contact with a morenoble material and the rate o corrosionwill thus be low In one case sacrificialanodes o aluminum were installedto protect the reinorcement bars in aconcrete construction or transportingseawater Te reinorcement bars wereunintentionally in electrical contactwith pumps made o stainless steel andthe sacrificial anodes rapidly deteriorat-ed Te stainless steel pumps probablytook up a large portion o the protective
current compared with the reinorce-ment bars Tere is thereore a risk that
the reinorcement bars were not beingsufficiently protected by the sacrificialanodes
On this basis a PhD project has beeninitiated to investigate how the moisturecontent in concrete affects the chloridethreshold values as well as to inves-tigate the risk or galvanic corrosion
o steel in concrete Te PhD projectencompasses experimental methodsor determining the chloride threshold
values modeling o corrosion processesand field studies o concrete construc-tions situated in seawater
Application of the resultsTe purpose o the project is to surveyin detail which actors interact inchloride-initialized reinorcement barcorrosion and to establish relevant
threshold values or these Increasedunderstanding and clearer limit valuesor chloride-initialized reinorcementbar corrosion enable more reliable as-sessments o condition
Project informationTe PhD project will be conductedthrough collaboration between SwereaKIMAB and the Faculty o Engineering
at Lund University (LH) Te projectis co-financed by the Elorsk Kaumlrnkrafconcrete programme SBUFrsquos develop-ment und and Swerea KIMAB
ContactJohan Ahlstroumlm
johanahlstroumlmswerease
Schematic diagram of corrosion process for steel in concrete
Test configuration for determining moisture-
contentrsquos effects on the corrosion chloridevalue
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CORROSION NEWS 3 | 201210
The international standards ISO 983097983090983090983091-983097983090983090983094 arethe original source for the corrosivity categoriesC983089ndashC983093 used for the classification of the corro-
sivity of atmospheric environments thus serv-ing as a basis for the choice of corrosionprotection systems for many different indus-trial applications Revised versions of thesestandards were issued in the beginning of983090983088983089983090 including the addition of a new corro-sivity category CX and improved proce-dures for estimating corrosivity categories
A SYSTEM FOR CLASSIFICATION oatmospheric corrosivity is helpul orthe selection o materials and protectionagainst corrosion or estimating thelietime o coatings and materials andcan also serve as a guide when choos-ing appropriate corrosion tests Tecorrosivity categories C983089ndashC983093 are wellaccepted and used when selecting struc-tural metals protective coatings andhave been incorporated in other norma-
tive and guidance documents through-out the world Te system was originallydeveloped in the 983089983097983096983088s and the previous
version o ISO 983097983090983090983091 was dated 983089983097983097983090Tis article gives an overview o thenew versions issued in the beginning o983090983088983089983090 starting with a description o thescientific field work underpinning thestandards
Field exposure programsEven though the standards ISO 983097983090983090983091-
983097983090983090983094 are well accepted they have alsobeen the subject o some criticism Tis
was mainly related to the part o thestandard that describes procedures orestimating corrosivity categories basedon environmental data as opposed tothe more reliable way to determine thecorrosivity category by exposure ostandard specimens Tis was realizedearly and due to the act that the first
versions o the standards were based toa great extent on data rom the temper-ate region
Tereore the ISOCORRAG exposureprogram was initiated It was carriedout by nations involved in the standard-ization work and included 983093983091 test sites in983089983091 countries on our continents It wasconducted during an eight-year period983089983097983096983092ndash983089983097983097983093 and included six subsequentone-year exposures and long-termexposures or 983090 983092 and 983096 years Te datarom this exposure program orm thecore o the data used in the revision oISO 983097983090983090983091 (one-year data) and ISO 983097983090983090983092
(long term data) and has been summa-rized in ldquoISOCORRAG ndash International
Exposure ProgramrdquoISOCORRAG International
Atmospheric Exposure Program Sum-mary o Results Editors Sheldon WDean Dagmar Knotkova KaterinaKreislova ASM
Te MICA exposure program wasorganized and carried out in 983089983097983096983096ndash983089983097983097983090by 983089983092 Iberoamerican countries andcovered 983095983090 test sites Since the MICAprogram more or less ully adopted the
methodology or the ISOCORRAGprogram and in addition covered addi-tional climatic conditions it was naturalto create a common database used orderiving improved ways o estimatingcorrosivity categories based on environ-mental data
Classification determination andestimation (ISO 9223)Corrosion rates exceeding the upperlimit o category C983093 ia 983090983088983088 microm a-983089 or
carbon steel were previously consid-ered out o the scope o the standard
BY JOHAN TIDBLAD AND KATERINA KREI SLOVA
New developments in the
classification of corrosivityof atmospheres
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CORROSION NEWS 3 | 2012 11
During the analysis o the data rom theISOCORRAG and MICA programs itwas realized that several marine sites insubtropicaltropical regions had values
above the upper limit o C983093 Since theseare natural environments that should becovered by the standard a new categoryCX have been added with upper limit983095983088983088 microm a-983089 or carbon steel reerringto specific marine and marineindus-trial environments typically in a warmclimate
Dose-response unctions ie unc-tions giving an estimate o the corrosionrate based on environmental param-eters have been developed or the ISO983097983090983090983091 metals carbon steel zinc copperand aluminum based on measuredannual values o temperature relativehumidity SO983090 concentrationdeposi-tion and chloride deposition Tis isa significant improvement comparedto the previous standard in terms oreliability o predicted corrosivitycategories Even so the standard givesan important distinction between thedetermination (typical error 983093983077) o thecorrosivity category by exposure o
standard specimens and the estimation(typical error 983093983088983077) o the corrosiv -ity category based on environmentalparameters Furthermore the effect o
clean and acid rain was considered atan early stage but could not be includedin the dose-response unctions despitetheir importance or atmosphericcorrosion Tese new unctions are anintegral part o the KorrField databaseand prediction program developed bySwerea KIMAB
Guiding values for the corrosivitycategories (ISO 9224)Te newly issued ISO 983097983090983090983092 providesinstructions or predicting corrosionattack afer extended and long-term ex-posures Detailed ormulas are providedor carbon steel zinc copper and alu-minium and in addition specific criteriato be taken into account or alloyingelements in weathering steels and alloyso zinc copper and aluminium
Measurement of environmentalparameters (ISO 9225)Description o measurements o
environmental parameters ocus ontemperature relative humidity SO983090and salinity since these are given in thedose-response unctions New methods
are considered including or examplepassive samplers or pollutants andconversion actors are given between se-lected pollution measurement methodsTe methodologies to measure envi-ronmental parameters are now similarto those described in ISO 983089983089983096983092983092 whichdeals with classification o low corrosiv-ity o indoor atmospheres
Evaluation of standard specimens(ISO 9226)In the previous version o the standardit was possible to evaluate corrosioneither by exposing flat standard speci-mens or by exposing special wire helixspecimens Since the analysis showedthat they are not equivalent it is nowonly possible to determine the corrosiv-ity category by flat standard specimens
ContactJohan TidbladJohantidbladswerease
About 983093983088 experts romnine countries (Aus-tralia China CzechRepublic France
Germany Japan Korea Swedenand UK) participated the week o983089983089ndash983089983093 June 983090983088983089983090 at the meeting o
ISOC 983089983093983094 Corrosion o met-als and alloys and its 983089983091 workinggroups Te meeting was held atEspace la Rocheoucauld in ParisFrance and was hosted by AFNORthe French standardization bodyTe chairman o the committee isGoumlran Engstroumlm Swerea KIMABand the secretariat is at CMISI inChina
Read more about the results romthe working groups at httpwww
swereaseenStart983090983090Working-AreasovrigtStandardisation
Meeting of ISOTC 156 in Paris in June 2012
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CORROSION NEWS 3 | 201212
CORROSION ON OFFSHORE INSTALLATIONS requires almostconstant maintenance in order to keep structural membersand saety critical elements fit or purpose On board anoffshore installation the corrosivity varies depending on the
height rom sea level and wind direction as well as otherenvironmental effects such as temperature Many companieschoose to repair degraded coatings on the bases o prequalifi-cation tests carried out onshore or in the laboratory and alsoplan maintenance using corrosion rate data rom estimationsor again rom onshore or lab tests Swerea KIMAB is aimingto help companies gain more knowledge about the corrosionrates on their offshore assets and the coatings systems in use
Trough a newly started joint industry project (JIP) SwereaKIMAB is looking at these aspects in which samples o
various materials and coating systems will be placed offshoreand subsequently analysed in order to build up a picture o
corrosivity and coating system effectiveness It is envisionedthat the JIP will be made up o oil and gas operators their
service companies coating manuacturers as well as materialsand equipment manuacturers Te data obtained rom theexperiments will be used by specialists (designers and main-tenance teams) and this will allow them to better understand
the conditions in which their equipment and materials aredesigned to be used Materials and paint companies couldalso have access to unique testing environments that wouldallow them to prove existing products or trial developmentproducts
Tere is a particular requirement to improve the mainte-nance o coatings on offshore installations in the North Seacurrently Te Health and Saety Executive (HSE) in the UKare in the midst o their KP983092 (Key Programme 983092) projectwhich looks at the procedures used by asset owners in regardsto saety and operability In the previous project KP983091 coatingmaintenance (or abric maintenance as it is known in the
industry) was ound to be an area that required significantimprovement Te problem with this type o maintenance is
Offshore corrosivityBY ANDREW GORDON amp MARTIN JOumlNSSON
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CORROSION NEWS 3 | 2012 13
that it requires avourable weather condi-tions and with restrictions on bed spaceor example the logistics o such workbecomes very difficult to manage
Prequalification tests in the environ-mentWith an accurate picture o which areaso an installation corrode aster or sloweroperators can plan their maintenance moreeffectively ensuring resources are allocatedwhere they are most needed as well as al-lowing them to deer maintenance activitiesi required Te selection and use o coatingsystems can be tailored more effectively bycarrying out the prequalification tests inthe environment in which they will be usedrather than just in accelerated laboratorytests or onshore exposures
Swerea KIMAB has a long history oconducting research into materials andcorrosion having successully completedsimilar studies or inrastructure and auto-motive companies Te data obtained hashelped populate the Korrfield database andenabled companies to select materials moreeffectively or the environments in whichthey operate Te previous studies involvedplacing samples in very hostile environ-
ments such as on the underside o heavygood vehicles and so provides SwereaKIMAB with the expertise or ensuringsamples are saely exposed and easy toevaluate
Focussed on oil and gas operatorsTe first round o meetings with companieshas been completed and has been ocussedon oil and gas operators based in AberdeenUK However the aim is to encompass asmany participants as possible in order to
generate a data set that will be useul notonly to current installations in the NorthSea but also to new projects and otherregions o the world I you are a paint com-pany materials manuacturer equipmentmanuacturer or have an influence on theuse andor maintenance o materials usedin the offshore environment this projectcould be o benefit to you Please eel ree toget in contact i you wish to learn more
Contact
andrewgordonSwereasemartinjonssonswerease
Maintenance scheduling should take into account known degradation ratesof materials and coating systems in operating environments
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CORROSION NEWS 3 | 201214
BY MARIA AringSLUND
A nuclear power station can contain some fairly aggressiveenvironments for materials and it is vital in these environ-ments to try and avoid material failures Thomas Blomfeldtof Swerea KIMAB keeps a check on the condition of thepolymer materials at nuclear sites
RISKS IN NUCLEAR POWER stations areofen associated with meltdowns like atChernobyl or last year at Fukushima -a nightmare scenario that is thankullya rare occurrence However even smallequipment ailures can result in bigproblems or the operators such as pro-duction losses or injury to personnelFor that reason saety and reliability areparamount and this philosophy filtersdown to every component in the system
including nuts bolts and gasketsldquoTe saety margins specified by the
nuclear power station owners have beenset or very good reasons At the sametime or financial reasons they do notwant to replace materials unnecessarilyrdquosays Tomas Blomeldt who has thetask o determining the remaining ser-
vice lie o a rubber joint or exampleSwerea KIMAB has several teams
working on inspecting different typeso material Tomas specialises inpolymers both as an expert at Swerea
KIMAB and as a research scientist 983096983088per cent o his working hours involve
inspecting and evaluating samplesrom nuclear power stations Tomasis a requent visitor at Swedenrsquos threenuclear power stations this year he hasinspected seven out o the total o tenreactors
rdquoPlastic and rubber may not bewhat you first think o when you see anuclear power station However thereare large quantities o polymers thereIn a reactor building the cables alone
correspond to the street lighting systemo a medium-sized Swedish town In ad-
The smallest componentmust be reliable
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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CORROSION NEWS 3 | 20126
jointing technique is highly appreciated by proes-sionals and has stood the test o time in a multitudeo applications
Additionally a ront discoloration 983094983093 mm deep
was noted on the socket joints in the hydrofluoricacid application Assuming that this is a sign opermeation it is possible to calculate an averagepermeation o 983089983090 mm a year (according to Fickrsquos lawo diffusion)
Generally however the socket usion method hasproven reliable in manuacturing piping systemsthat are or example used to convey hydrofluoric ornitric acid
ConclusionTe extensive testing perormed by Swerea KIMABshowed that PVDF pipes rom GF Piping Systemsstill have excellent resistance to corrosion even un-der the harshest conditions and afer more than 983090983088years o use Other than a slight discoloration o thepipe material no other signs o corrosion fissuringor brittleness were determined on the pipes exam-ined Moreover the microtome cuts o the pipe wallsrevealed no indication o local material brittleness
Since chemicals at certain temperatures or pres-sures can cause macromolecular chains to split offor separate it was necessary to test the molecularstructure o the pipes even i there was no signifi-cant degeneration o the material during the utiliza-
tion periodTe mechanical properties o the pipes were not
altered during the course o use Tis result coin-cides with the results o the thermal analysis accord-ing to which there was no significant or substantialdegeneration
On the basis o the test results Swerea KIMABgenerally recommends socket usion as the preerredusion process or PVDF pipes
Assuming that the operating conditions wouldhave remained consistent with those during the pre-
vious 983090983088ndash983091983088 years the creep behavior data lead us to
conclude that the examined pipes would have beensuitable or a much longer period o use with a saetyactor o 983090983096 or higher
The investigated pipes was taken from Sandvik Materials
Technologys steel pickling plant
FACTS
THE AUTHOR HANS-JOumlRG SOMMER is head of Chem-icalMechanical Support and Claims at Georg Fischer
GF Piping Systems Schaffhausen Switzerland
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CORROSION NEWS 3 | 2012 7
in short
NURIA FUERTES began her PhD thesisin April 983090983088983089983090 on ldquoUse of localised electro-chemical techniques for studying stresscorrosion cracking of stainless steelsrdquoSwerea KIMAB recently purchased aScanning Vibrating Electrode Technique(SVET) which will be used in the projectto perform in-situ observations of cracknucleation and growth during stress
corrosion Other applications of this tech-nique include investigation of pitting cor-rosion galvanic corrosion and corrosionresistance of coatings Nuria has workedat Swerea KIMAB since June 983090983088983089983088 inthe research group Metallic Materials inCorrosive Environments
ContactNuacuteria Fuertesnuriafuertesswerease
IN A LETTER to the board of the Swedish
Metallographic Institute on 983090983088 December983089983097983092983093 Carl Benedicks assigned ownershipof his books off-prints and journals to theInstitute Benedicks was the founder of theMetallographic Institute (Swerea KIMAB)From 983089983097983090983089 when the MetallographicInstitute was founded and for fifteen yearsafter that he was its director
The collection ranges over six centuriesand comprises metallurgy mineralogy andmining but also general chemistry physicsand reference works of a historical natureThe majority of the collection consists of
prints from the period of hand printing upto the end of the 983089983097th century These books
are the most valuable in terms of cultural
history and science as well as in financialterms
An example of an interesting book isVanoccio Biringucciorsquos ldquoDe la Pirotechniardquo(983089983093983092983088) which is one of the classic bookswithin the science of mining Another clas-sic is Georg Agricolarsquos ldquoDe Re MetallicardquoMost editions of this title are included buttwo are of particular interest The Italianwork ldquoLrsquoarte de Metallirdquo (983089983093983094983091) which isprobably not held by any other library inSweden The second edition which is alsoin the collection was translated by Herbert
Clark Hoover and his wife Hoover laterbecame President of the United States but
was a qualified mining engineer In addition
to the translation of the book the Hoovercouple have added valuable commentsS
The Benedicks collection contains manyof the more important publications onSwedish mining All books by ldquothe father ofthe Swedish mining industryrdquo Sven Rinmanare included in the collection for example
Most of the Benedicks collection of booksare now stored in the Hagstroumlmer Librarya medico-historical research library andmuseum of books in Stockholm Sweden
Contact
Louise Parnefjordlouiseparnefjordswerease
The Benedicks collection
NEW MEMBER CONSORTIA
Surface Technology
AT SWEREA KIMAB we are now initiating the much-requested membership pro-gramme MRC Surface Technology In its first stage the programme will focus onsurface treatment systems increased understanding concerning corrosion protec-tion and other functional properties of surfaces Joint projects are going to be runwithin surface properties surface analysis and different types of surface treatmentAs well as the properties of surfaces in finished products understanding process-critical parameters will also be included to ensure that selected applications obtainthe very best surface treatments Swerea KIMAB has many years of experienceconcerning surfaces and now in collaboration with interested companies we willbe concentrating on developing current and future requirements within the field
Do not hesitate to contact us for further information about the programme orabout surface technology ideas in general
ContactJohan Nordstroumlm johannordstromswerease
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CORROSION NEWS 3 | 20128
Why do reinforcementbars rust in concrete
BY JOHAN AHLSTROumlM
Reinforcement bars cast in concretenormally have a very low rate of corro-sion The low corrosion rate is due tothe concretersquos high alkalinity the pHvalue in concrete is about 983089983090ndash983089983091Corrosion can occur in environmentswhere chlorides are present which aretransported through the concrete tothe reinforcement bar surface andbreak down the steelrsquos passivity Manytests have been made to determinethe chloride concentration thresholdvalue on the reinforcement bar sur-face that is required to initiate corro-sion The distribution in the resultsfrom these tests is quite wide and canprobably be explained by differentexperimental methods having beenused as well as different externalenvironmental factors
CORROSION NEWS 3 | 20128
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CORROSION NEWS 3 | 2012 9
Tere is a critical chloride thresholdwhich dictates steel corrosion rate oreach quality o concrete Te corrosionrate is largely determined by the con-
cretersquos moisture content Te moisturecontent affects the concretersquos resistiv-ity and transport o both oxygen andchlorides Te time it takes or chloridesto be transported to the reinorcementbar surace where corrosion beginsis called the initialisation period Apropagation stage begins thereafer seefigure Concrete with high moisturecontent has relatively low resistivity andslow transport o oxygen Te propaga-tion rate is consequently low even i thechloride concentration is significantlyhigher than the chloride threshold val-ue Concrete with low moisture contentexhibits rapid transport o oxygen andhigh resistivity which produces a lowrate o corrosion as well At a specificmoisture interval however the transporto oxygen can be high at the same timeas resistivity is low which produces ahigh corrosion rate It is at this specificmoisture interval that the chloridethreshold values should be determined
Te corrosion rate or steel in water-
saturated concrete constructions isusually low due to slow transporto oxygen to the reinorcement barsurace However i the reinorcementbars are in contact with a more noblematerial the corrosion rate can showa marked increase Te magnitude othe galvanic effects or steel in concreteare determined by among other thingschloride and the oxygen concentrationI the chloride concentration is low thereinorcement bar can maintain passiv-
ity despite electrical contact with a morenoble material and the rate o corrosionwill thus be low In one case sacrificialanodes o aluminum were installedto protect the reinorcement bars in aconcrete construction or transportingseawater Te reinorcement bars wereunintentionally in electrical contactwith pumps made o stainless steel andthe sacrificial anodes rapidly deteriorat-ed Te stainless steel pumps probablytook up a large portion o the protective
current compared with the reinorce-ment bars Tere is thereore a risk that
the reinorcement bars were not beingsufficiently protected by the sacrificialanodes
On this basis a PhD project has beeninitiated to investigate how the moisturecontent in concrete affects the chloridethreshold values as well as to inves-tigate the risk or galvanic corrosion
o steel in concrete Te PhD projectencompasses experimental methodsor determining the chloride threshold
values modeling o corrosion processesand field studies o concrete construc-tions situated in seawater
Application of the resultsTe purpose o the project is to surveyin detail which actors interact inchloride-initialized reinorcement barcorrosion and to establish relevant
threshold values or these Increasedunderstanding and clearer limit valuesor chloride-initialized reinorcementbar corrosion enable more reliable as-sessments o condition
Project informationTe PhD project will be conductedthrough collaboration between SwereaKIMAB and the Faculty o Engineering
at Lund University (LH) Te projectis co-financed by the Elorsk Kaumlrnkrafconcrete programme SBUFrsquos develop-ment und and Swerea KIMAB
ContactJohan Ahlstroumlm
johanahlstroumlmswerease
Schematic diagram of corrosion process for steel in concrete
Test configuration for determining moisture-
contentrsquos effects on the corrosion chloridevalue
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CORROSION NEWS 3 | 201210
The international standards ISO 983097983090983090983091-983097983090983090983094 arethe original source for the corrosivity categoriesC983089ndashC983093 used for the classification of the corro-
sivity of atmospheric environments thus serv-ing as a basis for the choice of corrosionprotection systems for many different indus-trial applications Revised versions of thesestandards were issued in the beginning of983090983088983089983090 including the addition of a new corro-sivity category CX and improved proce-dures for estimating corrosivity categories
A SYSTEM FOR CLASSIFICATION oatmospheric corrosivity is helpul orthe selection o materials and protectionagainst corrosion or estimating thelietime o coatings and materials andcan also serve as a guide when choos-ing appropriate corrosion tests Tecorrosivity categories C983089ndashC983093 are wellaccepted and used when selecting struc-tural metals protective coatings andhave been incorporated in other norma-
tive and guidance documents through-out the world Te system was originallydeveloped in the 983089983097983096983088s and the previous
version o ISO 983097983090983090983091 was dated 983089983097983097983090Tis article gives an overview o thenew versions issued in the beginning o983090983088983089983090 starting with a description o thescientific field work underpinning thestandards
Field exposure programsEven though the standards ISO 983097983090983090983091-
983097983090983090983094 are well accepted they have alsobeen the subject o some criticism Tis
was mainly related to the part o thestandard that describes procedures orestimating corrosivity categories basedon environmental data as opposed tothe more reliable way to determine thecorrosivity category by exposure ostandard specimens Tis was realizedearly and due to the act that the first
versions o the standards were based toa great extent on data rom the temper-ate region
Tereore the ISOCORRAG exposureprogram was initiated It was carriedout by nations involved in the standard-ization work and included 983093983091 test sites in983089983091 countries on our continents It wasconducted during an eight-year period983089983097983096983092ndash983089983097983097983093 and included six subsequentone-year exposures and long-termexposures or 983090 983092 and 983096 years Te datarom this exposure program orm thecore o the data used in the revision oISO 983097983090983090983091 (one-year data) and ISO 983097983090983090983092
(long term data) and has been summa-rized in ldquoISOCORRAG ndash International
Exposure ProgramrdquoISOCORRAG International
Atmospheric Exposure Program Sum-mary o Results Editors Sheldon WDean Dagmar Knotkova KaterinaKreislova ASM
Te MICA exposure program wasorganized and carried out in 983089983097983096983096ndash983089983097983097983090by 983089983092 Iberoamerican countries andcovered 983095983090 test sites Since the MICAprogram more or less ully adopted the
methodology or the ISOCORRAGprogram and in addition covered addi-tional climatic conditions it was naturalto create a common database used orderiving improved ways o estimatingcorrosivity categories based on environ-mental data
Classification determination andestimation (ISO 9223)Corrosion rates exceeding the upperlimit o category C983093 ia 983090983088983088 microm a-983089 or
carbon steel were previously consid-ered out o the scope o the standard
BY JOHAN TIDBLAD AND KATERINA KREI SLOVA
New developments in the
classification of corrosivityof atmospheres
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CORROSION NEWS 3 | 2012 11
During the analysis o the data rom theISOCORRAG and MICA programs itwas realized that several marine sites insubtropicaltropical regions had values
above the upper limit o C983093 Since theseare natural environments that should becovered by the standard a new categoryCX have been added with upper limit983095983088983088 microm a-983089 or carbon steel reerringto specific marine and marineindus-trial environments typically in a warmclimate
Dose-response unctions ie unc-tions giving an estimate o the corrosionrate based on environmental param-eters have been developed or the ISO983097983090983090983091 metals carbon steel zinc copperand aluminum based on measuredannual values o temperature relativehumidity SO983090 concentrationdeposi-tion and chloride deposition Tis isa significant improvement comparedto the previous standard in terms oreliability o predicted corrosivitycategories Even so the standard givesan important distinction between thedetermination (typical error 983093983077) o thecorrosivity category by exposure o
standard specimens and the estimation(typical error 983093983088983077) o the corrosiv -ity category based on environmentalparameters Furthermore the effect o
clean and acid rain was considered atan early stage but could not be includedin the dose-response unctions despitetheir importance or atmosphericcorrosion Tese new unctions are anintegral part o the KorrField databaseand prediction program developed bySwerea KIMAB
Guiding values for the corrosivitycategories (ISO 9224)Te newly issued ISO 983097983090983090983092 providesinstructions or predicting corrosionattack afer extended and long-term ex-posures Detailed ormulas are providedor carbon steel zinc copper and alu-minium and in addition specific criteriato be taken into account or alloyingelements in weathering steels and alloyso zinc copper and aluminium
Measurement of environmentalparameters (ISO 9225)Description o measurements o
environmental parameters ocus ontemperature relative humidity SO983090and salinity since these are given in thedose-response unctions New methods
are considered including or examplepassive samplers or pollutants andconversion actors are given between se-lected pollution measurement methodsTe methodologies to measure envi-ronmental parameters are now similarto those described in ISO 983089983089983096983092983092 whichdeals with classification o low corrosiv-ity o indoor atmospheres
Evaluation of standard specimens(ISO 9226)In the previous version o the standardit was possible to evaluate corrosioneither by exposing flat standard speci-mens or by exposing special wire helixspecimens Since the analysis showedthat they are not equivalent it is nowonly possible to determine the corrosiv-ity category by flat standard specimens
ContactJohan TidbladJohantidbladswerease
About 983093983088 experts romnine countries (Aus-tralia China CzechRepublic France
Germany Japan Korea Swedenand UK) participated the week o983089983089ndash983089983093 June 983090983088983089983090 at the meeting o
ISOC 983089983093983094 Corrosion o met-als and alloys and its 983089983091 workinggroups Te meeting was held atEspace la Rocheoucauld in ParisFrance and was hosted by AFNORthe French standardization bodyTe chairman o the committee isGoumlran Engstroumlm Swerea KIMABand the secretariat is at CMISI inChina
Read more about the results romthe working groups at httpwww
swereaseenStart983090983090Working-AreasovrigtStandardisation
Meeting of ISOTC 156 in Paris in June 2012
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CORROSION NEWS 3 | 201212
CORROSION ON OFFSHORE INSTALLATIONS requires almostconstant maintenance in order to keep structural membersand saety critical elements fit or purpose On board anoffshore installation the corrosivity varies depending on the
height rom sea level and wind direction as well as otherenvironmental effects such as temperature Many companieschoose to repair degraded coatings on the bases o prequalifi-cation tests carried out onshore or in the laboratory and alsoplan maintenance using corrosion rate data rom estimationsor again rom onshore or lab tests Swerea KIMAB is aimingto help companies gain more knowledge about the corrosionrates on their offshore assets and the coatings systems in use
Trough a newly started joint industry project (JIP) SwereaKIMAB is looking at these aspects in which samples o
various materials and coating systems will be placed offshoreand subsequently analysed in order to build up a picture o
corrosivity and coating system effectiveness It is envisionedthat the JIP will be made up o oil and gas operators their
service companies coating manuacturers as well as materialsand equipment manuacturers Te data obtained rom theexperiments will be used by specialists (designers and main-tenance teams) and this will allow them to better understand
the conditions in which their equipment and materials aredesigned to be used Materials and paint companies couldalso have access to unique testing environments that wouldallow them to prove existing products or trial developmentproducts
Tere is a particular requirement to improve the mainte-nance o coatings on offshore installations in the North Seacurrently Te Health and Saety Executive (HSE) in the UKare in the midst o their KP983092 (Key Programme 983092) projectwhich looks at the procedures used by asset owners in regardsto saety and operability In the previous project KP983091 coatingmaintenance (or abric maintenance as it is known in the
industry) was ound to be an area that required significantimprovement Te problem with this type o maintenance is
Offshore corrosivityBY ANDREW GORDON amp MARTIN JOumlNSSON
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CORROSION NEWS 3 | 2012 13
that it requires avourable weather condi-tions and with restrictions on bed spaceor example the logistics o such workbecomes very difficult to manage
Prequalification tests in the environ-mentWith an accurate picture o which areaso an installation corrode aster or sloweroperators can plan their maintenance moreeffectively ensuring resources are allocatedwhere they are most needed as well as al-lowing them to deer maintenance activitiesi required Te selection and use o coatingsystems can be tailored more effectively bycarrying out the prequalification tests inthe environment in which they will be usedrather than just in accelerated laboratorytests or onshore exposures
Swerea KIMAB has a long history oconducting research into materials andcorrosion having successully completedsimilar studies or inrastructure and auto-motive companies Te data obtained hashelped populate the Korrfield database andenabled companies to select materials moreeffectively or the environments in whichthey operate Te previous studies involvedplacing samples in very hostile environ-
ments such as on the underside o heavygood vehicles and so provides SwereaKIMAB with the expertise or ensuringsamples are saely exposed and easy toevaluate
Focussed on oil and gas operatorsTe first round o meetings with companieshas been completed and has been ocussedon oil and gas operators based in AberdeenUK However the aim is to encompass asmany participants as possible in order to
generate a data set that will be useul notonly to current installations in the NorthSea but also to new projects and otherregions o the world I you are a paint com-pany materials manuacturer equipmentmanuacturer or have an influence on theuse andor maintenance o materials usedin the offshore environment this projectcould be o benefit to you Please eel ree toget in contact i you wish to learn more
Contact
andrewgordonSwereasemartinjonssonswerease
Maintenance scheduling should take into account known degradation ratesof materials and coating systems in operating environments
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CORROSION NEWS 3 | 201214
BY MARIA AringSLUND
A nuclear power station can contain some fairly aggressiveenvironments for materials and it is vital in these environ-ments to try and avoid material failures Thomas Blomfeldtof Swerea KIMAB keeps a check on the condition of thepolymer materials at nuclear sites
RISKS IN NUCLEAR POWER stations areofen associated with meltdowns like atChernobyl or last year at Fukushima -a nightmare scenario that is thankullya rare occurrence However even smallequipment ailures can result in bigproblems or the operators such as pro-duction losses or injury to personnelFor that reason saety and reliability areparamount and this philosophy filtersdown to every component in the system
including nuts bolts and gasketsldquoTe saety margins specified by the
nuclear power station owners have beenset or very good reasons At the sametime or financial reasons they do notwant to replace materials unnecessarilyrdquosays Tomas Blomeldt who has thetask o determining the remaining ser-
vice lie o a rubber joint or exampleSwerea KIMAB has several teams
working on inspecting different typeso material Tomas specialises inpolymers both as an expert at Swerea
KIMAB and as a research scientist 983096983088per cent o his working hours involve
inspecting and evaluating samplesrom nuclear power stations Tomasis a requent visitor at Swedenrsquos threenuclear power stations this year he hasinspected seven out o the total o tenreactors
rdquoPlastic and rubber may not bewhat you first think o when you see anuclear power station However thereare large quantities o polymers thereIn a reactor building the cables alone
correspond to the street lighting systemo a medium-sized Swedish town In ad-
The smallest componentmust be reliable
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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CORROSION NEWS 3 | 2012 7
in short
NURIA FUERTES began her PhD thesisin April 983090983088983089983090 on ldquoUse of localised electro-chemical techniques for studying stresscorrosion cracking of stainless steelsrdquoSwerea KIMAB recently purchased aScanning Vibrating Electrode Technique(SVET) which will be used in the projectto perform in-situ observations of cracknucleation and growth during stress
corrosion Other applications of this tech-nique include investigation of pitting cor-rosion galvanic corrosion and corrosionresistance of coatings Nuria has workedat Swerea KIMAB since June 983090983088983089983088 inthe research group Metallic Materials inCorrosive Environments
ContactNuacuteria Fuertesnuriafuertesswerease
IN A LETTER to the board of the Swedish
Metallographic Institute on 983090983088 December983089983097983092983093 Carl Benedicks assigned ownershipof his books off-prints and journals to theInstitute Benedicks was the founder of theMetallographic Institute (Swerea KIMAB)From 983089983097983090983089 when the MetallographicInstitute was founded and for fifteen yearsafter that he was its director
The collection ranges over six centuriesand comprises metallurgy mineralogy andmining but also general chemistry physicsand reference works of a historical natureThe majority of the collection consists of
prints from the period of hand printing upto the end of the 983089983097th century These books
are the most valuable in terms of cultural
history and science as well as in financialterms
An example of an interesting book isVanoccio Biringucciorsquos ldquoDe la Pirotechniardquo(983089983093983092983088) which is one of the classic bookswithin the science of mining Another clas-sic is Georg Agricolarsquos ldquoDe Re MetallicardquoMost editions of this title are included buttwo are of particular interest The Italianwork ldquoLrsquoarte de Metallirdquo (983089983093983094983091) which isprobably not held by any other library inSweden The second edition which is alsoin the collection was translated by Herbert
Clark Hoover and his wife Hoover laterbecame President of the United States but
was a qualified mining engineer In addition
to the translation of the book the Hoovercouple have added valuable commentsS
The Benedicks collection contains manyof the more important publications onSwedish mining All books by ldquothe father ofthe Swedish mining industryrdquo Sven Rinmanare included in the collection for example
Most of the Benedicks collection of booksare now stored in the Hagstroumlmer Librarya medico-historical research library andmuseum of books in Stockholm Sweden
Contact
Louise Parnefjordlouiseparnefjordswerease
The Benedicks collection
NEW MEMBER CONSORTIA
Surface Technology
AT SWEREA KIMAB we are now initiating the much-requested membership pro-gramme MRC Surface Technology In its first stage the programme will focus onsurface treatment systems increased understanding concerning corrosion protec-tion and other functional properties of surfaces Joint projects are going to be runwithin surface properties surface analysis and different types of surface treatmentAs well as the properties of surfaces in finished products understanding process-critical parameters will also be included to ensure that selected applications obtainthe very best surface treatments Swerea KIMAB has many years of experienceconcerning surfaces and now in collaboration with interested companies we willbe concentrating on developing current and future requirements within the field
Do not hesitate to contact us for further information about the programme orabout surface technology ideas in general
ContactJohan Nordstroumlm johannordstromswerease
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CORROSION NEWS 3 | 20128
Why do reinforcementbars rust in concrete
BY JOHAN AHLSTROumlM
Reinforcement bars cast in concretenormally have a very low rate of corro-sion The low corrosion rate is due tothe concretersquos high alkalinity the pHvalue in concrete is about 983089983090ndash983089983091Corrosion can occur in environmentswhere chlorides are present which aretransported through the concrete tothe reinforcement bar surface andbreak down the steelrsquos passivity Manytests have been made to determinethe chloride concentration thresholdvalue on the reinforcement bar sur-face that is required to initiate corro-sion The distribution in the resultsfrom these tests is quite wide and canprobably be explained by differentexperimental methods having beenused as well as different externalenvironmental factors
CORROSION NEWS 3 | 20128
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CORROSION NEWS 3 | 2012 9
Tere is a critical chloride thresholdwhich dictates steel corrosion rate oreach quality o concrete Te corrosionrate is largely determined by the con-
cretersquos moisture content Te moisturecontent affects the concretersquos resistiv-ity and transport o both oxygen andchlorides Te time it takes or chloridesto be transported to the reinorcementbar surace where corrosion beginsis called the initialisation period Apropagation stage begins thereafer seefigure Concrete with high moisturecontent has relatively low resistivity andslow transport o oxygen Te propaga-tion rate is consequently low even i thechloride concentration is significantlyhigher than the chloride threshold val-ue Concrete with low moisture contentexhibits rapid transport o oxygen andhigh resistivity which produces a lowrate o corrosion as well At a specificmoisture interval however the transporto oxygen can be high at the same timeas resistivity is low which produces ahigh corrosion rate It is at this specificmoisture interval that the chloridethreshold values should be determined
Te corrosion rate or steel in water-
saturated concrete constructions isusually low due to slow transporto oxygen to the reinorcement barsurace However i the reinorcementbars are in contact with a more noblematerial the corrosion rate can showa marked increase Te magnitude othe galvanic effects or steel in concreteare determined by among other thingschloride and the oxygen concentrationI the chloride concentration is low thereinorcement bar can maintain passiv-
ity despite electrical contact with a morenoble material and the rate o corrosionwill thus be low In one case sacrificialanodes o aluminum were installedto protect the reinorcement bars in aconcrete construction or transportingseawater Te reinorcement bars wereunintentionally in electrical contactwith pumps made o stainless steel andthe sacrificial anodes rapidly deteriorat-ed Te stainless steel pumps probablytook up a large portion o the protective
current compared with the reinorce-ment bars Tere is thereore a risk that
the reinorcement bars were not beingsufficiently protected by the sacrificialanodes
On this basis a PhD project has beeninitiated to investigate how the moisturecontent in concrete affects the chloridethreshold values as well as to inves-tigate the risk or galvanic corrosion
o steel in concrete Te PhD projectencompasses experimental methodsor determining the chloride threshold
values modeling o corrosion processesand field studies o concrete construc-tions situated in seawater
Application of the resultsTe purpose o the project is to surveyin detail which actors interact inchloride-initialized reinorcement barcorrosion and to establish relevant
threshold values or these Increasedunderstanding and clearer limit valuesor chloride-initialized reinorcementbar corrosion enable more reliable as-sessments o condition
Project informationTe PhD project will be conductedthrough collaboration between SwereaKIMAB and the Faculty o Engineering
at Lund University (LH) Te projectis co-financed by the Elorsk Kaumlrnkrafconcrete programme SBUFrsquos develop-ment und and Swerea KIMAB
ContactJohan Ahlstroumlm
johanahlstroumlmswerease
Schematic diagram of corrosion process for steel in concrete
Test configuration for determining moisture-
contentrsquos effects on the corrosion chloridevalue
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CORROSION NEWS 3 | 201210
The international standards ISO 983097983090983090983091-983097983090983090983094 arethe original source for the corrosivity categoriesC983089ndashC983093 used for the classification of the corro-
sivity of atmospheric environments thus serv-ing as a basis for the choice of corrosionprotection systems for many different indus-trial applications Revised versions of thesestandards were issued in the beginning of983090983088983089983090 including the addition of a new corro-sivity category CX and improved proce-dures for estimating corrosivity categories
A SYSTEM FOR CLASSIFICATION oatmospheric corrosivity is helpul orthe selection o materials and protectionagainst corrosion or estimating thelietime o coatings and materials andcan also serve as a guide when choos-ing appropriate corrosion tests Tecorrosivity categories C983089ndashC983093 are wellaccepted and used when selecting struc-tural metals protective coatings andhave been incorporated in other norma-
tive and guidance documents through-out the world Te system was originallydeveloped in the 983089983097983096983088s and the previous
version o ISO 983097983090983090983091 was dated 983089983097983097983090Tis article gives an overview o thenew versions issued in the beginning o983090983088983089983090 starting with a description o thescientific field work underpinning thestandards
Field exposure programsEven though the standards ISO 983097983090983090983091-
983097983090983090983094 are well accepted they have alsobeen the subject o some criticism Tis
was mainly related to the part o thestandard that describes procedures orestimating corrosivity categories basedon environmental data as opposed tothe more reliable way to determine thecorrosivity category by exposure ostandard specimens Tis was realizedearly and due to the act that the first
versions o the standards were based toa great extent on data rom the temper-ate region
Tereore the ISOCORRAG exposureprogram was initiated It was carriedout by nations involved in the standard-ization work and included 983093983091 test sites in983089983091 countries on our continents It wasconducted during an eight-year period983089983097983096983092ndash983089983097983097983093 and included six subsequentone-year exposures and long-termexposures or 983090 983092 and 983096 years Te datarom this exposure program orm thecore o the data used in the revision oISO 983097983090983090983091 (one-year data) and ISO 983097983090983090983092
(long term data) and has been summa-rized in ldquoISOCORRAG ndash International
Exposure ProgramrdquoISOCORRAG International
Atmospheric Exposure Program Sum-mary o Results Editors Sheldon WDean Dagmar Knotkova KaterinaKreislova ASM
Te MICA exposure program wasorganized and carried out in 983089983097983096983096ndash983089983097983097983090by 983089983092 Iberoamerican countries andcovered 983095983090 test sites Since the MICAprogram more or less ully adopted the
methodology or the ISOCORRAGprogram and in addition covered addi-tional climatic conditions it was naturalto create a common database used orderiving improved ways o estimatingcorrosivity categories based on environ-mental data
Classification determination andestimation (ISO 9223)Corrosion rates exceeding the upperlimit o category C983093 ia 983090983088983088 microm a-983089 or
carbon steel were previously consid-ered out o the scope o the standard
BY JOHAN TIDBLAD AND KATERINA KREI SLOVA
New developments in the
classification of corrosivityof atmospheres
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CORROSION NEWS 3 | 2012 11
During the analysis o the data rom theISOCORRAG and MICA programs itwas realized that several marine sites insubtropicaltropical regions had values
above the upper limit o C983093 Since theseare natural environments that should becovered by the standard a new categoryCX have been added with upper limit983095983088983088 microm a-983089 or carbon steel reerringto specific marine and marineindus-trial environments typically in a warmclimate
Dose-response unctions ie unc-tions giving an estimate o the corrosionrate based on environmental param-eters have been developed or the ISO983097983090983090983091 metals carbon steel zinc copperand aluminum based on measuredannual values o temperature relativehumidity SO983090 concentrationdeposi-tion and chloride deposition Tis isa significant improvement comparedto the previous standard in terms oreliability o predicted corrosivitycategories Even so the standard givesan important distinction between thedetermination (typical error 983093983077) o thecorrosivity category by exposure o
standard specimens and the estimation(typical error 983093983088983077) o the corrosiv -ity category based on environmentalparameters Furthermore the effect o
clean and acid rain was considered atan early stage but could not be includedin the dose-response unctions despitetheir importance or atmosphericcorrosion Tese new unctions are anintegral part o the KorrField databaseand prediction program developed bySwerea KIMAB
Guiding values for the corrosivitycategories (ISO 9224)Te newly issued ISO 983097983090983090983092 providesinstructions or predicting corrosionattack afer extended and long-term ex-posures Detailed ormulas are providedor carbon steel zinc copper and alu-minium and in addition specific criteriato be taken into account or alloyingelements in weathering steels and alloyso zinc copper and aluminium
Measurement of environmentalparameters (ISO 9225)Description o measurements o
environmental parameters ocus ontemperature relative humidity SO983090and salinity since these are given in thedose-response unctions New methods
are considered including or examplepassive samplers or pollutants andconversion actors are given between se-lected pollution measurement methodsTe methodologies to measure envi-ronmental parameters are now similarto those described in ISO 983089983089983096983092983092 whichdeals with classification o low corrosiv-ity o indoor atmospheres
Evaluation of standard specimens(ISO 9226)In the previous version o the standardit was possible to evaluate corrosioneither by exposing flat standard speci-mens or by exposing special wire helixspecimens Since the analysis showedthat they are not equivalent it is nowonly possible to determine the corrosiv-ity category by flat standard specimens
ContactJohan TidbladJohantidbladswerease
About 983093983088 experts romnine countries (Aus-tralia China CzechRepublic France
Germany Japan Korea Swedenand UK) participated the week o983089983089ndash983089983093 June 983090983088983089983090 at the meeting o
ISOC 983089983093983094 Corrosion o met-als and alloys and its 983089983091 workinggroups Te meeting was held atEspace la Rocheoucauld in ParisFrance and was hosted by AFNORthe French standardization bodyTe chairman o the committee isGoumlran Engstroumlm Swerea KIMABand the secretariat is at CMISI inChina
Read more about the results romthe working groups at httpwww
swereaseenStart983090983090Working-AreasovrigtStandardisation
Meeting of ISOTC 156 in Paris in June 2012
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CORROSION NEWS 3 | 201212
CORROSION ON OFFSHORE INSTALLATIONS requires almostconstant maintenance in order to keep structural membersand saety critical elements fit or purpose On board anoffshore installation the corrosivity varies depending on the
height rom sea level and wind direction as well as otherenvironmental effects such as temperature Many companieschoose to repair degraded coatings on the bases o prequalifi-cation tests carried out onshore or in the laboratory and alsoplan maintenance using corrosion rate data rom estimationsor again rom onshore or lab tests Swerea KIMAB is aimingto help companies gain more knowledge about the corrosionrates on their offshore assets and the coatings systems in use
Trough a newly started joint industry project (JIP) SwereaKIMAB is looking at these aspects in which samples o
various materials and coating systems will be placed offshoreand subsequently analysed in order to build up a picture o
corrosivity and coating system effectiveness It is envisionedthat the JIP will be made up o oil and gas operators their
service companies coating manuacturers as well as materialsand equipment manuacturers Te data obtained rom theexperiments will be used by specialists (designers and main-tenance teams) and this will allow them to better understand
the conditions in which their equipment and materials aredesigned to be used Materials and paint companies couldalso have access to unique testing environments that wouldallow them to prove existing products or trial developmentproducts
Tere is a particular requirement to improve the mainte-nance o coatings on offshore installations in the North Seacurrently Te Health and Saety Executive (HSE) in the UKare in the midst o their KP983092 (Key Programme 983092) projectwhich looks at the procedures used by asset owners in regardsto saety and operability In the previous project KP983091 coatingmaintenance (or abric maintenance as it is known in the
industry) was ound to be an area that required significantimprovement Te problem with this type o maintenance is
Offshore corrosivityBY ANDREW GORDON amp MARTIN JOumlNSSON
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CORROSION NEWS 3 | 2012 13
that it requires avourable weather condi-tions and with restrictions on bed spaceor example the logistics o such workbecomes very difficult to manage
Prequalification tests in the environ-mentWith an accurate picture o which areaso an installation corrode aster or sloweroperators can plan their maintenance moreeffectively ensuring resources are allocatedwhere they are most needed as well as al-lowing them to deer maintenance activitiesi required Te selection and use o coatingsystems can be tailored more effectively bycarrying out the prequalification tests inthe environment in which they will be usedrather than just in accelerated laboratorytests or onshore exposures
Swerea KIMAB has a long history oconducting research into materials andcorrosion having successully completedsimilar studies or inrastructure and auto-motive companies Te data obtained hashelped populate the Korrfield database andenabled companies to select materials moreeffectively or the environments in whichthey operate Te previous studies involvedplacing samples in very hostile environ-
ments such as on the underside o heavygood vehicles and so provides SwereaKIMAB with the expertise or ensuringsamples are saely exposed and easy toevaluate
Focussed on oil and gas operatorsTe first round o meetings with companieshas been completed and has been ocussedon oil and gas operators based in AberdeenUK However the aim is to encompass asmany participants as possible in order to
generate a data set that will be useul notonly to current installations in the NorthSea but also to new projects and otherregions o the world I you are a paint com-pany materials manuacturer equipmentmanuacturer or have an influence on theuse andor maintenance o materials usedin the offshore environment this projectcould be o benefit to you Please eel ree toget in contact i you wish to learn more
Contact
andrewgordonSwereasemartinjonssonswerease
Maintenance scheduling should take into account known degradation ratesof materials and coating systems in operating environments
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CORROSION NEWS 3 | 201214
BY MARIA AringSLUND
A nuclear power station can contain some fairly aggressiveenvironments for materials and it is vital in these environ-ments to try and avoid material failures Thomas Blomfeldtof Swerea KIMAB keeps a check on the condition of thepolymer materials at nuclear sites
RISKS IN NUCLEAR POWER stations areofen associated with meltdowns like atChernobyl or last year at Fukushima -a nightmare scenario that is thankullya rare occurrence However even smallequipment ailures can result in bigproblems or the operators such as pro-duction losses or injury to personnelFor that reason saety and reliability areparamount and this philosophy filtersdown to every component in the system
including nuts bolts and gasketsldquoTe saety margins specified by the
nuclear power station owners have beenset or very good reasons At the sametime or financial reasons they do notwant to replace materials unnecessarilyrdquosays Tomas Blomeldt who has thetask o determining the remaining ser-
vice lie o a rubber joint or exampleSwerea KIMAB has several teams
working on inspecting different typeso material Tomas specialises inpolymers both as an expert at Swerea
KIMAB and as a research scientist 983096983088per cent o his working hours involve
inspecting and evaluating samplesrom nuclear power stations Tomasis a requent visitor at Swedenrsquos threenuclear power stations this year he hasinspected seven out o the total o tenreactors
rdquoPlastic and rubber may not bewhat you first think o when you see anuclear power station However thereare large quantities o polymers thereIn a reactor building the cables alone
correspond to the street lighting systemo a medium-sized Swedish town In ad-
The smallest componentmust be reliable
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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CORROSION NEWS 3 | 20128
Why do reinforcementbars rust in concrete
BY JOHAN AHLSTROumlM
Reinforcement bars cast in concretenormally have a very low rate of corro-sion The low corrosion rate is due tothe concretersquos high alkalinity the pHvalue in concrete is about 983089983090ndash983089983091Corrosion can occur in environmentswhere chlorides are present which aretransported through the concrete tothe reinforcement bar surface andbreak down the steelrsquos passivity Manytests have been made to determinethe chloride concentration thresholdvalue on the reinforcement bar sur-face that is required to initiate corro-sion The distribution in the resultsfrom these tests is quite wide and canprobably be explained by differentexperimental methods having beenused as well as different externalenvironmental factors
CORROSION NEWS 3 | 20128
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CORROSION NEWS 3 | 2012 9
Tere is a critical chloride thresholdwhich dictates steel corrosion rate oreach quality o concrete Te corrosionrate is largely determined by the con-
cretersquos moisture content Te moisturecontent affects the concretersquos resistiv-ity and transport o both oxygen andchlorides Te time it takes or chloridesto be transported to the reinorcementbar surace where corrosion beginsis called the initialisation period Apropagation stage begins thereafer seefigure Concrete with high moisturecontent has relatively low resistivity andslow transport o oxygen Te propaga-tion rate is consequently low even i thechloride concentration is significantlyhigher than the chloride threshold val-ue Concrete with low moisture contentexhibits rapid transport o oxygen andhigh resistivity which produces a lowrate o corrosion as well At a specificmoisture interval however the transporto oxygen can be high at the same timeas resistivity is low which produces ahigh corrosion rate It is at this specificmoisture interval that the chloridethreshold values should be determined
Te corrosion rate or steel in water-
saturated concrete constructions isusually low due to slow transporto oxygen to the reinorcement barsurace However i the reinorcementbars are in contact with a more noblematerial the corrosion rate can showa marked increase Te magnitude othe galvanic effects or steel in concreteare determined by among other thingschloride and the oxygen concentrationI the chloride concentration is low thereinorcement bar can maintain passiv-
ity despite electrical contact with a morenoble material and the rate o corrosionwill thus be low In one case sacrificialanodes o aluminum were installedto protect the reinorcement bars in aconcrete construction or transportingseawater Te reinorcement bars wereunintentionally in electrical contactwith pumps made o stainless steel andthe sacrificial anodes rapidly deteriorat-ed Te stainless steel pumps probablytook up a large portion o the protective
current compared with the reinorce-ment bars Tere is thereore a risk that
the reinorcement bars were not beingsufficiently protected by the sacrificialanodes
On this basis a PhD project has beeninitiated to investigate how the moisturecontent in concrete affects the chloridethreshold values as well as to inves-tigate the risk or galvanic corrosion
o steel in concrete Te PhD projectencompasses experimental methodsor determining the chloride threshold
values modeling o corrosion processesand field studies o concrete construc-tions situated in seawater
Application of the resultsTe purpose o the project is to surveyin detail which actors interact inchloride-initialized reinorcement barcorrosion and to establish relevant
threshold values or these Increasedunderstanding and clearer limit valuesor chloride-initialized reinorcementbar corrosion enable more reliable as-sessments o condition
Project informationTe PhD project will be conductedthrough collaboration between SwereaKIMAB and the Faculty o Engineering
at Lund University (LH) Te projectis co-financed by the Elorsk Kaumlrnkrafconcrete programme SBUFrsquos develop-ment und and Swerea KIMAB
ContactJohan Ahlstroumlm
johanahlstroumlmswerease
Schematic diagram of corrosion process for steel in concrete
Test configuration for determining moisture-
contentrsquos effects on the corrosion chloridevalue
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CORROSION NEWS 3 | 201210
The international standards ISO 983097983090983090983091-983097983090983090983094 arethe original source for the corrosivity categoriesC983089ndashC983093 used for the classification of the corro-
sivity of atmospheric environments thus serv-ing as a basis for the choice of corrosionprotection systems for many different indus-trial applications Revised versions of thesestandards were issued in the beginning of983090983088983089983090 including the addition of a new corro-sivity category CX and improved proce-dures for estimating corrosivity categories
A SYSTEM FOR CLASSIFICATION oatmospheric corrosivity is helpul orthe selection o materials and protectionagainst corrosion or estimating thelietime o coatings and materials andcan also serve as a guide when choos-ing appropriate corrosion tests Tecorrosivity categories C983089ndashC983093 are wellaccepted and used when selecting struc-tural metals protective coatings andhave been incorporated in other norma-
tive and guidance documents through-out the world Te system was originallydeveloped in the 983089983097983096983088s and the previous
version o ISO 983097983090983090983091 was dated 983089983097983097983090Tis article gives an overview o thenew versions issued in the beginning o983090983088983089983090 starting with a description o thescientific field work underpinning thestandards
Field exposure programsEven though the standards ISO 983097983090983090983091-
983097983090983090983094 are well accepted they have alsobeen the subject o some criticism Tis
was mainly related to the part o thestandard that describes procedures orestimating corrosivity categories basedon environmental data as opposed tothe more reliable way to determine thecorrosivity category by exposure ostandard specimens Tis was realizedearly and due to the act that the first
versions o the standards were based toa great extent on data rom the temper-ate region
Tereore the ISOCORRAG exposureprogram was initiated It was carriedout by nations involved in the standard-ization work and included 983093983091 test sites in983089983091 countries on our continents It wasconducted during an eight-year period983089983097983096983092ndash983089983097983097983093 and included six subsequentone-year exposures and long-termexposures or 983090 983092 and 983096 years Te datarom this exposure program orm thecore o the data used in the revision oISO 983097983090983090983091 (one-year data) and ISO 983097983090983090983092
(long term data) and has been summa-rized in ldquoISOCORRAG ndash International
Exposure ProgramrdquoISOCORRAG International
Atmospheric Exposure Program Sum-mary o Results Editors Sheldon WDean Dagmar Knotkova KaterinaKreislova ASM
Te MICA exposure program wasorganized and carried out in 983089983097983096983096ndash983089983097983097983090by 983089983092 Iberoamerican countries andcovered 983095983090 test sites Since the MICAprogram more or less ully adopted the
methodology or the ISOCORRAGprogram and in addition covered addi-tional climatic conditions it was naturalto create a common database used orderiving improved ways o estimatingcorrosivity categories based on environ-mental data
Classification determination andestimation (ISO 9223)Corrosion rates exceeding the upperlimit o category C983093 ia 983090983088983088 microm a-983089 or
carbon steel were previously consid-ered out o the scope o the standard
BY JOHAN TIDBLAD AND KATERINA KREI SLOVA
New developments in the
classification of corrosivityof atmospheres
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CORROSION NEWS 3 | 2012 11
During the analysis o the data rom theISOCORRAG and MICA programs itwas realized that several marine sites insubtropicaltropical regions had values
above the upper limit o C983093 Since theseare natural environments that should becovered by the standard a new categoryCX have been added with upper limit983095983088983088 microm a-983089 or carbon steel reerringto specific marine and marineindus-trial environments typically in a warmclimate
Dose-response unctions ie unc-tions giving an estimate o the corrosionrate based on environmental param-eters have been developed or the ISO983097983090983090983091 metals carbon steel zinc copperand aluminum based on measuredannual values o temperature relativehumidity SO983090 concentrationdeposi-tion and chloride deposition Tis isa significant improvement comparedto the previous standard in terms oreliability o predicted corrosivitycategories Even so the standard givesan important distinction between thedetermination (typical error 983093983077) o thecorrosivity category by exposure o
standard specimens and the estimation(typical error 983093983088983077) o the corrosiv -ity category based on environmentalparameters Furthermore the effect o
clean and acid rain was considered atan early stage but could not be includedin the dose-response unctions despitetheir importance or atmosphericcorrosion Tese new unctions are anintegral part o the KorrField databaseand prediction program developed bySwerea KIMAB
Guiding values for the corrosivitycategories (ISO 9224)Te newly issued ISO 983097983090983090983092 providesinstructions or predicting corrosionattack afer extended and long-term ex-posures Detailed ormulas are providedor carbon steel zinc copper and alu-minium and in addition specific criteriato be taken into account or alloyingelements in weathering steels and alloyso zinc copper and aluminium
Measurement of environmentalparameters (ISO 9225)Description o measurements o
environmental parameters ocus ontemperature relative humidity SO983090and salinity since these are given in thedose-response unctions New methods
are considered including or examplepassive samplers or pollutants andconversion actors are given between se-lected pollution measurement methodsTe methodologies to measure envi-ronmental parameters are now similarto those described in ISO 983089983089983096983092983092 whichdeals with classification o low corrosiv-ity o indoor atmospheres
Evaluation of standard specimens(ISO 9226)In the previous version o the standardit was possible to evaluate corrosioneither by exposing flat standard speci-mens or by exposing special wire helixspecimens Since the analysis showedthat they are not equivalent it is nowonly possible to determine the corrosiv-ity category by flat standard specimens
ContactJohan TidbladJohantidbladswerease
About 983093983088 experts romnine countries (Aus-tralia China CzechRepublic France
Germany Japan Korea Swedenand UK) participated the week o983089983089ndash983089983093 June 983090983088983089983090 at the meeting o
ISOC 983089983093983094 Corrosion o met-als and alloys and its 983089983091 workinggroups Te meeting was held atEspace la Rocheoucauld in ParisFrance and was hosted by AFNORthe French standardization bodyTe chairman o the committee isGoumlran Engstroumlm Swerea KIMABand the secretariat is at CMISI inChina
Read more about the results romthe working groups at httpwww
swereaseenStart983090983090Working-AreasovrigtStandardisation
Meeting of ISOTC 156 in Paris in June 2012
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CORROSION NEWS 3 | 201212
CORROSION ON OFFSHORE INSTALLATIONS requires almostconstant maintenance in order to keep structural membersand saety critical elements fit or purpose On board anoffshore installation the corrosivity varies depending on the
height rom sea level and wind direction as well as otherenvironmental effects such as temperature Many companieschoose to repair degraded coatings on the bases o prequalifi-cation tests carried out onshore or in the laboratory and alsoplan maintenance using corrosion rate data rom estimationsor again rom onshore or lab tests Swerea KIMAB is aimingto help companies gain more knowledge about the corrosionrates on their offshore assets and the coatings systems in use
Trough a newly started joint industry project (JIP) SwereaKIMAB is looking at these aspects in which samples o
various materials and coating systems will be placed offshoreand subsequently analysed in order to build up a picture o
corrosivity and coating system effectiveness It is envisionedthat the JIP will be made up o oil and gas operators their
service companies coating manuacturers as well as materialsand equipment manuacturers Te data obtained rom theexperiments will be used by specialists (designers and main-tenance teams) and this will allow them to better understand
the conditions in which their equipment and materials aredesigned to be used Materials and paint companies couldalso have access to unique testing environments that wouldallow them to prove existing products or trial developmentproducts
Tere is a particular requirement to improve the mainte-nance o coatings on offshore installations in the North Seacurrently Te Health and Saety Executive (HSE) in the UKare in the midst o their KP983092 (Key Programme 983092) projectwhich looks at the procedures used by asset owners in regardsto saety and operability In the previous project KP983091 coatingmaintenance (or abric maintenance as it is known in the
industry) was ound to be an area that required significantimprovement Te problem with this type o maintenance is
Offshore corrosivityBY ANDREW GORDON amp MARTIN JOumlNSSON
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CORROSION NEWS 3 | 2012 13
that it requires avourable weather condi-tions and with restrictions on bed spaceor example the logistics o such workbecomes very difficult to manage
Prequalification tests in the environ-mentWith an accurate picture o which areaso an installation corrode aster or sloweroperators can plan their maintenance moreeffectively ensuring resources are allocatedwhere they are most needed as well as al-lowing them to deer maintenance activitiesi required Te selection and use o coatingsystems can be tailored more effectively bycarrying out the prequalification tests inthe environment in which they will be usedrather than just in accelerated laboratorytests or onshore exposures
Swerea KIMAB has a long history oconducting research into materials andcorrosion having successully completedsimilar studies or inrastructure and auto-motive companies Te data obtained hashelped populate the Korrfield database andenabled companies to select materials moreeffectively or the environments in whichthey operate Te previous studies involvedplacing samples in very hostile environ-
ments such as on the underside o heavygood vehicles and so provides SwereaKIMAB with the expertise or ensuringsamples are saely exposed and easy toevaluate
Focussed on oil and gas operatorsTe first round o meetings with companieshas been completed and has been ocussedon oil and gas operators based in AberdeenUK However the aim is to encompass asmany participants as possible in order to
generate a data set that will be useul notonly to current installations in the NorthSea but also to new projects and otherregions o the world I you are a paint com-pany materials manuacturer equipmentmanuacturer or have an influence on theuse andor maintenance o materials usedin the offshore environment this projectcould be o benefit to you Please eel ree toget in contact i you wish to learn more
Contact
andrewgordonSwereasemartinjonssonswerease
Maintenance scheduling should take into account known degradation ratesof materials and coating systems in operating environments
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CORROSION NEWS 3 | 201214
BY MARIA AringSLUND
A nuclear power station can contain some fairly aggressiveenvironments for materials and it is vital in these environ-ments to try and avoid material failures Thomas Blomfeldtof Swerea KIMAB keeps a check on the condition of thepolymer materials at nuclear sites
RISKS IN NUCLEAR POWER stations areofen associated with meltdowns like atChernobyl or last year at Fukushima -a nightmare scenario that is thankullya rare occurrence However even smallequipment ailures can result in bigproblems or the operators such as pro-duction losses or injury to personnelFor that reason saety and reliability areparamount and this philosophy filtersdown to every component in the system
including nuts bolts and gasketsldquoTe saety margins specified by the
nuclear power station owners have beenset or very good reasons At the sametime or financial reasons they do notwant to replace materials unnecessarilyrdquosays Tomas Blomeldt who has thetask o determining the remaining ser-
vice lie o a rubber joint or exampleSwerea KIMAB has several teams
working on inspecting different typeso material Tomas specialises inpolymers both as an expert at Swerea
KIMAB and as a research scientist 983096983088per cent o his working hours involve
inspecting and evaluating samplesrom nuclear power stations Tomasis a requent visitor at Swedenrsquos threenuclear power stations this year he hasinspected seven out o the total o tenreactors
rdquoPlastic and rubber may not bewhat you first think o when you see anuclear power station However thereare large quantities o polymers thereIn a reactor building the cables alone
correspond to the street lighting systemo a medium-sized Swedish town In ad-
The smallest componentmust be reliable
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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CORROSION NEWS 3 | 2012 9
Tere is a critical chloride thresholdwhich dictates steel corrosion rate oreach quality o concrete Te corrosionrate is largely determined by the con-
cretersquos moisture content Te moisturecontent affects the concretersquos resistiv-ity and transport o both oxygen andchlorides Te time it takes or chloridesto be transported to the reinorcementbar surace where corrosion beginsis called the initialisation period Apropagation stage begins thereafer seefigure Concrete with high moisturecontent has relatively low resistivity andslow transport o oxygen Te propaga-tion rate is consequently low even i thechloride concentration is significantlyhigher than the chloride threshold val-ue Concrete with low moisture contentexhibits rapid transport o oxygen andhigh resistivity which produces a lowrate o corrosion as well At a specificmoisture interval however the transporto oxygen can be high at the same timeas resistivity is low which produces ahigh corrosion rate It is at this specificmoisture interval that the chloridethreshold values should be determined
Te corrosion rate or steel in water-
saturated concrete constructions isusually low due to slow transporto oxygen to the reinorcement barsurace However i the reinorcementbars are in contact with a more noblematerial the corrosion rate can showa marked increase Te magnitude othe galvanic effects or steel in concreteare determined by among other thingschloride and the oxygen concentrationI the chloride concentration is low thereinorcement bar can maintain passiv-
ity despite electrical contact with a morenoble material and the rate o corrosionwill thus be low In one case sacrificialanodes o aluminum were installedto protect the reinorcement bars in aconcrete construction or transportingseawater Te reinorcement bars wereunintentionally in electrical contactwith pumps made o stainless steel andthe sacrificial anodes rapidly deteriorat-ed Te stainless steel pumps probablytook up a large portion o the protective
current compared with the reinorce-ment bars Tere is thereore a risk that
the reinorcement bars were not beingsufficiently protected by the sacrificialanodes
On this basis a PhD project has beeninitiated to investigate how the moisturecontent in concrete affects the chloridethreshold values as well as to inves-tigate the risk or galvanic corrosion
o steel in concrete Te PhD projectencompasses experimental methodsor determining the chloride threshold
values modeling o corrosion processesand field studies o concrete construc-tions situated in seawater
Application of the resultsTe purpose o the project is to surveyin detail which actors interact inchloride-initialized reinorcement barcorrosion and to establish relevant
threshold values or these Increasedunderstanding and clearer limit valuesor chloride-initialized reinorcementbar corrosion enable more reliable as-sessments o condition
Project informationTe PhD project will be conductedthrough collaboration between SwereaKIMAB and the Faculty o Engineering
at Lund University (LH) Te projectis co-financed by the Elorsk Kaumlrnkrafconcrete programme SBUFrsquos develop-ment und and Swerea KIMAB
ContactJohan Ahlstroumlm
johanahlstroumlmswerease
Schematic diagram of corrosion process for steel in concrete
Test configuration for determining moisture-
contentrsquos effects on the corrosion chloridevalue
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CORROSION NEWS 3 | 201210
The international standards ISO 983097983090983090983091-983097983090983090983094 arethe original source for the corrosivity categoriesC983089ndashC983093 used for the classification of the corro-
sivity of atmospheric environments thus serv-ing as a basis for the choice of corrosionprotection systems for many different indus-trial applications Revised versions of thesestandards were issued in the beginning of983090983088983089983090 including the addition of a new corro-sivity category CX and improved proce-dures for estimating corrosivity categories
A SYSTEM FOR CLASSIFICATION oatmospheric corrosivity is helpul orthe selection o materials and protectionagainst corrosion or estimating thelietime o coatings and materials andcan also serve as a guide when choos-ing appropriate corrosion tests Tecorrosivity categories C983089ndashC983093 are wellaccepted and used when selecting struc-tural metals protective coatings andhave been incorporated in other norma-
tive and guidance documents through-out the world Te system was originallydeveloped in the 983089983097983096983088s and the previous
version o ISO 983097983090983090983091 was dated 983089983097983097983090Tis article gives an overview o thenew versions issued in the beginning o983090983088983089983090 starting with a description o thescientific field work underpinning thestandards
Field exposure programsEven though the standards ISO 983097983090983090983091-
983097983090983090983094 are well accepted they have alsobeen the subject o some criticism Tis
was mainly related to the part o thestandard that describes procedures orestimating corrosivity categories basedon environmental data as opposed tothe more reliable way to determine thecorrosivity category by exposure ostandard specimens Tis was realizedearly and due to the act that the first
versions o the standards were based toa great extent on data rom the temper-ate region
Tereore the ISOCORRAG exposureprogram was initiated It was carriedout by nations involved in the standard-ization work and included 983093983091 test sites in983089983091 countries on our continents It wasconducted during an eight-year period983089983097983096983092ndash983089983097983097983093 and included six subsequentone-year exposures and long-termexposures or 983090 983092 and 983096 years Te datarom this exposure program orm thecore o the data used in the revision oISO 983097983090983090983091 (one-year data) and ISO 983097983090983090983092
(long term data) and has been summa-rized in ldquoISOCORRAG ndash International
Exposure ProgramrdquoISOCORRAG International
Atmospheric Exposure Program Sum-mary o Results Editors Sheldon WDean Dagmar Knotkova KaterinaKreislova ASM
Te MICA exposure program wasorganized and carried out in 983089983097983096983096ndash983089983097983097983090by 983089983092 Iberoamerican countries andcovered 983095983090 test sites Since the MICAprogram more or less ully adopted the
methodology or the ISOCORRAGprogram and in addition covered addi-tional climatic conditions it was naturalto create a common database used orderiving improved ways o estimatingcorrosivity categories based on environ-mental data
Classification determination andestimation (ISO 9223)Corrosion rates exceeding the upperlimit o category C983093 ia 983090983088983088 microm a-983089 or
carbon steel were previously consid-ered out o the scope o the standard
BY JOHAN TIDBLAD AND KATERINA KREI SLOVA
New developments in the
classification of corrosivityof atmospheres
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CORROSION NEWS 3 | 2012 11
During the analysis o the data rom theISOCORRAG and MICA programs itwas realized that several marine sites insubtropicaltropical regions had values
above the upper limit o C983093 Since theseare natural environments that should becovered by the standard a new categoryCX have been added with upper limit983095983088983088 microm a-983089 or carbon steel reerringto specific marine and marineindus-trial environments typically in a warmclimate
Dose-response unctions ie unc-tions giving an estimate o the corrosionrate based on environmental param-eters have been developed or the ISO983097983090983090983091 metals carbon steel zinc copperand aluminum based on measuredannual values o temperature relativehumidity SO983090 concentrationdeposi-tion and chloride deposition Tis isa significant improvement comparedto the previous standard in terms oreliability o predicted corrosivitycategories Even so the standard givesan important distinction between thedetermination (typical error 983093983077) o thecorrosivity category by exposure o
standard specimens and the estimation(typical error 983093983088983077) o the corrosiv -ity category based on environmentalparameters Furthermore the effect o
clean and acid rain was considered atan early stage but could not be includedin the dose-response unctions despitetheir importance or atmosphericcorrosion Tese new unctions are anintegral part o the KorrField databaseand prediction program developed bySwerea KIMAB
Guiding values for the corrosivitycategories (ISO 9224)Te newly issued ISO 983097983090983090983092 providesinstructions or predicting corrosionattack afer extended and long-term ex-posures Detailed ormulas are providedor carbon steel zinc copper and alu-minium and in addition specific criteriato be taken into account or alloyingelements in weathering steels and alloyso zinc copper and aluminium
Measurement of environmentalparameters (ISO 9225)Description o measurements o
environmental parameters ocus ontemperature relative humidity SO983090and salinity since these are given in thedose-response unctions New methods
are considered including or examplepassive samplers or pollutants andconversion actors are given between se-lected pollution measurement methodsTe methodologies to measure envi-ronmental parameters are now similarto those described in ISO 983089983089983096983092983092 whichdeals with classification o low corrosiv-ity o indoor atmospheres
Evaluation of standard specimens(ISO 9226)In the previous version o the standardit was possible to evaluate corrosioneither by exposing flat standard speci-mens or by exposing special wire helixspecimens Since the analysis showedthat they are not equivalent it is nowonly possible to determine the corrosiv-ity category by flat standard specimens
ContactJohan TidbladJohantidbladswerease
About 983093983088 experts romnine countries (Aus-tralia China CzechRepublic France
Germany Japan Korea Swedenand UK) participated the week o983089983089ndash983089983093 June 983090983088983089983090 at the meeting o
ISOC 983089983093983094 Corrosion o met-als and alloys and its 983089983091 workinggroups Te meeting was held atEspace la Rocheoucauld in ParisFrance and was hosted by AFNORthe French standardization bodyTe chairman o the committee isGoumlran Engstroumlm Swerea KIMABand the secretariat is at CMISI inChina
Read more about the results romthe working groups at httpwww
swereaseenStart983090983090Working-AreasovrigtStandardisation
Meeting of ISOTC 156 in Paris in June 2012
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CORROSION NEWS 3 | 201212
CORROSION ON OFFSHORE INSTALLATIONS requires almostconstant maintenance in order to keep structural membersand saety critical elements fit or purpose On board anoffshore installation the corrosivity varies depending on the
height rom sea level and wind direction as well as otherenvironmental effects such as temperature Many companieschoose to repair degraded coatings on the bases o prequalifi-cation tests carried out onshore or in the laboratory and alsoplan maintenance using corrosion rate data rom estimationsor again rom onshore or lab tests Swerea KIMAB is aimingto help companies gain more knowledge about the corrosionrates on their offshore assets and the coatings systems in use
Trough a newly started joint industry project (JIP) SwereaKIMAB is looking at these aspects in which samples o
various materials and coating systems will be placed offshoreand subsequently analysed in order to build up a picture o
corrosivity and coating system effectiveness It is envisionedthat the JIP will be made up o oil and gas operators their
service companies coating manuacturers as well as materialsand equipment manuacturers Te data obtained rom theexperiments will be used by specialists (designers and main-tenance teams) and this will allow them to better understand
the conditions in which their equipment and materials aredesigned to be used Materials and paint companies couldalso have access to unique testing environments that wouldallow them to prove existing products or trial developmentproducts
Tere is a particular requirement to improve the mainte-nance o coatings on offshore installations in the North Seacurrently Te Health and Saety Executive (HSE) in the UKare in the midst o their KP983092 (Key Programme 983092) projectwhich looks at the procedures used by asset owners in regardsto saety and operability In the previous project KP983091 coatingmaintenance (or abric maintenance as it is known in the
industry) was ound to be an area that required significantimprovement Te problem with this type o maintenance is
Offshore corrosivityBY ANDREW GORDON amp MARTIN JOumlNSSON
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CORROSION NEWS 3 | 2012 13
that it requires avourable weather condi-tions and with restrictions on bed spaceor example the logistics o such workbecomes very difficult to manage
Prequalification tests in the environ-mentWith an accurate picture o which areaso an installation corrode aster or sloweroperators can plan their maintenance moreeffectively ensuring resources are allocatedwhere they are most needed as well as al-lowing them to deer maintenance activitiesi required Te selection and use o coatingsystems can be tailored more effectively bycarrying out the prequalification tests inthe environment in which they will be usedrather than just in accelerated laboratorytests or onshore exposures
Swerea KIMAB has a long history oconducting research into materials andcorrosion having successully completedsimilar studies or inrastructure and auto-motive companies Te data obtained hashelped populate the Korrfield database andenabled companies to select materials moreeffectively or the environments in whichthey operate Te previous studies involvedplacing samples in very hostile environ-
ments such as on the underside o heavygood vehicles and so provides SwereaKIMAB with the expertise or ensuringsamples are saely exposed and easy toevaluate
Focussed on oil and gas operatorsTe first round o meetings with companieshas been completed and has been ocussedon oil and gas operators based in AberdeenUK However the aim is to encompass asmany participants as possible in order to
generate a data set that will be useul notonly to current installations in the NorthSea but also to new projects and otherregions o the world I you are a paint com-pany materials manuacturer equipmentmanuacturer or have an influence on theuse andor maintenance o materials usedin the offshore environment this projectcould be o benefit to you Please eel ree toget in contact i you wish to learn more
Contact
andrewgordonSwereasemartinjonssonswerease
Maintenance scheduling should take into account known degradation ratesof materials and coating systems in operating environments
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CORROSION NEWS 3 | 201214
BY MARIA AringSLUND
A nuclear power station can contain some fairly aggressiveenvironments for materials and it is vital in these environ-ments to try and avoid material failures Thomas Blomfeldtof Swerea KIMAB keeps a check on the condition of thepolymer materials at nuclear sites
RISKS IN NUCLEAR POWER stations areofen associated with meltdowns like atChernobyl or last year at Fukushima -a nightmare scenario that is thankullya rare occurrence However even smallequipment ailures can result in bigproblems or the operators such as pro-duction losses or injury to personnelFor that reason saety and reliability areparamount and this philosophy filtersdown to every component in the system
including nuts bolts and gasketsldquoTe saety margins specified by the
nuclear power station owners have beenset or very good reasons At the sametime or financial reasons they do notwant to replace materials unnecessarilyrdquosays Tomas Blomeldt who has thetask o determining the remaining ser-
vice lie o a rubber joint or exampleSwerea KIMAB has several teams
working on inspecting different typeso material Tomas specialises inpolymers both as an expert at Swerea
KIMAB and as a research scientist 983096983088per cent o his working hours involve
inspecting and evaluating samplesrom nuclear power stations Tomasis a requent visitor at Swedenrsquos threenuclear power stations this year he hasinspected seven out o the total o tenreactors
rdquoPlastic and rubber may not bewhat you first think o when you see anuclear power station However thereare large quantities o polymers thereIn a reactor building the cables alone
correspond to the street lighting systemo a medium-sized Swedish town In ad-
The smallest componentmust be reliable
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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CORROSION NEWS 3 | 201210
The international standards ISO 983097983090983090983091-983097983090983090983094 arethe original source for the corrosivity categoriesC983089ndashC983093 used for the classification of the corro-
sivity of atmospheric environments thus serv-ing as a basis for the choice of corrosionprotection systems for many different indus-trial applications Revised versions of thesestandards were issued in the beginning of983090983088983089983090 including the addition of a new corro-sivity category CX and improved proce-dures for estimating corrosivity categories
A SYSTEM FOR CLASSIFICATION oatmospheric corrosivity is helpul orthe selection o materials and protectionagainst corrosion or estimating thelietime o coatings and materials andcan also serve as a guide when choos-ing appropriate corrosion tests Tecorrosivity categories C983089ndashC983093 are wellaccepted and used when selecting struc-tural metals protective coatings andhave been incorporated in other norma-
tive and guidance documents through-out the world Te system was originallydeveloped in the 983089983097983096983088s and the previous
version o ISO 983097983090983090983091 was dated 983089983097983097983090Tis article gives an overview o thenew versions issued in the beginning o983090983088983089983090 starting with a description o thescientific field work underpinning thestandards
Field exposure programsEven though the standards ISO 983097983090983090983091-
983097983090983090983094 are well accepted they have alsobeen the subject o some criticism Tis
was mainly related to the part o thestandard that describes procedures orestimating corrosivity categories basedon environmental data as opposed tothe more reliable way to determine thecorrosivity category by exposure ostandard specimens Tis was realizedearly and due to the act that the first
versions o the standards were based toa great extent on data rom the temper-ate region
Tereore the ISOCORRAG exposureprogram was initiated It was carriedout by nations involved in the standard-ization work and included 983093983091 test sites in983089983091 countries on our continents It wasconducted during an eight-year period983089983097983096983092ndash983089983097983097983093 and included six subsequentone-year exposures and long-termexposures or 983090 983092 and 983096 years Te datarom this exposure program orm thecore o the data used in the revision oISO 983097983090983090983091 (one-year data) and ISO 983097983090983090983092
(long term data) and has been summa-rized in ldquoISOCORRAG ndash International
Exposure ProgramrdquoISOCORRAG International
Atmospheric Exposure Program Sum-mary o Results Editors Sheldon WDean Dagmar Knotkova KaterinaKreislova ASM
Te MICA exposure program wasorganized and carried out in 983089983097983096983096ndash983089983097983097983090by 983089983092 Iberoamerican countries andcovered 983095983090 test sites Since the MICAprogram more or less ully adopted the
methodology or the ISOCORRAGprogram and in addition covered addi-tional climatic conditions it was naturalto create a common database used orderiving improved ways o estimatingcorrosivity categories based on environ-mental data
Classification determination andestimation (ISO 9223)Corrosion rates exceeding the upperlimit o category C983093 ia 983090983088983088 microm a-983089 or
carbon steel were previously consid-ered out o the scope o the standard
BY JOHAN TIDBLAD AND KATERINA KREI SLOVA
New developments in the
classification of corrosivityof atmospheres
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CORROSION NEWS 3 | 2012 11
During the analysis o the data rom theISOCORRAG and MICA programs itwas realized that several marine sites insubtropicaltropical regions had values
above the upper limit o C983093 Since theseare natural environments that should becovered by the standard a new categoryCX have been added with upper limit983095983088983088 microm a-983089 or carbon steel reerringto specific marine and marineindus-trial environments typically in a warmclimate
Dose-response unctions ie unc-tions giving an estimate o the corrosionrate based on environmental param-eters have been developed or the ISO983097983090983090983091 metals carbon steel zinc copperand aluminum based on measuredannual values o temperature relativehumidity SO983090 concentrationdeposi-tion and chloride deposition Tis isa significant improvement comparedto the previous standard in terms oreliability o predicted corrosivitycategories Even so the standard givesan important distinction between thedetermination (typical error 983093983077) o thecorrosivity category by exposure o
standard specimens and the estimation(typical error 983093983088983077) o the corrosiv -ity category based on environmentalparameters Furthermore the effect o
clean and acid rain was considered atan early stage but could not be includedin the dose-response unctions despitetheir importance or atmosphericcorrosion Tese new unctions are anintegral part o the KorrField databaseand prediction program developed bySwerea KIMAB
Guiding values for the corrosivitycategories (ISO 9224)Te newly issued ISO 983097983090983090983092 providesinstructions or predicting corrosionattack afer extended and long-term ex-posures Detailed ormulas are providedor carbon steel zinc copper and alu-minium and in addition specific criteriato be taken into account or alloyingelements in weathering steels and alloyso zinc copper and aluminium
Measurement of environmentalparameters (ISO 9225)Description o measurements o
environmental parameters ocus ontemperature relative humidity SO983090and salinity since these are given in thedose-response unctions New methods
are considered including or examplepassive samplers or pollutants andconversion actors are given between se-lected pollution measurement methodsTe methodologies to measure envi-ronmental parameters are now similarto those described in ISO 983089983089983096983092983092 whichdeals with classification o low corrosiv-ity o indoor atmospheres
Evaluation of standard specimens(ISO 9226)In the previous version o the standardit was possible to evaluate corrosioneither by exposing flat standard speci-mens or by exposing special wire helixspecimens Since the analysis showedthat they are not equivalent it is nowonly possible to determine the corrosiv-ity category by flat standard specimens
ContactJohan TidbladJohantidbladswerease
About 983093983088 experts romnine countries (Aus-tralia China CzechRepublic France
Germany Japan Korea Swedenand UK) participated the week o983089983089ndash983089983093 June 983090983088983089983090 at the meeting o
ISOC 983089983093983094 Corrosion o met-als and alloys and its 983089983091 workinggroups Te meeting was held atEspace la Rocheoucauld in ParisFrance and was hosted by AFNORthe French standardization bodyTe chairman o the committee isGoumlran Engstroumlm Swerea KIMABand the secretariat is at CMISI inChina
Read more about the results romthe working groups at httpwww
swereaseenStart983090983090Working-AreasovrigtStandardisation
Meeting of ISOTC 156 in Paris in June 2012
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CORROSION NEWS 3 | 201212
CORROSION ON OFFSHORE INSTALLATIONS requires almostconstant maintenance in order to keep structural membersand saety critical elements fit or purpose On board anoffshore installation the corrosivity varies depending on the
height rom sea level and wind direction as well as otherenvironmental effects such as temperature Many companieschoose to repair degraded coatings on the bases o prequalifi-cation tests carried out onshore or in the laboratory and alsoplan maintenance using corrosion rate data rom estimationsor again rom onshore or lab tests Swerea KIMAB is aimingto help companies gain more knowledge about the corrosionrates on their offshore assets and the coatings systems in use
Trough a newly started joint industry project (JIP) SwereaKIMAB is looking at these aspects in which samples o
various materials and coating systems will be placed offshoreand subsequently analysed in order to build up a picture o
corrosivity and coating system effectiveness It is envisionedthat the JIP will be made up o oil and gas operators their
service companies coating manuacturers as well as materialsand equipment manuacturers Te data obtained rom theexperiments will be used by specialists (designers and main-tenance teams) and this will allow them to better understand
the conditions in which their equipment and materials aredesigned to be used Materials and paint companies couldalso have access to unique testing environments that wouldallow them to prove existing products or trial developmentproducts
Tere is a particular requirement to improve the mainte-nance o coatings on offshore installations in the North Seacurrently Te Health and Saety Executive (HSE) in the UKare in the midst o their KP983092 (Key Programme 983092) projectwhich looks at the procedures used by asset owners in regardsto saety and operability In the previous project KP983091 coatingmaintenance (or abric maintenance as it is known in the
industry) was ound to be an area that required significantimprovement Te problem with this type o maintenance is
Offshore corrosivityBY ANDREW GORDON amp MARTIN JOumlNSSON
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CORROSION NEWS 3 | 2012 13
that it requires avourable weather condi-tions and with restrictions on bed spaceor example the logistics o such workbecomes very difficult to manage
Prequalification tests in the environ-mentWith an accurate picture o which areaso an installation corrode aster or sloweroperators can plan their maintenance moreeffectively ensuring resources are allocatedwhere they are most needed as well as al-lowing them to deer maintenance activitiesi required Te selection and use o coatingsystems can be tailored more effectively bycarrying out the prequalification tests inthe environment in which they will be usedrather than just in accelerated laboratorytests or onshore exposures
Swerea KIMAB has a long history oconducting research into materials andcorrosion having successully completedsimilar studies or inrastructure and auto-motive companies Te data obtained hashelped populate the Korrfield database andenabled companies to select materials moreeffectively or the environments in whichthey operate Te previous studies involvedplacing samples in very hostile environ-
ments such as on the underside o heavygood vehicles and so provides SwereaKIMAB with the expertise or ensuringsamples are saely exposed and easy toevaluate
Focussed on oil and gas operatorsTe first round o meetings with companieshas been completed and has been ocussedon oil and gas operators based in AberdeenUK However the aim is to encompass asmany participants as possible in order to
generate a data set that will be useul notonly to current installations in the NorthSea but also to new projects and otherregions o the world I you are a paint com-pany materials manuacturer equipmentmanuacturer or have an influence on theuse andor maintenance o materials usedin the offshore environment this projectcould be o benefit to you Please eel ree toget in contact i you wish to learn more
Contact
andrewgordonSwereasemartinjonssonswerease
Maintenance scheduling should take into account known degradation ratesof materials and coating systems in operating environments
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CORROSION NEWS 3 | 201214
BY MARIA AringSLUND
A nuclear power station can contain some fairly aggressiveenvironments for materials and it is vital in these environ-ments to try and avoid material failures Thomas Blomfeldtof Swerea KIMAB keeps a check on the condition of thepolymer materials at nuclear sites
RISKS IN NUCLEAR POWER stations areofen associated with meltdowns like atChernobyl or last year at Fukushima -a nightmare scenario that is thankullya rare occurrence However even smallequipment ailures can result in bigproblems or the operators such as pro-duction losses or injury to personnelFor that reason saety and reliability areparamount and this philosophy filtersdown to every component in the system
including nuts bolts and gasketsldquoTe saety margins specified by the
nuclear power station owners have beenset or very good reasons At the sametime or financial reasons they do notwant to replace materials unnecessarilyrdquosays Tomas Blomeldt who has thetask o determining the remaining ser-
vice lie o a rubber joint or exampleSwerea KIMAB has several teams
working on inspecting different typeso material Tomas specialises inpolymers both as an expert at Swerea
KIMAB and as a research scientist 983096983088per cent o his working hours involve
inspecting and evaluating samplesrom nuclear power stations Tomasis a requent visitor at Swedenrsquos threenuclear power stations this year he hasinspected seven out o the total o tenreactors
rdquoPlastic and rubber may not bewhat you first think o when you see anuclear power station However thereare large quantities o polymers thereIn a reactor building the cables alone
correspond to the street lighting systemo a medium-sized Swedish town In ad-
The smallest componentmust be reliable
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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CORROSION NEWS 3 | 2012 11
During the analysis o the data rom theISOCORRAG and MICA programs itwas realized that several marine sites insubtropicaltropical regions had values
above the upper limit o C983093 Since theseare natural environments that should becovered by the standard a new categoryCX have been added with upper limit983095983088983088 microm a-983089 or carbon steel reerringto specific marine and marineindus-trial environments typically in a warmclimate
Dose-response unctions ie unc-tions giving an estimate o the corrosionrate based on environmental param-eters have been developed or the ISO983097983090983090983091 metals carbon steel zinc copperand aluminum based on measuredannual values o temperature relativehumidity SO983090 concentrationdeposi-tion and chloride deposition Tis isa significant improvement comparedto the previous standard in terms oreliability o predicted corrosivitycategories Even so the standard givesan important distinction between thedetermination (typical error 983093983077) o thecorrosivity category by exposure o
standard specimens and the estimation(typical error 983093983088983077) o the corrosiv -ity category based on environmentalparameters Furthermore the effect o
clean and acid rain was considered atan early stage but could not be includedin the dose-response unctions despitetheir importance or atmosphericcorrosion Tese new unctions are anintegral part o the KorrField databaseand prediction program developed bySwerea KIMAB
Guiding values for the corrosivitycategories (ISO 9224)Te newly issued ISO 983097983090983090983092 providesinstructions or predicting corrosionattack afer extended and long-term ex-posures Detailed ormulas are providedor carbon steel zinc copper and alu-minium and in addition specific criteriato be taken into account or alloyingelements in weathering steels and alloyso zinc copper and aluminium
Measurement of environmentalparameters (ISO 9225)Description o measurements o
environmental parameters ocus ontemperature relative humidity SO983090and salinity since these are given in thedose-response unctions New methods
are considered including or examplepassive samplers or pollutants andconversion actors are given between se-lected pollution measurement methodsTe methodologies to measure envi-ronmental parameters are now similarto those described in ISO 983089983089983096983092983092 whichdeals with classification o low corrosiv-ity o indoor atmospheres
Evaluation of standard specimens(ISO 9226)In the previous version o the standardit was possible to evaluate corrosioneither by exposing flat standard speci-mens or by exposing special wire helixspecimens Since the analysis showedthat they are not equivalent it is nowonly possible to determine the corrosiv-ity category by flat standard specimens
ContactJohan TidbladJohantidbladswerease
About 983093983088 experts romnine countries (Aus-tralia China CzechRepublic France
Germany Japan Korea Swedenand UK) participated the week o983089983089ndash983089983093 June 983090983088983089983090 at the meeting o
ISOC 983089983093983094 Corrosion o met-als and alloys and its 983089983091 workinggroups Te meeting was held atEspace la Rocheoucauld in ParisFrance and was hosted by AFNORthe French standardization bodyTe chairman o the committee isGoumlran Engstroumlm Swerea KIMABand the secretariat is at CMISI inChina
Read more about the results romthe working groups at httpwww
swereaseenStart983090983090Working-AreasovrigtStandardisation
Meeting of ISOTC 156 in Paris in June 2012
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CORROSION NEWS 3 | 201212
CORROSION ON OFFSHORE INSTALLATIONS requires almostconstant maintenance in order to keep structural membersand saety critical elements fit or purpose On board anoffshore installation the corrosivity varies depending on the
height rom sea level and wind direction as well as otherenvironmental effects such as temperature Many companieschoose to repair degraded coatings on the bases o prequalifi-cation tests carried out onshore or in the laboratory and alsoplan maintenance using corrosion rate data rom estimationsor again rom onshore or lab tests Swerea KIMAB is aimingto help companies gain more knowledge about the corrosionrates on their offshore assets and the coatings systems in use
Trough a newly started joint industry project (JIP) SwereaKIMAB is looking at these aspects in which samples o
various materials and coating systems will be placed offshoreand subsequently analysed in order to build up a picture o
corrosivity and coating system effectiveness It is envisionedthat the JIP will be made up o oil and gas operators their
service companies coating manuacturers as well as materialsand equipment manuacturers Te data obtained rom theexperiments will be used by specialists (designers and main-tenance teams) and this will allow them to better understand
the conditions in which their equipment and materials aredesigned to be used Materials and paint companies couldalso have access to unique testing environments that wouldallow them to prove existing products or trial developmentproducts
Tere is a particular requirement to improve the mainte-nance o coatings on offshore installations in the North Seacurrently Te Health and Saety Executive (HSE) in the UKare in the midst o their KP983092 (Key Programme 983092) projectwhich looks at the procedures used by asset owners in regardsto saety and operability In the previous project KP983091 coatingmaintenance (or abric maintenance as it is known in the
industry) was ound to be an area that required significantimprovement Te problem with this type o maintenance is
Offshore corrosivityBY ANDREW GORDON amp MARTIN JOumlNSSON
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CORROSION NEWS 3 | 2012 13
that it requires avourable weather condi-tions and with restrictions on bed spaceor example the logistics o such workbecomes very difficult to manage
Prequalification tests in the environ-mentWith an accurate picture o which areaso an installation corrode aster or sloweroperators can plan their maintenance moreeffectively ensuring resources are allocatedwhere they are most needed as well as al-lowing them to deer maintenance activitiesi required Te selection and use o coatingsystems can be tailored more effectively bycarrying out the prequalification tests inthe environment in which they will be usedrather than just in accelerated laboratorytests or onshore exposures
Swerea KIMAB has a long history oconducting research into materials andcorrosion having successully completedsimilar studies or inrastructure and auto-motive companies Te data obtained hashelped populate the Korrfield database andenabled companies to select materials moreeffectively or the environments in whichthey operate Te previous studies involvedplacing samples in very hostile environ-
ments such as on the underside o heavygood vehicles and so provides SwereaKIMAB with the expertise or ensuringsamples are saely exposed and easy toevaluate
Focussed on oil and gas operatorsTe first round o meetings with companieshas been completed and has been ocussedon oil and gas operators based in AberdeenUK However the aim is to encompass asmany participants as possible in order to
generate a data set that will be useul notonly to current installations in the NorthSea but also to new projects and otherregions o the world I you are a paint com-pany materials manuacturer equipmentmanuacturer or have an influence on theuse andor maintenance o materials usedin the offshore environment this projectcould be o benefit to you Please eel ree toget in contact i you wish to learn more
Contact
andrewgordonSwereasemartinjonssonswerease
Maintenance scheduling should take into account known degradation ratesof materials and coating systems in operating environments
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CORROSION NEWS 3 | 201214
BY MARIA AringSLUND
A nuclear power station can contain some fairly aggressiveenvironments for materials and it is vital in these environ-ments to try and avoid material failures Thomas Blomfeldtof Swerea KIMAB keeps a check on the condition of thepolymer materials at nuclear sites
RISKS IN NUCLEAR POWER stations areofen associated with meltdowns like atChernobyl or last year at Fukushima -a nightmare scenario that is thankullya rare occurrence However even smallequipment ailures can result in bigproblems or the operators such as pro-duction losses or injury to personnelFor that reason saety and reliability areparamount and this philosophy filtersdown to every component in the system
including nuts bolts and gasketsldquoTe saety margins specified by the
nuclear power station owners have beenset or very good reasons At the sametime or financial reasons they do notwant to replace materials unnecessarilyrdquosays Tomas Blomeldt who has thetask o determining the remaining ser-
vice lie o a rubber joint or exampleSwerea KIMAB has several teams
working on inspecting different typeso material Tomas specialises inpolymers both as an expert at Swerea
KIMAB and as a research scientist 983096983088per cent o his working hours involve
inspecting and evaluating samplesrom nuclear power stations Tomasis a requent visitor at Swedenrsquos threenuclear power stations this year he hasinspected seven out o the total o tenreactors
rdquoPlastic and rubber may not bewhat you first think o when you see anuclear power station However thereare large quantities o polymers thereIn a reactor building the cables alone
correspond to the street lighting systemo a medium-sized Swedish town In ad-
The smallest componentmust be reliable
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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CORROSION NEWS 3 | 201212
CORROSION ON OFFSHORE INSTALLATIONS requires almostconstant maintenance in order to keep structural membersand saety critical elements fit or purpose On board anoffshore installation the corrosivity varies depending on the
height rom sea level and wind direction as well as otherenvironmental effects such as temperature Many companieschoose to repair degraded coatings on the bases o prequalifi-cation tests carried out onshore or in the laboratory and alsoplan maintenance using corrosion rate data rom estimationsor again rom onshore or lab tests Swerea KIMAB is aimingto help companies gain more knowledge about the corrosionrates on their offshore assets and the coatings systems in use
Trough a newly started joint industry project (JIP) SwereaKIMAB is looking at these aspects in which samples o
various materials and coating systems will be placed offshoreand subsequently analysed in order to build up a picture o
corrosivity and coating system effectiveness It is envisionedthat the JIP will be made up o oil and gas operators their
service companies coating manuacturers as well as materialsand equipment manuacturers Te data obtained rom theexperiments will be used by specialists (designers and main-tenance teams) and this will allow them to better understand
the conditions in which their equipment and materials aredesigned to be used Materials and paint companies couldalso have access to unique testing environments that wouldallow them to prove existing products or trial developmentproducts
Tere is a particular requirement to improve the mainte-nance o coatings on offshore installations in the North Seacurrently Te Health and Saety Executive (HSE) in the UKare in the midst o their KP983092 (Key Programme 983092) projectwhich looks at the procedures used by asset owners in regardsto saety and operability In the previous project KP983091 coatingmaintenance (or abric maintenance as it is known in the
industry) was ound to be an area that required significantimprovement Te problem with this type o maintenance is
Offshore corrosivityBY ANDREW GORDON amp MARTIN JOumlNSSON
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CORROSION NEWS 3 | 2012 13
that it requires avourable weather condi-tions and with restrictions on bed spaceor example the logistics o such workbecomes very difficult to manage
Prequalification tests in the environ-mentWith an accurate picture o which areaso an installation corrode aster or sloweroperators can plan their maintenance moreeffectively ensuring resources are allocatedwhere they are most needed as well as al-lowing them to deer maintenance activitiesi required Te selection and use o coatingsystems can be tailored more effectively bycarrying out the prequalification tests inthe environment in which they will be usedrather than just in accelerated laboratorytests or onshore exposures
Swerea KIMAB has a long history oconducting research into materials andcorrosion having successully completedsimilar studies or inrastructure and auto-motive companies Te data obtained hashelped populate the Korrfield database andenabled companies to select materials moreeffectively or the environments in whichthey operate Te previous studies involvedplacing samples in very hostile environ-
ments such as on the underside o heavygood vehicles and so provides SwereaKIMAB with the expertise or ensuringsamples are saely exposed and easy toevaluate
Focussed on oil and gas operatorsTe first round o meetings with companieshas been completed and has been ocussedon oil and gas operators based in AberdeenUK However the aim is to encompass asmany participants as possible in order to
generate a data set that will be useul notonly to current installations in the NorthSea but also to new projects and otherregions o the world I you are a paint com-pany materials manuacturer equipmentmanuacturer or have an influence on theuse andor maintenance o materials usedin the offshore environment this projectcould be o benefit to you Please eel ree toget in contact i you wish to learn more
Contact
andrewgordonSwereasemartinjonssonswerease
Maintenance scheduling should take into account known degradation ratesof materials and coating systems in operating environments
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CORROSION NEWS 3 | 201214
BY MARIA AringSLUND
A nuclear power station can contain some fairly aggressiveenvironments for materials and it is vital in these environ-ments to try and avoid material failures Thomas Blomfeldtof Swerea KIMAB keeps a check on the condition of thepolymer materials at nuclear sites
RISKS IN NUCLEAR POWER stations areofen associated with meltdowns like atChernobyl or last year at Fukushima -a nightmare scenario that is thankullya rare occurrence However even smallequipment ailures can result in bigproblems or the operators such as pro-duction losses or injury to personnelFor that reason saety and reliability areparamount and this philosophy filtersdown to every component in the system
including nuts bolts and gasketsldquoTe saety margins specified by the
nuclear power station owners have beenset or very good reasons At the sametime or financial reasons they do notwant to replace materials unnecessarilyrdquosays Tomas Blomeldt who has thetask o determining the remaining ser-
vice lie o a rubber joint or exampleSwerea KIMAB has several teams
working on inspecting different typeso material Tomas specialises inpolymers both as an expert at Swerea
KIMAB and as a research scientist 983096983088per cent o his working hours involve
inspecting and evaluating samplesrom nuclear power stations Tomasis a requent visitor at Swedenrsquos threenuclear power stations this year he hasinspected seven out o the total o tenreactors
rdquoPlastic and rubber may not bewhat you first think o when you see anuclear power station However thereare large quantities o polymers thereIn a reactor building the cables alone
correspond to the street lighting systemo a medium-sized Swedish town In ad-
The smallest componentmust be reliable
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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CORROSION NEWS 3 | 2012 13
that it requires avourable weather condi-tions and with restrictions on bed spaceor example the logistics o such workbecomes very difficult to manage
Prequalification tests in the environ-mentWith an accurate picture o which areaso an installation corrode aster or sloweroperators can plan their maintenance moreeffectively ensuring resources are allocatedwhere they are most needed as well as al-lowing them to deer maintenance activitiesi required Te selection and use o coatingsystems can be tailored more effectively bycarrying out the prequalification tests inthe environment in which they will be usedrather than just in accelerated laboratorytests or onshore exposures
Swerea KIMAB has a long history oconducting research into materials andcorrosion having successully completedsimilar studies or inrastructure and auto-motive companies Te data obtained hashelped populate the Korrfield database andenabled companies to select materials moreeffectively or the environments in whichthey operate Te previous studies involvedplacing samples in very hostile environ-
ments such as on the underside o heavygood vehicles and so provides SwereaKIMAB with the expertise or ensuringsamples are saely exposed and easy toevaluate
Focussed on oil and gas operatorsTe first round o meetings with companieshas been completed and has been ocussedon oil and gas operators based in AberdeenUK However the aim is to encompass asmany participants as possible in order to
generate a data set that will be useul notonly to current installations in the NorthSea but also to new projects and otherregions o the world I you are a paint com-pany materials manuacturer equipmentmanuacturer or have an influence on theuse andor maintenance o materials usedin the offshore environment this projectcould be o benefit to you Please eel ree toget in contact i you wish to learn more
Contact
andrewgordonSwereasemartinjonssonswerease
Maintenance scheduling should take into account known degradation ratesof materials and coating systems in operating environments
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CORROSION NEWS 3 | 201214
BY MARIA AringSLUND
A nuclear power station can contain some fairly aggressiveenvironments for materials and it is vital in these environ-ments to try and avoid material failures Thomas Blomfeldtof Swerea KIMAB keeps a check on the condition of thepolymer materials at nuclear sites
RISKS IN NUCLEAR POWER stations areofen associated with meltdowns like atChernobyl or last year at Fukushima -a nightmare scenario that is thankullya rare occurrence However even smallequipment ailures can result in bigproblems or the operators such as pro-duction losses or injury to personnelFor that reason saety and reliability areparamount and this philosophy filtersdown to every component in the system
including nuts bolts and gasketsldquoTe saety margins specified by the
nuclear power station owners have beenset or very good reasons At the sametime or financial reasons they do notwant to replace materials unnecessarilyrdquosays Tomas Blomeldt who has thetask o determining the remaining ser-
vice lie o a rubber joint or exampleSwerea KIMAB has several teams
working on inspecting different typeso material Tomas specialises inpolymers both as an expert at Swerea
KIMAB and as a research scientist 983096983088per cent o his working hours involve
inspecting and evaluating samplesrom nuclear power stations Tomasis a requent visitor at Swedenrsquos threenuclear power stations this year he hasinspected seven out o the total o tenreactors
rdquoPlastic and rubber may not bewhat you first think o when you see anuclear power station However thereare large quantities o polymers thereIn a reactor building the cables alone
correspond to the street lighting systemo a medium-sized Swedish town In ad-
The smallest componentmust be reliable
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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CORROSION NEWS 3 | 201214
BY MARIA AringSLUND
A nuclear power station can contain some fairly aggressiveenvironments for materials and it is vital in these environ-ments to try and avoid material failures Thomas Blomfeldtof Swerea KIMAB keeps a check on the condition of thepolymer materials at nuclear sites
RISKS IN NUCLEAR POWER stations areofen associated with meltdowns like atChernobyl or last year at Fukushima -a nightmare scenario that is thankullya rare occurrence However even smallequipment ailures can result in bigproblems or the operators such as pro-duction losses or injury to personnelFor that reason saety and reliability areparamount and this philosophy filtersdown to every component in the system
including nuts bolts and gasketsldquoTe saety margins specified by the
nuclear power station owners have beenset or very good reasons At the sametime or financial reasons they do notwant to replace materials unnecessarilyrdquosays Tomas Blomeldt who has thetask o determining the remaining ser-
vice lie o a rubber joint or exampleSwerea KIMAB has several teams
working on inspecting different typeso material Tomas specialises inpolymers both as an expert at Swerea
KIMAB and as a research scientist 983096983088per cent o his working hours involve
inspecting and evaluating samplesrom nuclear power stations Tomasis a requent visitor at Swedenrsquos threenuclear power stations this year he hasinspected seven out o the total o tenreactors
rdquoPlastic and rubber may not bewhat you first think o when you see anuclear power station However thereare large quantities o polymers thereIn a reactor building the cables alone
correspond to the street lighting systemo a medium-sized Swedish town In ad-
The smallest componentmust be reliable
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
8132019 Corrnew Nr 3 LR
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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CORROSION NEWS 3 | 2012 15
The reactor hall at the Swedish nuclear reactor Oskarshamn 3 (Photo OKG)
dition there are joints gaskets suracecoatings and so onrdquo he explains
Te nuclear power stations are shutdown every year or planned mainte-nance that is when the audits are done
rdquoTe owners o the nuclear powerstations determine what is to be au-dited Tis year I have been workingwithin the research project o Swedishresearch oundation Elorsk studying
polymers in concrete structures Tatmay involve anything rom coatings torubber gaskets and ordinary sealantsrdquosays Tomas
Heat oxygen and radiation are harshon all polymer materials in a nuclearpower station Tomas and his col-leagues at Swerea KIMAB do on-siteinspections and also take samples backto the laboratory in Kista
rdquoOne o the greatest problems withpolymers is that they are less standard-
ized compared with steel or exam-ple Te grades vary between various
manuacturers Another problem is thatover time some additives have had ap-proval removed and are off the marketPlasticisers are a well-known examplerdquo
explains TomasrdquoTe additives in polymers thatexisted when the nuclear power stationswere initially brought into operationare not always available today estingand research are required to determinewhether new additives are workingTe act that the grades can differ iseasily understood when you know thatthe additives can sometimes constitutemore than hal o the material ndash involv-ing plasticisers pigment and bulkingagents In addition our nuclear powerstations are undergoing upgrades cur-rently which makes urther demandson the materials
New materials and those that havebeen in service are both analysed atthe laboratory Te tests cover relevantmaterial properties what happens indifferent load cases what happens tothe additives and whether the materialcan influence the nuclear power stationrsquos
operating environmentrdquoBy comparing materials that have
undergone accelerated testing withmaterials that have been aged in the
actual environment service lie can beestimated with the greatest possibleaccuracy Because o that we are in theprocess o building up a bank o materi-als data based on the test resultsrdquo saysTomas
On the basis o these tests SwereaKIMAB provides recommendationsas to whether a material ought to bereplaced or i by a good margin it canbe expected to last or a urther numbero years
rdquoWe also help the materials supplierswith input data when they are develop-ing new productsrdquo says Tomas
oday Swerea KIMAB only has apresence on the Swedish market butthere are ambitions to become estab-lished in the rest o Europe includingFrance
Contactthomasblomeldtswerease
Oskarshamn nuclear power plant Photo OKG
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
8132019 Corrnew Nr 3 LR
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CORROSION NEWS 3 | 201216
The right fuel andtemperature keepthe steam up
CORROSION NEWS 3 | 201216
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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CORROSION NEWS 3 | 2012 17
All waste-to-energy plants are affected by corrosion to a greater or lesser extent This isbecause they are exposed to extreme conditions in the form of high temperatures andcorrosive fuels Above all the problems are due to the fact that the substances in the flue
gases precipitate and attack parts of the system It is the salts (chlorides) that are thegreatest villains of the piece
ldquoIT MIGHT BE COMPARED a little withwhat happens to cars that are exposedto salt on the roadsrdquo says Rikard Nor-ling Research Leader or Corrosion inHot Environments at Swerea KIMABldquoWhen cars are exposed to salt-ladencoatings we gradually get rust attack-
ingrdquoWhat can occur is ndash in a worst-case
scenario ndash that holes and other damageorm in parts o the system Te cor-rosion can also mean that pipes andcomponents thin out and have to bereplaced afer a period o time
ldquoTat type o disruption involvesoperating stoppages and repair costsrdquosays Rikard
ldquoSalts and ash rom the combus-tion process also mean that insulating
deposits are ormed within the systemand output must then be reduced inorder to avoid overheating In turn thatleads to a lower degree o efficiency ndash toput it quite simply lower energy or heatoutputrdquo
Combustion plants are usually sub-divided into combined heat and powerstations condensing power stations andheat-only boiler stations Te systemsare used or the production o electric-ity andor heating (district heating)
Within industry there are also a numbero different systems that are used in theindustrial processes such as the sodarecovery boilers at paper mills
Tere are no collective statistics onthe number o combustion plants inSweden but an estimate made by theSwedish Environmental ProtectionAgency a ew years ago indicates thatthere are approximately 983091983093983088983088 plantswithin the district heating sector aloneTe energy authority calculates that the
production o electricity rom bio-mass combustion amounts to around
983089983088983088 Wh per yearA combined heat and power station
is able to produce both electricity andheating at the same time A system thatonly produces electricity and where theexcession heat is cooled is called a con-densing power station In these plants
more electricity is produced than incombined heat and power stations butsince the heat is cooled away the uelconsumption is viewed as being lowerSystems that only produce district heat-ing are called heat-only boiler stations
Combustion plants are subject to various types o attack High tem-perature corrosion arises on metallicsuraces with temperatures o around983093983088983088 degrees Celsius or over In that caseit is primarily a matter o sodium and
potassium chlorides being precipitatedout Te risk o high temperature corro-sion is highest in plants in which energyis produced rom waste
One normal way o reducing thisrisk is to keep the vapour temperatureat lower levels around 983092983088983088 degrees Cwhen waste is used as the uel
ldquoHowever it also means that energyproduction in the plant reduces quitea lot In addition problems may thenarise as a consequence o the precipita-
tion o zinc and lead which orm cor-rosive dspositsrdquo
Corrosion also occurs in cooler partso the system as a consequence othe condensation o water which cancontain sulphuric acid and hydrochloricacid rom the flue gases
ldquoTe uel used or the waste-to-energyis thereore really crucialrdquo maintainsRikard Norling ldquoIn simplified termsthe types o uel can be subdivided intocoal biomass and waste In this context
coal is the lsquokindestrsquo whereas differ-ent types o waste may contain many
substances that give rise to corrosionincluding potassium sodium PVC andmetals such as zinc and lead Biouel ispositioned somewhere between thesedepending on how lsquocleanrsquo it isrdquo
Te uel that causes most problems isthereore waste
ldquoHere people usually differentiatebetween household waste and commer-cialindustrial waste Te latter are ofenbetter separated and thereore lsquocleanerrsquoWhereas virtually everything may beound in household waste In realityhowever many systems that combustwaste run on a mixture o both house-hold and commercial waste and it is anadvantage to stick to similar uel overa period o time to avoid unexpectedproblems occurringrdquo explains Rikard
Recycled wood is also problematicldquoWaste may comprise demolition
waste recycled loading pallets and simi-lar items and it thereore does not countas biomass since it could contain metalsimpregnation chemicals remnants opaint plastic etc I you investigate care-ully it would probably be possible tofind a sample card o the whole periodictable in this type o wastehelliprdquo
Te materials in the actual plants canalso have an impact and can be very
varied Tere can be low-alloy parts orstainless steel materials depending onthe age and design o the plant
As experts in corrosion SwereaKIMAB is commissioned by the heatingand energy industry or projects suchas taking measurements and samples atthe plants
ldquoYes apart rom working on researchwithin the field or example we takemeasurements that can be used to de-termine the useul lie o various mate-
rialsrdquo says Rikard ldquoWe also investigatethe causes o component ailuresrdquo
BY JOHAN HAringRD AF SEGER STAD
CORROSION NEWS 3 | 2012 17
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
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Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
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CORROSION NEWS 3 | 201218
In Sweden and the other Nordiccountries it is most common today tofire combustion plants with biomassand waste while in other parts o Eu-rope coal is used as a uel
ldquoraditionally more coal has beenused there or a long time and it willcertainly continue to do so or some
time However we are noticing anincrease in interest in other uels It is
probably a sign o the times and be-cause o the EUrsquos endeavours to reducecarbon dioxide emissions we will prob-ably be seeing an increase in the use oboth biomass and waste as uels
ldquoIt is difficult to oretell whether thatmight give rise to potential new com-missions or Swerea KIMAB we have a
tradition o participating in EU projectswithin the field and the difficulties
that can be expected with new uelscould definitely lead to an even greateramount o research collaboration withEuropean playersrdquo concludes RikardNorling
Contact
Rikard Norlingrikardnorlingswerease
Fuel
Steam drum
Downcomer
Inlet steam
Steam outlet Steamturbine
Generator
Stack
Primary
air fan
District heating out to customer
Flue gascondenser
District heating in from customer
Secondary
air fan
Combustionchamber
Electrostaticprecipitator
Air preheater
Economizer
Waterwall
boiler tubes
Superheater
Steamturbinecondenser
Feedwater inlet
Schematic diagram of a combustion plant
IN 2011 ENERGY COMPANY Fortum dis-covered cracks in the downcomer (a typeof pipeline) at the Haumlsselbyverket plant
a combined heating and power stationoutside Stockholm Crack formation hadpreviously also been established at otherplants which is why an investigation wasalso required at the Haumlsselbyverket stationSwerea KIMAB was engaged to investigatethe tubes The fears were that the crackswould be critically deep thereby posing ahuge risk of a failure especially bearing inmind the fact that the plant and the tubeshad been in operation since 983089983097983093983096 with noextensive replacements of any parts havingbeen undertaken since then
According to Fortumrsquos operations andmaintenance personnel the indications
were that the cracks could be as deep as 983094millimetres with the total thickness of thetube material being 983089983090 millimetres
However the investigationrsquos results werereassuring The cracks were relativelyshallow at around 983088983090 millimetres and inaddition they had not started to spread toany great extent The length of the cracksvaried from a few millimetres to around 983091983088983088millimetres and they ran lengthwise alongthe pipe
It was a fair assumption that the cracksarose as a consequence of fatigue al-though it has not been possible to establishthis unequivocally Certain details also madeit evident that the crack formation could
be connected with the manufacture of thetubes but that could not be ascertained
definitely either Nor were there any signsthat corrosion could have caused thecracks
Swerea KIMAB therefore believed thatthere was no immediate danger to opera-tions but recommended that careful andmore frequent checks should be madeas to whether the crack formation wasincreasing Swerea KIMAB also suggestedthat the crack formation could be groundaway in order to be able to see more easilywhether new cracks arise
That was done at the plant and certainparts of the tube were also replacedBecause of this operations were able tocontinue without any major expensive
repairs or interventions on this occa-sion
Investigation of cracks ndash safeguarded operations at Haumlsselbyverket CHP station
case
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THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2828
Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 1928
THE CHEMICALS USED IN pulp and paper industry are often very corrosive suchas chlorine dioxide and spent acid in the bleaching step and in the recoverycycle with green black and white liquor There is also a constant developmentof the processes in the pulp and paper industry which often leads to increasedpressures and temperatures which often increase the corrosion rates In additionimproved chemical recycling can lead to enrichment of corrosive species in thesystem due to closed loops The use of eucalyptus which is common in millsoutside of Scandinavia is for example causing a more corrosive environment thantraditionally used raw materials Since the service reliability is of very high con-cern for both health and economic reasons this calls for proper material choice
Swerea KIMAB has over the years worked extensively with material and corro-sion issues for the pulp and paper industry including both metallic and polymeric
INSTITUT DE LA CORROSION the French
subsidiary of Swerea KIMAB established inBrest (France) since 983090983088983088983090 has celebratedits 983089983088th anniversary on May 983090983091rd together withcustomers and employees After a day richin meetings a relaxing dinner was organizedin the splendid location of Saint Mathew tipclose to Brest
Dominique Thierry (MD) expressed hisgratitude to the customers for their supportbut also to all the employees of Institut de laCorrosion who contributed to the success ofthe company Special congratulations wereaddressed by Daniegravele Quantin (Arcelormit-
tal) Per-Erik Augustsson (SSAB) and StaffanSoumlderberg (MD Swerea KIMAB)
Institut de la Corrosion has celebrated
its 10th anniversary
Proper material choice for harsh and corrosive
environments in the pulp and paper industry
materials Two member research consortia arehandling with these issues MRC Corrosion in pulpand paper industry as well as the MRC CorrosionProperties of Polymeric Materials
The best choice of material often vary depend-ing on the concentration and temperature of thechemical but can also vary depending on the time
it is intended to be in service At some occasions itmight be necessary to replace a pipe-line or a vesselor similar just for a month or two before it can bereplaced properly This kind of temporary solutioncould call for a much less expensive material solutionthan what would normally be recommended for thatservice This makes it very hard to find any informa-tion on what material that can be just ldquogood enoughrdquofor these types of applications
A new project ldquoProper material choice for harshand corrosive environments in the pulp and paperindustryrdquo starts during the fall 983090983088983089983090 The project isfinanced by grant from Aringforsk on a two year basis
and by the two member research consortia The pro- ject aims at producing a guideline with informationfor selecting the most suitable material plastic andor metallic for the pulp and paper industry in someselected and prioritized chemical environments
ContactTobias Olli MRC Corrosion in pulpamppaper industrytobiasolliswereaseKarin Jacobson MRC Corrosion Properties ofPolymeric Materialskarinjacobsonswerease
983089 983088
NEW PROJECT
CORROSION NEWS 3 | 2012 19
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CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
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CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
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CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
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CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
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CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
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CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2828
Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2028
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2128
CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2228
CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2328
CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
8132019 Corrnew Nr 3 LR
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CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2528
CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2628
CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2728
CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2828
Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2128
CORROSION NEWS 3 | 2012 21
00
10
20
30
40
0 24 48 72 96 120 144 168
C o r r o s i o n d e p t h [ μ m ]
Exposure time [hours]
L1C1
L2C1
L1C2
L1C3
L2C2
B1
B2
B3
A1 A
2 A
3C
L1 logger 1
L2 logger 2
C1 C2 C3 1st 2nd amp 3rd cycle
Zn 25microm
S a l t s p r a y
S a l t s p r a y
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle B
0
20
40
60
80
100
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i e h u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle A
s a l t s p r a y ( N a C l 1 w
t )
0
20
40
60
80
100
-20
-10
0
10
20
30
40
50
60
0 4 8 12 16 20 24
R e l a t i v e H
u m i d i t y
T e m p e r a t u r e
deg C
Time h
T
RH
Cycle C F r e e z i n g p
h a s e ( - 1 5
C )
Figure 3 Sub-cycles of N-VDA test (VDA 233-102)
the data can be read via a wireless interaceFrom the measurements the developed small
and battery-driven atmospheric corrosionloggers provided high sensitivity allowing or
sub-angstrom (lt983089983088ndash983089983088 m) measurements ocorrosion depth and good accuracy Te actualcorrosion rate was affected by the exposurehistory due to a limited rate o wettingdryingand oxygen and ion transport to the reactioninterace under a layer o corrosion productsTe hysteresis was particularly strong or carbonsteel Except the reezing phase the steel corro-sion rate varied in a narrow range rom 983088983090 to983088983094 μmhour For zinc the corrosion rate variedrom 983088983088983088983089 to 983088983089 μmhour in particular phaseso the cycle with the maximum in the salt sprayphase 983095983093983077 o the metal corroded in the saltspray phase and in the ollowing drying periodrepresenting only 983089983091983077 o the total test timeDuring drying phases the corrosion rate usuallydropped when the relative humidity decreasedbelow about 983095983093 983077 ie close to the deliquescencepoint o sodium chloride Examples o records ocorrosion depth registered by two loggers withresh zinc sensors L983089 and L983090 during three con-secutive week cycles C983089 C983090 and C983091 are plottedin Figure 983092 Te obtained data suggest that theproposed test cycle allowed or rather efficientdrying o the zinc surace which is believed to
be crucial or the ormation o corrosion prod-ucts with certain protective ability observed alsoin field conditions
AirCorr loggers may also be used on operating vehicles in order to assess the corrosion aggres-siveness towards steel and zinc as a unction olocations on operating vehicle Te corrosionloggers were successully applied also in extremecorrosive environments represented by out-door locations on operating ships navigating inworldwide ocean
Contactomas Prosektomasprosekinstitut-corrosionrNathalie LeBozecNathalielebozecinstitut-corrosionr
MUSECORR project funded by European Commis-sion FP 983095 (contract number 983090983090983094983093983091983097)Figure 4 Record of corrosion depth measurements with Zn-25μm sensorsin N-VDA test
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2228
CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2328
CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2428
CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2528
CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2628
CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2728
CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2828
Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2228
CORROSION NEWS 3 | 201222
WATER INJECTION or water flooding iswidely used as a secondary recoverymethod to increase the production o
oil usually rom mature oil fields Tefigure shows a schematic drawing o theinjection water process Te water injec-tion pipeline WIP is usually severalkilometers in length and is typicallymade o carbon steel Due to availabil-ity and economy the water used comesrom different sources as sea wateraquier water produced water (recov-ered rom the oil-water mix extractedrom oil fields) or resh water Eventhough the water is degassed and ofen
corrosion inhibitors oxygen scavengerand scale inhibitors are added ailures
due to corrosion occur Reerring todata rom 983090983088983088983096 (983089) approximately 983092983088 983077o the world oil and gas pipe lines (983091 x
983089983088983094 km) is approaching nominal designlie and corrosion represents 983090983088-983092983088983077 orecorded ailures
Most o the industries are carryingout regularly inspections o the interiorwalls in order to obtain corrosion statuso the pipelines Tese can either beperormed by so called intelligentpigging tools andor by exposure o cor-rosion coupons ypical data receivedare corrosion rate corrosion pit depthpresence o biological consortia and
corrosion productsRecent assessment and monitoring
has shown that MIC (microbiologicallyinfluenced corrosion) plays an impor-tant role in the internal corrosion o the
pipelines Other corrosion phenomenato consider are CO
1048626 corrosion and
under-deposit corrosionSwerea KIMAB is taking part in the
Marie Curie Network Project BIOCOR(see urther inormation beside) AtSwerea KIMAB we ocus on collect-ing and assessing data rom corrosionailures on WIP o carbon steel inorder to improve the understandingo the influence o bacterial activityon corrosion and develop a basis or
better management o pipeline systemsObservation data taken to consideration
ACTIVITIES WITHIN THE MARIE CURIE NETWORK BIOCOR
Oil amp Gas
BY EVA JOHANSSON IULIAN COMANESCU amp CLAES TAXEacuteN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2328
CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2428
CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2528
CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2628
CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2728
CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2828
Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2328
CORROSION NEWS 3 | 2012 23
are water quality process parameters and compo-sition o corrosion products biological consortiapipeline geometry and pigging operation inorma-tion biocide treatment Te work is done in close
collaboration with the industrial partnersParallel to the activities o collecting data at-tempts towards predictive models o bio corrosionare made Models or prediction o lie time or tolocate areas o extend corrosion damage can bedivided in two general categories Models based ondata and Models based on first electrochemical andhydrodynamic principles By application o reason-able simplifications o the biological processes andapplication o basic corrosion principles mucho the observed corrosion can be understood andpossibly also predicted Field data will then beused to calibrate and validate candidate predic-tive model ormulations So ar the work has beenpublished at three conerences and two papers willbe presented at E983157983154983151983139983151983154983154 983090983088983089983090 in September 983090983088983089983090(983090ndash983094)
Supports to the project work are two Biocor visit-ing scientists Pro Robert E Melchers NewcastleUniversity Australia and Pro Mirna Urquidi-Macdonald Penn State University USA Teyhave stayed at Swerea KIMAB during some monthsin object to assist the project with their experiencein corrosion modeling
PublicationsA C Palmer R A King Subsea Pipeline Engineering983090nd Edition 983090983088983088983096I Comanescu C Taxeacuten E Johansson Data Base andCorrosion Model for MIC in Oil amp Gas- An IndustryRelevant Approach for Management of Bio-corrosionin Oil amp Gas Transport Systems Poster Eurocorr 983090983088983089983089StockholmI Comanescu RE Melchers C Taxeacuten ldquoAssessmentof MIC in Carbon Steel Water Injection PipelinesrdquoSPE983089983093983093983089983097983097 SPE International Conference and Exhibi-tion on Oilfield Corrosion Aberdeen UK May 983090983096-983090983097983090983088983089983090
I Comanescu RE Melchers C Taxeacuten rdquoLife TimeAssessment of Offshore Water Injection Pipelines asa Function of Microbiologically Influenced CorrosionrdquoProceedings of the Twenty-second (983090983088983089983090) InternationalOffshore and Polar Engineering Conference RhodesGreece June 983089983095ndash983090983090 983090983088983089983090CTaxeacuten IComanescu R E Melchers ldquoFrameworkmodel for under deposit corrosion in water injectionpipelinesrdquo The European Corrosion Congress 983090983088983089983090Istanbul Paper No 983089983093983090983095 (in press)I Comanescu RE Melchers C Taxen ldquoCorrelationbetween MIC and water quality pigging frequency andbiocide dosing in oil field water injection pipelinesrdquo The
European Corrosion Congress 983090983088983089983090 Istanbul Paper No983089983093983090983095 (in press)
Gas
Produced water
re-injection
Oil
Injection Pipeline
Production
pipeline
Sea water
Aquifer
water
Separator
Degasser
Oil Reservoir
Hydrocyclon
Schematic diagram of the injection water process
BIOCOR partners
FACTS
BIOCOR is a Marie Curie Initial Training Network (ITN) funded by theEU 983095th Framework ldquoPeoplerdquo Programme www biocoreu
The overall goal is to provide the European Community with new mul-tidisciplinary expertise in the area of bio-corrosion in order to developmore efficient knowledge-based solutions for the industry The project isdesigned to the benefit of the industry and as such a ldquoproblem-orientedapproachrdquo is chosen to tackle microbial influenced corrosion (MIC) intwo large industrial sectors the oil and gas industry and the power sup-ply facilities The project is accomplished by 983089983090 European research teamsand 983093 associated partners The project started in September 983090983088983088983097 and
ends in August 983090983088983089983091
BIOCOR ITN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2428
CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2528
CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2628
CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2728
CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2828
Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2428
CORROSION NEWS 3 | 201224
FOR MANY INDUSTRIAL SECTORS suchas building automotive or aerospacemetallic materials are requently usedunder the orm o painted parts Teapplication o organic coatings couldhave an aesthetic unction but it alsoofen provides a corrosion protectionor these metallic structures Ten it
appears logical to investigate the paint-ing process to improve and optimize the
service lie o painted materials Moreo- ver in the last decades environmentalregulations have driven to prohibit or atleast to limit the use o some hazardoussubstances widely used in the paint-ing products such as chromates Tusmost painting processes include a pre-treatment step or conversion coating
that provides adhesion and corrosionresistance o polymermetal interaces
Chromate-based conversion coatingshave excellent adhesion and corrosionproperties Unortunately they are toxicand carcinogenic and consequentlythere are needs to replace these coat-ings with saer products More glob-ally many coating products have to bemodified or replaced which requirenumerous tests and the optimizationo the whole process rom A the metalcleaning to Z the curing o the topcoat
In this context the French corrosioninstitute has installed a new suracetreatment laboratory in Brest Tis labo-ratory has been designed to reproducethe whole painting process as used inthe coil industry rom surace cleaningto paint curing not to mention analyti-cal techniques needed to control theprocess and products
Coating process and characteriza-tion tehcniques
Te first step in all suraces coatingprocess is the cleaning o metallicmaterials Te importance o this stepis ofen underestimated which leadto many ailures o coated parted inservice Te laboratory is equippedwith a washing machine that sprays thecleaning solution on the metallic parts(Figure 983089) Tis method requently usedin the industry is much more efficientthat the traditional dipping processusually experimented or laboratory
studies For steel and zinc-based materi-als the cleaning solutions consist inalkaline cleaners Te temperature timeo cleaning or pH o cleaners can bemodulated to investigate and optimizethis step
Te control o cleaned suracescould be the simple water break testwhich involves the examination ocleaned parts to check the presence oa continuous water film However or aprecise assessment o cleaning process
the water-contact angle measurementcan be perormed Tus the angle o a
Figure 1 Paint laboratory with from left to right roll coater washing machine and oven
Figure 2 Fourier Transform InfraRed (FTIR) spectrometer
Surface treatment laboratory
CORROSION NEWS 3 | 201224
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2528
CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2628
CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2728
CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2828
Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2528
CORROSION NEWS 3 | 2012 25
drop o water on a metallic surace islinked to its surace energy and so to itscleanliness A clean metallic surace isusually more hydrophilic ie a lower
contact angle than the oiled and oxi-dized substratesTanks to specific equipment that
measures and records the spread-ing o water droplet on suraces thecleanliness o metallic material can beprecisely evaluated Additional meas-urement with the Fourier ransormInraRed (FIR) at grazing angle canalso give inormation on oil or oxidespresence on surace (Figure 983090)
Te main step ollowing the cleaningis the application o a conversion coat-ing or pre-treatment Conversion coat-ings are applied in continuous steel oraluminium sheet production lines andwithin the paint shop o the automotiveindustry In a similar way the pre-treatment is applied using a roll coater(Figure 983089) Tis machine reproduces ata smaller scale the application methodused by the coil industry Te rollingspeed roll pressure can be adjusted tofind optimum parameters It has beenshown that structure and thickness o
conversion coatings ormed with thismethod can be dramatically differentrom the dipping method used in mostlaboratory studies Afer a drying stepin the oven pre-treated surace can becoated with organic coatings
Handheld analyserA handheld X-ray Fluorescence XRFspectrometer as shown in Figure 983091 isuseul or the control and analysis oconversion coatings XRF technique
basically consists in exciting the matterto analyse with X-Rays Te mattergenerates a fluorescence radiationspecific to the analysed element Tehandheld analyser can detect andquantiy elements heavier than themagnesium By using a specific cali-bration XRF can be used to determinethe quantity o titaniumzirconium orsilicon applied on metallic suracesTis technique is requently used inproduction or the control or products
on the line Te analyser can also beused to the control o pre-treatment
baths A complementary techniqueFourier ransorm InraRed spectros-copy (FIR) at grazing angle is also
very useul to analyse thin coatings
such as conversion coatings It providesinormation on the chemical com-pounds orming this thin layer Tanksto cooperation with the local university(Universiteacute de Bretagne Occiden-tal) additional analytical techniquessuch as X-Ray photon spectroscopy(XPS) or Scanning Kelvin Probe ForceMicroscopy (SKPFM) are also used toinvestigate new conversion coatingsand to improve our understanding onthe ormation mechanisms o thesenanometer-thick layers
RampD project in progressFinally primer and topcoat could beapplied on the pre-treated suracesand the thermal curing o paint canbe carried out in an oven at a spe-cific temperature called Paint Metalemperature Tis curing step mustbe perormed in a specific oven thatguarantee a very precise and stabletemperature (Figure 983092)
One RampD project sponsored by 983096
industrial companies is in progressto investigate the structure and tounderstand the ormation mechanismso some chrome-ree pre-treatment onZn-Al and Zn-Al-Mg coated steel Tisproject is ocused on pretreatmentsbased on itaniumZirconium (iZr) chemistry silanes or a combina-tion o both Commercial as well asmodel treatment products are testedand the role o different steps in thepretreatment are analyzed in the light
o the structure and properties o theseconversion layers
Tis newly installed laboratory as-sociated with other equipment o theInstitut de la Corrosion offers manyopportunities to apply and investigategreen pre-treatments and organiccoatings in development or manyindustrial fields orm building toaeronautics
Contact
Gilles RannouGillesrannouinstitut-corrosionfr
Figure 3 X-ray Flurorescence (XRF) analyserinstalled on the measurement stand
Figure 4 Paint oven
CORROSION NEWS 3 | 2012 25
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2628
CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2728
CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2828
Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2628
CORROSION NEWS 3 | 201226
THE MRC which was createdin May 983090983088983089983088 is devoted to theprotection of steel structures bypaints and linings in atmos-phere and immersion for ap-plication in shipbuilding industryoffshore and infrastructureRampD projects focus essentiallyon topics regarding surfacepreparation durability of paintsystems in accelerated corro-sion tests or field exposure hellip983094 companies are members ofthis MRC They include for ex-amples ship building company
Oil and Gas Company or paintsuppliersSeveral projects are currentlyon-going such projects relatedto assessment of paint systemsin accelerated corrosion testsand field exposures
RampD ActivityTesting the corrosion resistanceof marine and offshore paintsystems for C983093M environmentis crucial in order to make an
appropriate and durable selec-tion of the coatings as well as
to validate surface preparationsThe selection of the coatingsis often based on results fromaccelerated corrosion testsperformed in laboratory such asthe conventional salt spray test(ISO 983097983090983090983095 ASTM B-983089983089983095) or usingcyclic corrosion tests Amongcyclic corrosion tests that areused for the qualification ofoffshore coatings two majortest methods may be conductedupon which specifications ISOor NACE are selected Indeedthese refer to ISO 983090983088983091983092983088 Annex
A and ASTM D983093983096983097983092 as citedin NACE TM 983088983091983088983092 (Offshoreplateform atmospheric andsplash zone maintenancecoating system evaluation) andTM983088983092983088983092 (Offshore plateform at-mospheric and splash zone newconstruction coating systemevaluation) and more generallyin NACE SP983088983089983088983096 (StandardPractice ndash Corrosion Control ofOffshore Structures by Protec-tive Coatings) These testing
methods differ a lot regardingthe test duration (983091 months for
ASTM versus 983094 months in ISO)the salt solution (Syntheticseawater in ASTM versus NaClin ISO) the cycles as well asthe sample preparation (scribe)However there are no data inthe open literature comparingboth testing methods in rankingoffshore and marine coatingsfor C983093M environments Twointerconnected projects werethus initiated
Project 1 Field performanceof marineoffshore coating
systems (CoatField-C5M)The aims of the project are ndash To assess the performance
of about 983089983088 different paintsystems applied on steel instationary marine atmos-pheres of C983093M class on longterm duration
ndash To assess the performanceof about 983089983088 different paintsystems applied on steel onreal structure such as onoperating ship on long term
durationndash To compare the performance
of the coating systems as afunction of exposure condi-tions
ndash To compare field data withdata from accelerated corro-sion tests
Project 2 Comparison ofNACE and ISO standards forC5M atmosphere (CoatTest-C5M)The aims of the project arendash To assess the performance
of different paint systemsapplied on steel in ISO 983090983088983091983092983088
(Annex A)ndash To assess the performance
of different paint systemsapplied on steel in ASTMD983093983096983097983092 (as cited in TM983088983091983088983092and TM983088983092983088983092)
ndash To compare the resultsobtained in both testingconditions
ContactNathalie Le Bozec
nathalielebozecinstitut-corrosionfr
Paints and linings for steel and related alloysstructures in atmosphere and in immersion
Member Research Consortia (MRC)
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2728
CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2828
Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2728
CORROSION NEWS 3 | 2012 27
OCTOBER 23 2012
Open house
WELCOME TO SWEDEN and Kista in October 983090983091 We willbe inviting customers and member companies to an inau-guration featuring open house lectures a question andanswer session and a demonstration of the new laborato-ries We hope that many of you will be able to participateduring the day and evening We look forward to meetingyou all in Kista
L E C T U R
E SN E W L A B O R A T O R I E S P
O S T E R
S E S S I O N
D I N N E R
MOST OF US would agree that exchange of ideas is often easier andmore efficient at smaller and highly focused conferences gatheringpeople with the same professional interest This may explain thesuccess of Coil Coating Symposium organized by Institut de la Cor-rosion and Member Research Consortium ldquoCorrosion properties ofcoil-coated productsrdquo in 983090983088983088983093 and 983090983088983088983096 The third edition of the sym-posium is scheduled for November 983090983096 983090983088983089983090 Thirteen papers wereinvited by organizers and split into three sessions New pretreatmentand paint technologies Reliability of accelerated tests and develop-
Work Shop SeaTechWeek 2012
Institut de la Corrosion
MATERIALS AND CORROSION IN MARINEAND OFFSHORE WIND ENERGY INDUSTRY
Tuesday 9th of October 2012Le Quartz Brest France
Marine and offshore wind energies are rapidly developing inEurope Consequently large efforts and investments are performedin this field (a recent study showed that the 983089983088 years investmentdemand was estimated at about 983089983091983088 billon 991404 in Northern Europe)Seawater and offshore environments are known to be very corro-
sive media for most materials In addition systems may be exposedto high mechanical stresses To comply with these demandingoperating conditions the material selection for marine energysystems (e g offshore wind energy or marine energy) must beperform with very special care Corrosion and anti-corrosion sys-tems must be considered from the beginning of any marine energyproject together with a well defined corrosion management policyIn this workshop engineering producers and end users are invitedto expose and discuss corrosion and material issues related tomarine and offshore wind energy systems Presentations aboutmaterial selection corrosion anti-corrosion systems and corrosionmonitoring systems will be given by European technical expertsForum discussions will be held at the end of the presentations
Contact Nicolas Larcheacute nicolaslarcheinstitut-corrosionfr
COIL COATED STEEL
DURABILITY AND TESTING OFADVANCED MATERIALS
28 November 2012Paris C2RMF Palais du Louvre
ment of new test methods and Alloy coatings for construction andautomotive industry The attendance is limited to 983094983093 participants toensure high interactivity and facilitate discussions after each sessionmoderated by Dominique Thierry
THE PRINCIPAL THEME of the symposium is the relevance of ac-celerated testing methods and their further improvement Rapid
material assessment in accelerated and laboratory tests is crucialfor product development and quality control However we have tokeep asking ourselves how relevant the techniques we use are forlife time prediction as many of them showed poor correlation tomaterial performance in service conditions
ALTHOUGH THE MAIN focus of the symposium is the developmentcorrosion performance and testing of coil coated materials forbuilding applications there are presentations relevant also for theautomotive industry The last session is fully devoted to new zinccoatings alloyed with magnesium and aluminium intended not onlyfor roofing and siding but also for car bodies and home appliancesPresentations will include recent studies aiming at understanding
the inhibition effect of magnesium results of series of acceleratedtests and data from field
A LEAFLET WITH a list of presentations details about the venue anda registration form is available on wwwinstitut-corrosionfrThe registration is open until September 983091983088 983090983088983089983090
ContactTomas Prosek tomasprosekinstitut-corrosionfr
3rd International Symposium
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2828
Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN
8132019 Corrnew Nr 3 LR
httpslidepdfcomreaderfullcorrnew-nr-3-lr 2828
Calendar October 983097 983090983088983089983090Work Shop at SeaTechWeek 2012Materials and Corrosion in Marine and OffshoreWind Energy IndustryLocation Le Quartz Brest France
nicolaslarcheinstitut-corrosionfr
October 983090983091 983090983088983089983090Swerea KIMAB Open House
We will be inviting customers and member companies toan open house at our new location in KistaLocation Swerea KIMAB Stockholm Sweden
More information at wwwswereakimabse
November 983090983096 983090983088983089983090Coil coated steelDurability and testing ofadvanced materialsLocation Paris C983090RMF Palais du Louvre France
More information wwwinstitut-corrosionfr
or mail tomasprosekinstitut-corrosionfr
More information at
Certification in cathodicprotection for the seawaterapplication sector
Level 983089October 8ndash17 2012
Level 983089SJanuary 28ndashFebruary 1 2013
This courses are in French(English on demand)
KorrosionslaumlraDel 1 September 25ndash28 2012Del 2 October 16-18 2012
Inspektoumlr avrostskyddsmaringlningDecember 3-7
This courses are in Swedish
Courses
More information at
FRANCE SWEDEN