CORROSION ENGINEERS & DOCTORS

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CORROSION ENGINEERS DOCTORS

• Corrosion Engineers are akin to doctors - The
  patient calls when the problem is very serious
  or is on his/hers death bed.
• Corrosion Engineers cannot replace lost metals
  but can prevent from more being lost.
• Build it, bury it and forget it is the normal
  philosophy. Penny wise, pound foolish.

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COST OF CORROSION

• USA 1.25 OF G.N.P.. 2002 NACE STUDY ESTIMATED
  DIRECT COST OF CORROSION IN USA TO BE 276
  BILLION (3.1 GDP). IN 1975 BATELLE STUDY
  ESTIMATED THIS TO BE 70 BILLION (4.2 OF
  G.N.P.). 3.5 OF TOTAL US ENERGY DEMAND WAS
  GENERATED BECAUSE OF METALLIC CORROSION.
• U.K. 3.5 OF G.N.P. (1365m, 1969)
• INDIA ESTIMATED TO BE AROUND 364 billion AS OF
  2004.
• SWEDEN 1.25 OF G.N.P.
• WEST GERMANY 3 (DM 6 BILLION, 1969)
• PAKISTAN AT 3 OF GNP, 107.28 BILLION
  (2005)-APPROX 3.2 BILLION

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COST OF CORROSION INPUTS

• That part of the maintenance cost which arises
  because of corrosion damage
• The cost of inhibitors and other protective
  systems
• Consequential losses known to be caused by
  corrosion
• The cost of conservatism in design due to
  uncertainties in operating conditions, properties
  of materials, etc.
• The cost of technical effort devoted to corrosion

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SAVINGS

• 22 CAN BE POTENTIALLY SAVED BY
• 1. BETTER DISSEMINATION OF INFORMATION ON
  CORROSION PROTECTION
• 2. GREATER EDUCATION IN CORROSION PROTECTION
• 3. INCREASED AWARENESS OF THE HAZARDS OF
  CORROSION

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CORROSION does it matter?

• YES - if it jeopardises human safety
• YES - if it causes waste of valuable resources
• YES - if it causes loss or contamination of
  product
• YES if it causes reduction in equipment
  efficiency
• YES if it means expensive maintenance
• YES if it causes expensive over-design
• YES if it causes customer alienation

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LEGAL ASPECTS

• Negligence can be defined as the causing of
  foreseeable damage and is the omission to do
  something which a reasonable man, guided upon the
  circumstances which ordinarily regulate the
  conduct of human affairs, would do, or do
  something which a reasonable or prudent man would
  not do. (Blyth v Birmingham Water Works Co. 1856
  per Alderson, B.) It is known that steel will
  corrode, therefore a steel pipeline will leak in
  time if cathodic protection is not applied.
• It is now an accepted pre-requisite of good
  petroleum pipeline and high pressure gas line
  operations to prevent external corrosion, by a
  good external coating, properly applied, and
  supplemented by cathodic protection. Failure to
  apply cathodic protection to a coated, high
  pressure pipeline can reduce the leak free life
  to 18 months and, in the event of damage to
  property, leave the door open to court
  proceedings and consequent adverse publicity.
• Above quoted from PIPELINE CORROSION The Legal
  Aspects, Hatley, H.M., p6, Nov 1971.
  

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• CLASSIC CORROSION CASES

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THE CASE OF FUEL STORAGE TANKS
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THE CASE OF KDA
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built-in obsolescence

• built-in/planned obsolescence when a product is
  intentionally designed and made so that it will
  not last for a long time
• planned obsolescence Planned obsolescence, also
  called built-in obsolescence, is the conception,
  design and production of a product, such as
  hardware or software , with the intent that it
  should be useful, functional or popular for a
  limited length of time. The term was coined in
  the 1950s by Brooks Stevens who suggested that
  new and improved products are in constant demand
  by consumers and that corporations can best
  respond by manufacturing items that don't last
  very long.

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THE CASE OF SUKKUR BARRAGE
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• CH-517 Corrosion
• Introduction, definition of corrosion, forms of
  corrosion, cost of corrosion Electrochemistry,
• oxidation/reduction reactions, corrosion as an
  electrochemical reaction Reference Electrodes,
• Galvanic Series, Nernst Equation, Pourbix
  Diagrams Faradays Law, area effects, Galvanic
• Corrosion, Active/Passive Cells, Thermogalvanic
  Corrosion.
• Environment-related corrosion Physical and
  Chemical Soil Characteristics Moisture effects
• Electrical Resistivity Engineering Materials,
  metals and non-metals Forms of Corrosion,
• pitting, crevice corrosion, fill form corrosion,
  galvanic corrosion, environmental cracking, flow
• assisted corrosion, intergranular corrosion etc.
• Methods of Corrosion Control, material selection,
  modification of environment, protective
• coatings, cathodic and anodic protections
  Corrosion Monitoring Techniques, interoduction,
• inspection methods, specimen exposure, cathodic
  protection monitoring.