Title: Failure Investigation A pathway for Railways Safety
1Failure Investigation A pathway for Railways
Safety
- Corrosion related failure
- Paint perspective
RDSO Lucknow 5th December 2008 By Vasant
Kelkar Akzo Nobel Coatings India Private Limited
2Agenda
- Objective
- Corrosion theory
- Various factors governing the same
- Various methods adopted to check it
- Importance of painting amongst them
- Basis of system ISO12944
- Various options as per RDSO PCN spec
- What Akzo can / have offered
- How it can restrict corrosion and protect asset
3Objective
- Corrosion in steel and solution through various
types of coating system - RDSO-AKZO partnership to arrest and prevent
corrosion related failures
4What is Corrosion?
5What is Corrosion?
- Two basic Definitions
- Corrosion is the deterioration of a material,
(usually steel), because of a reaction with its
environment - The destruction of steel by an electrochemical
process that is recognised by the formation of
rust or pits - These two definitions bring together the idea of
an environment and an electrochemical process
which are fundamental in understanding corrosion
in terms of why it occurs and how it can be
prevented.
6Summary of Corrosion process
High Energy
STEEL Iron Metal Chemically Unstable Structural
HEAT (By Man)
CORROSION (By Nature)
Chemically the same!
IRON ORE Iron Oxide Chemically Stable Non-Structur
al
RUST Iron Oxide Chemically Stable Non-Structural
Low Energy
7The Electrochemical Process
RUST FORMATION AT ANODE
ELECTROCHEMICAL PROCESS
ELECTROLYTE OXYGEN
METALLIC PATHWAY (STEEL)
CATHODE
ANODE
8The consequences of Corrosion
- Corrosion (Rust) Steel Metal Loss
- Steel Metal Loss Maintenance Costs
- Steel Metal Loss Reduced Structure Design Life
- Steel Metal Loss Revenue Loss
- Steel Metal Loss Catastrophic Failure
- Steel Metal Loss Loss of Life?
STEEL
9Steel?
...SO WHY USE STEEL?
- Iron ore is very widely available
- It is relatively easy to make steel from iron
ore
- Steel is strong relative to its weight
- It is easy to fabricate with steel
10Corrosion How to control
- Adopting right technology at design stage
- Adopting suitable methods at fabrication stage
- Ensure no entrapment of Moisture and dirt
- Ensure proper insulation between different
materials - Applying metal coatings
- -Hot dip Galvanizing ( Limited performance )
- -Electroplating ( Limited performance )
- -Thermal Metal spraying
- Adding /changing chemical composition of coating
- -Weather resistance steel ( Incorporation of
cu/cr/ni/p ) - Applying appropriate paint coatings
11Why Paint ?
- Protection from Corrosion (Asset protection)
- Control Fouling
- Provide good Cosmetic appearance
(Aesthetics/Image) - Prevent Cargo contamination
- Provide Abrasion resistance
- Provide anti skid property
- Superior Anti Graffiti property
- Provide Fire Protection or fire retarding
property - Provide Heat resistance
- Provide Radar Attenuation
12 HOW COATINGS WORK ?
- Galvanic Protection Chemical Inhibition
Barrier Protection
13Corrosion Protection
14Cosmetic Appearance
15Cargo Contamination Prevention
16Abrasion Resistance
17Fouling Control
Acorn Barnacles
18Skid Prevention
Good grip is essential to land a plane on a deck
19Radar Attenuation
20Heat Resistance
21Fire Protection
22Low Solar Absorption (LSA) Coatings
- Coatings protect decks, topsides
superstructure from the harsh marine environment. - These are GREY due to the need for visual
camouflage. - BUT.
23Solar Absorption
24Rail Wagon
25Rail Wagons
26Rail Wagons
27Rail Wagons
28Rail Wagons
29Rail Wagons
30Rail Wagons
31Rail Wagons
32Rail wagons
33The Environment Basic Definitions
- Atmospheric essentially the earths weather
patterns! - Underwater in rivers, oceans and seas
- Underground within the earths surface
- Manmade artificial environments such as storage
tank internals, pipeline internals process
vessel internals - Steel Environment Potential for corrosion
- (Steel Environment) Coating Potential for
protection
34The Environment Impact on Corrosion Rate
- The electrolyte has a big influence on the rate
of corrosion - It is the environment that supplies the
electrolyte - Therefore, the environment has an influence on
the rate at which corrosion will occur - Fast corrosion fast steel metal loss and vice
versa - Steel structure design life is directly related
to the speed of steel metal loss - An electrolyte with good electrical conductivity
(i.e. plenty of ions) will provide the conditions
for a high rate of corrosion - i.e. it is MORE CORROSIVE !
35The Environment Impact on Corrosion Rate
Seawater, which contains the ions sodium and
chloride (salt), has greater conductivity than
drinking water which contains fewer ions.
A HIGHER CONCENTRATION OF IONS SUCH AS SODIUM
AND CHLORIDE INCREASE THE CORROSION RATE
36The Environment Impact on Corrosion Rate
- The degree of contact of the electrolyte with the
steel surface also affects corrosion rate - Intermittent electrolyte contact will switch the
corrosion process on and off - This idea of the corrosion process switching on
and off is controlled by the environment in
which the steel structure is in, i.e.
temperature, rainfall, humidity, immersion,
moisture, pollution and salinity etc - Warm temperatures will influence the degree of
electrolyte contact with the steel surface - When the electrolyte evaporates, the corrosion
process stops
37The Environment Impact on the Coating
THE COATING MUST BE ABLE TO WITHSTAND THE
ENVIRONMENT
STRESS
COATING
STEEL
38The Environment Impact on the Coating
Poor coating specification in a specific
environment can lead to early coating failure !
39Classification of Environments
- The ISO standard ISO 12944 Part 2
Classification of Environments provides us with
some very good guidelines on how to classify the
corrosivity of a particular environment - The idea of corrosion rate and steel metal loss
is used to categorise the environments - The greater the metal loss, the shorter the steel
structure lifetime and vice versa - The environment in which the steel structure is
in, dictates the level of coating protection
required - Misunderstanding the environment can lead to
incorrect coating specification and reduced
coating lifetime due to early degradation and
breakdown.
40Classification of Environments
- The ISO 12944 environment categories are shown
below
Increasing Metal loss C1 to C5
41The Environment Examples
Inside an Airport terminal C1 Very Low
Corrosivity
42The Environment Examples
Inside an unheated warehouse C2 Low Corrosivity
43The Environment Examples
Stadia in urban atmospheres C3 Medium Corrosivity
44The Environment Examples
Construction Yards in industrial / coastal
atmospheres C4 High Corrosivity
45The Environment Examples
Chemical Plants in Industrial atmospheres C5-I
Very High Industrial Corrosivity
46The Environment Examples
Offshore Structures C5-M Very High Offshore
Corrosivity
Im2 Seawater Immersion
47System Selection Parameters
- Corrosion Properties Expected E.g. Salt Spray,
Humidity - Design Life Expectancy. Repaint after how many
years of running. - Dry Film Properties Expected E.g. Impact,
Flexibility, Hardness, Abrasion resistance,
Scratch resistance etc. - Gloss Retention
- Overcoatability
- Ability to be coated Wet on Wet
- Cost per Sq Mtr/year
- Track record in similar industries
- Drying Times
- Technical service/Online Trouble shooting
48RDSO Specification coaches and wagons
- PCN 100 Epoxy primer ,polyester putty,PU
surfacer and PU top coat - Performance requirement - 500 hrs salt spray/750
hrs QUV resistance - Our Counter offer Interfine 878 polysiloxane
top coat against PU top coat for better
weathering resistance and better anti graffiti
property. - Advantage to RDSO Better paint life cycle time/
better appearance - PCN 102 specification for epoxy primer
- Performance requirement 500 hrs salt
spray/humidity resistance - Our Counter offer
- Intergard 251 High build epoxy primer having
high DFT built up and - Intercure 200 HS High vol. solid, fast drying ,
high dft built up - Advantage to RDSO Better paint life cycle time/
faster production
49RDSO Specification coaches and wagons
- PCN 109 Specification for PU Top coat
- Performance requirement - 750 hrs QUV resistance
- Our Counter offer
- Interthane 990 high vol. solid ,high dft built
up top coat - Interfine 878 polysiloxane top coat against PU
top coat for better weathering resistance and
anti graffiti property. - Advantage to RDSO Better paint life cycle time/
better appearance/faster productivity - PCN 104 specification for epoxy finishing
paint - Performance requirement 1000 hrs salt
spray/humidity resistance over primer - Our Counter offer
- Intergard 966 High build epoxy finish coat
- Intergard 345 High vol. solid, fast drying ,
high dft built up top primer cum finish coat - Advantage to RDSO No requirement of primer
/faster productivity
50RDSO Specification coaches and wagons
- PCN 111 High build epoxy paint
- Performance requirement - 2000 hrs salt spary
/humidity resistance - Our Counter offer Interseal 670 HS
- Advantage to RDSO more dft built up/faster
productivity - PCN 123 High performance anticorrosion epoxy
coating - Performance requirement - 2000 hrs salt spary
/humidity -
resistance/chemical resistance - Our Counter offer Interseal 547
- Advantage to RDSO better performance /single
coat solution, Higher volume solids
51Special Coating
- Intergard 774 single coat fast curing epoxy
finish for wagon external - Advantage to RDSO single coat solution /faster
productivity/less Inventory control - Intershield 300 Universal abrasion resistance
epoxy coating - Advantage to RDSO Better corrosion protection
/Prevention of weight loss due to erosion of
steel owing high abrasion /Prevention of
contamination of contents of wagons - Interzone 954 Two component high solid epoxy
barrier coat - Advantage to RDSO Better corrosion protection
/Prevention of weight loss due to erosion of
steel owing high abrasion /Prevention of
contamination of contents of wagons /Robust
coating than intershield 300
52Product information
Interseal 670HS Surface tolerant epoxy mastic
coating Intergard 251 Epoxy zinc phosphate
primer Intergard 200HS Epoxy primer cum
intermediate coat with MIO,Zinc
phosphate Intergard 774 Single coat DTM epoxy
coating Intergard 345 Single coat epoxy primer
cum finish Interthane 990 PU finish Interfine
878 Polysiloxane finish Interfine 979
Polysiloxane finish Interline 399 Epoxy Novolac
tank lining Interline 850 Epoxy phenolic tank
lining Interzone 954 Modified epoxy barrier
coat Interzone 1000 Epoxy with glass flake
lining Intershield 300 Abrasion resistant
aluminium epoxy coating Interprime 741 Hot oil
resistant, weld able, etch PVB
53Recommended system choice for RDSO
Open wagons External Primer Interseal 670HS,
Intergard 251 Finish Interthane
990 Internal Interline 399, Interline 850,
Intershield 300, Interzone 954, Interzone
1000 Closed wagons External Primer Interseal
670HS, Intergard 251 Finish Interthane
990 Internal Interline 399, Interline 850
54Recommended system choice for RDSO
Stainless steel as a substrate External Primer
Intergard 251, Intergard 269 Finish Interthane
990 Internal If needed can be recommended We
have a system approval from Siemens (Test report
from Siemens / IIT) over stainless steel
Transformers External and Internal Standard 2
coat, 3 coat system as per classified
environment We have an approval from ABB (Job
being carried out at Cimotec) for transformers to
be used for DMRC
55Recommended system choice for RDSO
External anti graffiti paint for
coaches External Primer Intergard 251,
Intergard 269, Intergard 200HS Finish Interfine
878, Interfine 979 Internal If needed can be
recommended
56Partnering Progress
- We have ROHS compliant products.
- Ecotech/Low VOC initiative lesser solvent
emissions. - Coal Tar, Chrome and mutagenic solvent free
products (PU) - Isocynate free products
- Internationally banned solvents are not used.
- Upgrade systems to increase productivity
- Upgrade system to increase quality
- Train people on all aspects related to paint and
its use - Line audit / monitoring to be done
- Offer PFP (Passive fire proofing) OR fire
retardant paints
57Advantages to RDSO
- Introduction of better paint systems
- Savings on cost by way of higher life, lower M
R and increased productivity and better
protection of asset over a longer period can be
offered to Indian Railway - Ensuring product aesthetics/corrosion protection
with professional approach. - Single point contact for supply, technical help
for paints. - Testing help from local and world wide
laboratories of ANCIPL - Contemporary products and application techniques.
- Increase visibility / image in market as quality
manufacturer in this segment.
58Akzo Nobel RDSO
59Akzo Nobel RDSO