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Ship & Marine Corrosion Control:

We Provide the following services ourselves or through our network partners and associates:

 

We Provide Corrosion Prevention Tools, Chemicals Equipments and Services.
*Inspection
*Material Testing
*Material Selection
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*Corrosion Inhibitors

Corrosion Control for Shipping & Marine: Article

Shipping and the Marine Industry suffers HEAVY LOSSES roughly estimated to be Billions of Dollars each year.

The factors listed below contribute to these losses:
Corrosion Related Downtime.
Repairs and Maintenance.
Construction of New Ship (replacements).
Not including the Safety and Readiness Cost that are hidden.

Why does Corrosion Occur:
It simply occurs due to the following Errors mainly;
Designing
Manufacturing
Installation
Operational
Supervisory
Maintenance

Is Corrosion Good or Bad- Although this topic is controversial, since everyday we are obsessed with Bio-Degradability. We strive to find ways to sustain our environment as it existed before the industrial revolution.

Corrosion is natures way of making materials bio-degradable(exactly what the word means- destroyed by Mother Nature itself).Most metals deteriorate when exposed to the environment (Natures way of Recycling). Rust is a simple example of corrosion.
There can be any number of reasons for the corrosion of metals. They may be exposed to rain , moisture, air, fumes, acids, alkalis, gases, liquid chemicals etc.

Corrosion Process:
The process of corrosion is normally electro-chemical in nature. The presence of positive and negative ions in an active environment completes the process. The positive ions are supplied by the metals and the negative ions by moisture in the air or water.

The important factors that contribute towards Shipping related or Marine Corrosion are:
Presence of High Solute content-(Sodium Chloride)
Presence of High Electric Activity-(Chloride ions)
High pH Values
Presence of Soluble Gas-(C02  and Oxygen)
Presence of Organic Compounds.
Presence of Microfouling and Macrofouling Organisms.- (fish, bacteria algae etc.)

Corrosion is mainly of two types-  Local or Spread:
Local corrosion is referred to that type, where it affects a small area and eats up the metal to form a pit. It is also called pitting. Pitting can cause holes, cracks and fatigue in metal resulting in structural failures. This can cause extensive damage and losses, especially in airplanes, sea vessels and concrete, where the stability of the structure is of prime importance. Errosion-corrosion and cavitations are other forms of localized corrosion, occuring in piping systems, boilers and steam equipments.
Corrosion spread over a large area cause general wastage of the metal or structure and if not immediately dealt with, results in costly repairs or sometimes can even lead to complete replacement.

Some of the factors that generally affect corrosion are:
1.The metal and its alloys:
    a.) The natural ability of the metal to form a Protective Coating(surface film).
    b.) The Electrolytic Conductivity of the Metal.
    c.) The Grain Boundary Composition.
    d.) Surface Condition.
    e.) The Physical and Chemical Composition.
    f.) The Evolvement of Hydrogen Gas.

2.The environment it is exposed to:
    a.) Affect of Oxygen dissolved in the Contact Solution.
    b.) Temperature of the Environment.
    c.) Reaction with the metal to form Protective Coating.
    d.) Viscosity and Rate of Flow of the Solution in Contact.
    e.) Presence of other Metals or Ions in the Contact Solution.
    f.) Contact of the Metal with other Materials or Metals.
    g.) Strength or Concentration of the Contact Solutions.
    h.) Cyclic Stress and Strain
    i.) Deposits
    j.) Time and Geometric factors

Since ancient times man has used metals and alloys, which has shown anti-corrosive properties
The use of these metals in everyday life has been phenomenal. Of prime importance was the use of this quality in the marine and wet environment, against salt and water combo.

Copper, lead, bronze, aluminum, magnesium, molybdenum have been widely known for their anti-corrosive properties and are extensively used.
Recent addition of alloys of Nickel, Nickel-Ferrous and Cobalt are high performance alloys also with anti-corrosive properties retaining them even at high temperature. Some alloys like the patented Monell has excellent anti-corrosive properties.

Since metals and its alloys are made up of micrograins, corrosion usually occurs at the grain boundaries or its adjacent areas. The factors can be many, but most prominently, it is due to segregation and precipitation of impurities present in the alloys.
That is why corrosion affects, some part of the metal, whereas the other part remains corrosion free. Mechanical process also has some detrimental effect on the properties of metals, most if it involves localized heating at high temperature, the best example of this is welding.
Welding joints are most prone to corrosion attacks since it can cause changes in the chemical composition along the grain boundaries adjacent to the joint.
The leafing effect observed in aluminum sheets and its alloys is also an example of intergranular corrosion. Leaching of an alloy can also cause corrosion in metals, dezincification of brass and graphitization of cast iron are example of this process.

Can Corrosion be prevented or at least minimized, can measures be taken in advance for its prevention and cure?

Off Course Yes.

Corrosion Prevention and Cure:
It is important to create an awareness system, by providing training and education about the cause, effect and also the implied cost of corrosion to everyone associated and involved.
The Designing stage is of utmost importance and at this stage itself there should be a tendency to do it right. Keeping in mind always the metals and there tendency to form oxides and sulfides naturally. Through a method of selection and elimination, of processes and materials, evaluating them at each stage is very essential.
Lastly the most important stage is, deciding and incorporating the fundamentals of corrosion management from the initial designing stage , through buying the system, and execution, always keeping in mind the importance of maintenance (regular & preventive ) and its cost.

Corrosion Risk Management:
Normally corrosion management and the risk involved with it are based on regulations, code of conduct and compliance by different governing bodies. It is left to people who act on their experience and personal judgments to carry out time based maintenance, usually on the job basis. 
Corrosion management should involve a structured well planned system, using as many variables available, in order to analyze and identify high risk, potential problems, of critical component and system failures. It should include instances of rare occurrence and the preventive steps to be taken in such cases.

Corrosion Monitoring:
Using a sophisticated system for corrosion management system, not only saves the cost of downtime, that is scheduled and unscheduled shutdown, but also protects people and the environment from contaminations & potential safety hazards.
The system should consist of devices, sensors, data logging, surveillance, and online data processing equipments.
All this data should be available to the operators, at all time and they should be able to process this information effectively and take timely action based on the process variables of conformity.

Corrosion Failure Analysis:
The data should be analyzed for three basic things:
Component failure
Human Failure
System Failure


To be continued...
 

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