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Most capital projects in the energy market face significant cost overrun issues. There is a real need for innovation to improve productivity; reduce the need for completion on site and to minimize the annual operations maintenance budget. By optimizing the coating specification, we can increase the likelihood of paint completion during the project while increasing productivity and quality.
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Cleanliness of a metal surface prior to coating is imperative, just ask the paint manufacturers. Whilst there are several measurement techniques available to determine the level of soluble salts on a substrate prior to coating, Bresle is still considered by many as the “gold standard”.
The USMC CPAC Program provides a holistic approach to corrosion engineering on ground vehicles. This starts with the acquisition of a new system, where CPAC will work with the Program Manager (PM) to develop the contractual requirements for corrosion prevention and aid in the evaluation and verification of an Original Equipment Manufacturer (OEM) to meeting those requirements.
In November 2004 ISO 19840 was published to provide a consistent method for the measurement of coatings applied to structural steel for corrosion prevention. This new standard includes methods for the adjustment of gauges to take account of surface roughness, the designation of inspection areas and the use of acceptance criteria.
Microbiologically Influenced Corrosion (MIC) is an important degradation mechanism for materials in civil infrastructure. Recent findings in Florida showed severe corrosion of submerged steel bridge piles associated with microbial activity. Furthermore, heavy marine growth (i.e., tunicates, hydroids, barnacles) was observed on the steel piles, which was also thought to affect the corrosion process by creating oxygen concentration cells and causing the initiation of localized corrosion.
Historically the corrosion condition and cathodic protection (CP) effectiveness of pipeline networks have been monitored by over-the-line surveys. Pipe-to-soil potentials and rectifier outputs are the major parameters measured, and for some pipelines a more intensive close interval survey is executed. Today test stations and more frequently rectifiers are equipped with remote monitoring devices which is shifting the industry towards the world of digitization. Unfortunately, external corrosion is still not fully under control.
The polarity of the zinc-steel galvanic couple in hot aqueous solutions was published more than 20 years ago. It used an inorganic zinc primer coating that was applied under thermal insulation at elevated temperatures [30C-60C (86F-140F)]. Since the year 2000, industrial practices or standards do not recommend using inorganic zinc rich coatings under thermal insulation. Research has showed over the years that good practice of corrosion prevention under insulation is to apply an additional layer of a heat resistant modified epoxy or inorganic polymer coating as an additional barrier.
This paper is a “high temperature” sequel to previous investigations of four specialty inorganic coatings said to prevent corrosion under wet insulation conditions with temperature cycling both in the CUI range of -5°C to 175°C and up to ca 400°C.