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CORROSION FORUM

CORROSION FORUM. Industry Perspective Sheldon W. Dean 20 May 2003. Industry Perspective Issues. • Cost of Corrosion • Communications • Standards. Cost of Corrosion. • C C Technology Study - 2001 3.2% GDP • Battelle Study – 1975 4.2% GDP • Industry View.

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CORROSION FORUM

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  1. CORROSION FORUM Industry Perspective Sheldon W. Dean 20 May 2003

  2. Industry Perspective Issues • • Cost of Corrosion • • Communications • • Standards

  3. Cost of Corrosion • • C C Technology Study - 2001 • 3.2% GDP • • Battelle Study – 1975 • 4.2% GDP • • Industry View

  4. Cost of CorrosionIndustry View • • Cost of Corrosion Prevention • • Cost of Corrosion Failures • • Safety and Reliability

  5. Cost of Corrosion Prevention • • Capital costs • • Operation costs • • Failure analyses • - Key to continuous improvement • • Education, training & development • - Culture change

  6. Cost of Corrosion Prevention • CAPITAL COSTS • • Upgrade to resistant alloys • • High performance coatings • • Cathodic protection systems • • Design improvements & analyses

  7. Cost of Corrosion Prevention • OPERATING COSTS • • Inhibitors • • Cathodic protection operation • • Maintenance • - Repairs • - Touch-up • • Inspections

  8. Cost of Corrosion Prevention • FAILURE ANALYSIS • • Failure analysis policy • - What failures to examine? • • Responsible organization • - Internal lab or outside lab? • • Follow up – Fix • Who? When?

  9. Cost of Corrosion Prevention • EDUCATION, TRAINING & DEVELOPMENT • • Engineering – purchasing • • Operations • • Policy • • Communications

  10. Cost of Corrosion Failures • • Loss of capital • • Cost of fix • • Inspection of similar equipment • • Related costs

  11. Cost of Corrosion Failures • • Cascading effects • - Many items fail in sequence • • Damage depends upon random factors • • Any analysis contains subjective elements

  12. Safety & Reliability • • Safety and reliability are key issues • • Safety is not subject to cost analysis • • Consequence analysis • • Probability of failure • • Reliability is a key benefit of corrosion control

  13. Communication – Key Issues • • Who needs to be involved? • • What level of communication needed? • - Technical level? • - How extensive? • • Who is responsible? • • What are the deliverables?

  14. Communications • • Review of Air Products materials and corrosion programs • • Presented as an example of a successful activity • • Developed over 25 years • - Evolutionary process • - Designed tomeet changing needs

  15. Air Products M&C Program • • M & C Seminar • • M & C Workshops • • M & C Round tables • • A P University presentations • • Other

  16. M & C Seminar • • Intended for new engineers (1 to 3 yrs) • • Featured different departments • • 10 to 20 presentations • • 30 to 45 minutes for each subject • • 1 to 2 days duration • • Presented annually • • Attendance: 60 to 100

  17. M & C Seminar • • Presentation of technologies in M & C area • • Notebook with written papers • • College level assumed • -Chemistry and basic engineering • • Responsibility rotated - senior M & C staff

  18. M & C Workshops • • Local presentations at operating plants • • Small group of presenters, 2 to 4 • - Include local specialists if possible • • Tailored to specific plant issues • - e.g. sulfuric acid if used in plant • - agenda negotiated with plant • • Arranged by request from plant

  19. M & C Workshops • • Duration: ½ to 2 days • • Attendance: 15 to 40 • • Frequency: every 2 to 3 years • • Level: No technical training assumed

  20. M & C Workshops • • Responsibility: • - M & C Department sets agenda • - Local management absorbs costs • - Safety Department involved • • Program: • - General topics • - MTI videos • - Specific plant topics ( Failure analyses)

  21. M & C Roundtables • • Professional level group • • World wide participation • • Purpose: to share recent problems and results • • Encourage joint action and cooperation

  22. M & C Roundtables • • Meeting 4 times a year or more • • Typical attendance: 10 to 20 • • Teleconference + web and video • • Responsibility: rotating among senior M & C engineers (2 year term)

  23. A P University • • Wide range of technical topics covered • • M & C only small part of program • • 1 hr. presentation (lunch time) • • Topic: Recent developments with major technical impact • • Presenter: Responsible engineer

  24. A P University • • Attendance: 30 to 100 • - Wide range, engineers and managers • • Frequency: As needed (one per yr.) • • Policy level communication

  25. Communications - Other • • Materials Technology Institute News Letter • -Distributed world wide to engineers • • NACE & ASTM developments • • Liaisons: • - Safety & Environment Dept. • - Engineering Dept. • - Management

  26. Standards • • Corrosion Standards: • - ASTM, NACE, ISO • • Voluntary consensus documents • • International scope • • Documents with wide usefullness

  27. NACE Standards • • RP = Recommended Practices • - Industry recognized practices • • MR = Material Requirements • • TM = Test Methods • • 5 year review • • Committee Reports – state of the art

  28. ASTM Standards • • Test methods • - Measure property or characteristic • - Precision and Bias provided • - Important in corrosion evaluations • • Practices • - Procedure only • - Does not give a result

  29. ASTM Standards • • Specifications • -Specific requirements for product • - Important for purchasing • • Classifications • - grouping of materials with similar properties • • Terminology • -Definitions of terms in standards

  30. ISO Standards • • Documents similar to ASTM • • ISO favors European members • • Voting based on one per country • • Negative votes require a majority • • ASTM now no longer supports ISO for corrosion standards

  31. Wrap Up • The cost of corrosion prevention is a necessary cost of being in business. Reducing this cost is not necessarily beneficial but may create significant problems.

  32. Wrap up • Safety and reliability are key issues in corrosion prevention. Corrosion control should increase safety and reliability if it is effective.

  33. Wrap up • Communication is an essential component of a successful corrosion control program. Communication should deliver the necessary information to the individuals responsible for corrosion control in a timely and understandable manner.

  34. Wrap up • The communication process must be tailored to the appropriate individuals at the level that will be most helpful. It should present new developments in a timely fashion.

  35. Wrap up • Standards provide a valuable resource for engineers and purchasing people to obtain proven results by the most reliable methods known to industry. Government people should be active in standards organizations to take full advantage of the expertise in these organizations.

  36. Thank You! • Questions please?

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