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ROUGE ALERT AND CORROSION MEASUREMENT

ROUGE ALERT AND CORROSION MEASUREMENT . IN HIGH PURITY WATER SYSTEMS PRESENTED BY: DARYL L. ROLL ASTRO PAK CORPORATION. NATURE OF ROUGE. Identification by Color (orange, brown, blue, black). Oxides of metals (iron- ferric and ferrous, abrasives, and other surface residues)

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ROUGE ALERT AND CORROSION MEASUREMENT

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  1. ROUGE ALERT AND CORROSION MEASUREMENT IN HIGH PURITY WATER SYSTEMS PRESENTED BY: DARYL L. ROLL ASTRO PAK CORPORATION

  2. NATURE OF ROUGE • Identification by Color (orange, brown, blue, black). • Oxides of metals (iron- ferric and ferrous, abrasives, and other surface residues) • Biogrowth or Organic residue deposits • Local versus deposition of deposits • Detection and research

  3. COMPOSITION OF ROUGES • Iron Oxide - Ferric oxide (Red) • Iron Oxide - Ferrous oxide (Grey or black) • Iron Oxide/Silicate - High Temperature Deposits (Black) • Aluminum/Iron Oxide - High Temperature Deposits (Grey) • Silicates/Carbonate - Water Scale Deposits (White) • Polishing Compounds - TiO, AlumOx (Grey/White) • Organic Compounds - Organic films (Brown)

  4. IMPORTANCE OF ROUGE CONTROL • Reduced effectiveness of sanitization treatments • Excessive corrosion degrades the surface • Rouge build-up enter process fluids • Color sensitive products affected • Fermentation process may be hindered • Rough surfaces aid biogrowth attachment

  5. STEPS IN ROUGE CONTROL • Complete an Effective, Thorough & Documented Initial Passivation • All surfaces must be contacted and processed • Documentation to meet FDA requirements • Proper design, conditions, and QA testing methods • Effects of Process Events • Circulation temperature above minimum requirements • Ozone or oxygen excursion into process fluids • Chlorides or other sanitants in system • Tracking System for Rouge Conditions • Visual inspection and wipe tests • Process Water testing for Iron concentration (ppb) • Electronic online monitoring system

  6. ROUGE MONITORING • Visual inspection program • Periodic scheduled documentation • Coupon system and Testing • Separated side flow stream for coupons • Water sampling and Testing • Storage unit, water source, distribution lines • Online monitoring system • Electronic monitor – Rouge Alert – passivation

  7. PROCESS OF DEROUGING • Sample of rouge for solubility and composition testing • Removal of organic and oxide deposits • Monitor removal of iron with spectrophotometer • Chemistry of derouging treatments • Repassivation after cleaning and derouging

  8. ROUGE REMOVAL • Chemical basis is passivation acid and specialty additives • Additional reducing agents/acids (reduction of ferric to ferrous iron) • Additional organic acid (dissolution of ferrous iron) • Added Fluorides (removal of silica) • Other specialty chemicals (removal of corrosion products or residues) • Diagnostic testing recommended

  9. FREQUENCY/IMPORTANCE OF PASSIVATION • Circulating Systems • Hot WFI Systems - 1 to 2 Years • Cold/Ambient Systems - 3 to 4 Years • Branch Systems (Steamed) • Microbial Dependent • Development of Rouge • Product Impact • Some product are sensitive to iron (rouge) • Iron could impact stability of product • Passivation Monitor • In-situ monitoring

  10. ROUGE PREVENTION AND ON-GOING MAINTENANCE • Complete effective initial Passivation • Inspection / system audits • Establish re-passivation cycle • De-rouging and cleaning processes • Cleaning / CIP skids

  11. PASSIVATION MONITOR • Rouge Alert system with Passivation Monitor • 316L Stainless steel construction • Inline Probe • 4-20ma output

  12. TECHNOLOGY OF ROUGE ALERT MONITOR • Solution Resistance Compensation: • Polarization Resistance • Solution Resistance • Double Layer Capacitance • Stearns Geary Equation • Rouge Accumulation Calculation • Derouge and Passivation Scheduling

  13. ROUGE ACCUMULATION

  14. ROUGING RATE HISTORY

  15. SUMMARY OF ROUGE CONTROL AND MEASUREMENT • Excessive rouge build-up is maintenace problem • Rouge is not a harmless and protective layer • Purity of process fluid is effected by cleanliness in distribution system • Schedule derouging based on inspection program • Monitor corrosion and rouge accummulation with an online process meter.

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