CORROSION of LININGS and COATINGS: Cathodic and Inhibitor Protection and Corrosion Monitoring (Corrosion Engineering Handbook, Second Edition)

570 Pages·2006·6.53 MB·English

by  Philip A. Schweitzer

CAT8247—PRELIMS—10/11/2006—21:00—SRIDHAR—XML MODEL B – pp. 1–15
CAT8247—PRELIMS—10/11/2006—21:01—SRIDHAR—XML MODEL B – pp. 1–15
CAT8247—PRELIMS—10/11/2006—21:01—SRIDHAR—XML MODEL B – pp. 1–15
CAT8247—PRELIMS—10/11/2006—21:01—SRIDHAR—XML MODEL B – pp. 1–15
Preface
Corrosion is both costly and dangerous. Billions of dollars are annually spent
for the replacement of corroded structures, machinery, and components,
including metal roofing, condenser tubes, pipelines, and many other items.
In addition to replacement costs are those associated with maintenance to
prevent corrosion, inspections, and the upkeep of cathodically protected
structures and pipelines. Indirect costs of corrosion result from shutdown,
loss of efficiency, and product contamination or loss.
Although the actual replacement cost of an itemmay not be high, the loss of
production resulting from the need to shut down an operation to permit the
replacement may amount to hundreds of dollars per hour. When a tank or
pipeline develops a leak, product is lost. If the leak goes undetected for a
periodof time, the value of the lost product could be considerable. In addition,
contamination can result from the leaking material, requiring cleanup, and
this can be quite expensive. When corrosion takes place, corrosion products
build up, resulting in reduced flow in pipelines and reduced efficiency of heat
transfer in heat exchangers. Both conditions increase operating costs.
Corrosion products may also be detrimental to the quality of the product
being handled, making it necessary to discard valuable materials.
Premature failure of bridges or structures because of corrosion can also
result in human injury or even loss of life. Failures of operating equipment
resulting from corrosion can have the same disastrous results.
When all of these factors are considered, it becomes obvious why the
potential problem of corrosion should be considered during the early design
stages of any project and why it is necessary to constantly monitor the
integrity of structures, bridges, machinery, and equipment to prevent
premature failures.
To cope with the potential problems of corrosion, it is necessary to
understand
1. Mechanisms of corrosion
2. Corrosion resistant properties of various materials
3. Proper fabrication and installation techniques
4. Methods to prevent or control corrosion
5. Corrosion testing techniques
6. Corrosion monitoring techniques
Corrosion is not only limited to metalic materials but also to all materials
of construction. Consequently, this handbook covers not only metallic
materials but also all materials of construction.
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Chapter 1 provides information on mortars, grouts, and monolithic
surfacings.
Chapter 2 and Chapter 3 explain means of controlling/preventing
corrosion through the use of inhibitors or cathodic protection.
In many instances, it is more economical to construct a tank or processing
vessel of a less expensive metal, such as carbon steel, rather than an expen-
sive alloy and install a lining to provide protection from corrosion. Chapter 4
through Chapter 6 provides details of various lining materials of both
sheet and liquid form, while Chapter 7 through Chapter 10 provides details
of coating materials, both organic and metallic. Compatibility charts are
provided in all cases.
Because processing conditions can change or upsets take place, it is
necessary that any corrosion that may occur be monitored. Chapter 11
discusses various techniques that may be employed to keep check on any
corrosion that may be taking place internally in a vessel or pipeline.
It is the intention of this book that regardless of what is being built,
whether it is a bridge, tower, pipeline, storage tank, or processing vessel,
information for the designer/engineer/maintenance personnel/or whoever
is responsible for the selection of material of construction will be found in
this book to enable them to avoid unnecessary loss of material through
corrosion.
Philip A. Schweitzer
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Author
Philip A. Schweitzer is a consultant in corrosion prevention, materials of
construction, and chemical engineering based in York, Pennsylvania. A
former contract manager and material specialist for Chem-Pro Corporation,
Fairfield, New Jersey, he is the editor of the Corrosion Engineering Handbook
and the Corrosion and Corrosion Protection Handbook, Second Edition; and the
author of Corrosion Resistance Tables, Fifth Edition; Encyclopedia of Corrosion
Technology, Second Edition; Metallic Materials; Corrosion Resistant Linings and
Coatings; Atmospheric Degradation and Corrosion Control; What Every Engineer
Should Know About Corrosion; Corrosion Resistance of Elastomers; Corrosion
Resistant Piping Systems; Mechanical and Corrosion Resistant Properties of
Plastics and Elastomers (all titles Marcel Dekker, Inc.), and Paint and Coatings,
Applications and Corrosion Resistance (Taylor & Francis). Schweitzer received
the BChE degree (1950) from Polytechnic University (formerly Polytechnic
Institute of Brooklyn), Brooklyn, New York.
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Contents
Chapter 1 Chemical Resistant Mortars, Grouts, and Monolithic
Surfacings ........................................................................................ 1
1.1 Introduction .................................................................................................. 1
1.2 Materials Selection....................................................................................... 3
1.3 Chemical-Resistant Mortars and Grouts.................................................. 3
1.3.1 Organic ............................................................................................. 4
1.3.1.1 Epoxy .................................................................................. 4
1.3.1.2 Furans ................................................................................. 7
1.3.1.3 Phenolics............................................................................. 9
1.3.1.4 Polyesters ......................................................................... 10
1.3.1.5 Vinyl Ester and Vinyl Ester Novolac........................... 12
1.3.2 Inorganic......................................................................................... 13
1.3.2.1 Sulfur................................................................................. 14
1.3.2.2 Silicates ............................................................................. 15
1.4 Chemical-Resistant Monolithic Surfacings and Polymer
Concretes ..................................................................................................... 16
1.4.1 Chemical Resistance ..................................................................... 37
1.4.2 Applications................................................................................... 40
Chapter 2 Cathodic Protection ..................................................................... 43
2.1 Introduction ................................................................................................ 43
2.2 Background................................................................................................. 43
2.3 Theory.......................................................................................................... 44
2.4 Method of Application.............................................................................. 46
2.4.1 Impressed Current Systems ........................................................ 46
2.4.1.1 Current Requirements.................................................... 47
2.4.2 Sacrificial Anodes ......................................................................... 47
2.4.2.1 Anode Requirements...................................................... 48
2.4.2.2 Anode Materials and Backfill ....................................... 50
2.5 Use with Coatings...................................................................................... 51
2.6 Testing for Completeness of Protection ................................................. 52
2.6.1 Coupon Tests ................................................................................. 52
2.6.2 Colormetric Tests .......................................................................... 52
2.6.3 Potential Measurements .............................................................. 52
2.7 Overprotection............................................................................................ 53
2.8 Economics ................................................................................................... 53
Chapter 3 Corrosion Inhibitors.................................................................... 55
3.1 Introduction ................................................................................................ 55
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