Engineering Failure Analysis 14 (2007) 15001511 www.elsevier.

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Identication of microbiologically inuenced corrosion (MIC) in industrial equipment failures

J. Starosvetsky
a

a,*

, D. Starosvetsky b, R. Armon

Division of Environmental, Water and Agricultural Engineering, Faculty of Civil Engineering, Technion, Haifa 32000, Israel b Division of Corrosion and Electrochemical Processes, Faculty of Materials Engineering, Technion, Haifa 32000, Israel Received 17 August 2006; accepted 6 January 2007 Available online 2 March 2007

Abstract The present study demonstrates dierent approaches towards MIC identication in three real cases of technological equipment failures. In the rst case the failure of carbon steel heat exchanger as a result of tubes, lids, tube sheets, and connection pipes clogging was investigated. Chemical analysis of cooling water and precipitates, as well laboratory screening of deposits for bacteria, revealed that activity of iron-oxidizing bacteria present in cooling water led to heat exchanger blockage. The second case is related to MIC detection on oating roofs made of magnesiumaluminum alloy following a 3-weeks hydro-test. Corrosion tests carried out on the original and sterilized water used in hydro-test conrmed MIC process. In the third case the potential of MIC occurrence in engine cooling system made of cast aluminum alloy and lled with 20% ethylene glycol coolant solution was evaluated. The simulation tests allowed determining the real causes of the severe corrosion attack of examined system, including MIC high probability. 2007 Elsevier Ltd. All rights reserved.
Keywords: MIC identication; Failure analysis; Simulation

1. Introduction In the last two decades MIC was recognized as an important mechanism of metallic construction materials degradation. The heavy cost of microbial corrosion in various branches of modern industry is now well documented [1,2]. However, ignoring this problem, taking as yet place in practice, gives rise new and new case histories of metallic equipment failure due to participation of microbes in corrosion processes. Uncovering of biological factor in corrosion processes that occurs in modern industry is quite an intricate task, since MIC does not produce any unique type of localized corrosion. Even isolation of corrosion induced microorganisms from a specic environment is not a sucient argument to exclusively state that these microbes were responsible in initiating or accelerating the corrosion failure. Successful identication of
*

Corresponding author. Tel.: +972 4 9591160. E-mail address: starjean@tx.technion.ac.il (J. Starosvetsky).

1350-6307/$ - see front matter 2007 Elsevier Ltd. All rights reserved. doi:10.1016/j.engfailanal.2007.01.020

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MIC having a multi-disciplinary nature requires an integrated approach. Chemical and microbiological analysis of the milieu, examination of metal characteristics and its corrosion behavior, examination of corrosion products, etc. are necessary to understand the corrosion problem, however only corrosion process simulation may exclusively conrm microorganisms contribution in the corrosion failure and assess their true role. In this work we present three typical investigations from our failure analysis practice devoted to assessing of microorganisms involving in corrosion destructions occurred in Israeli industry. 2. Experimental Water or coolant samples were collected in 1 L sterile plastic or glass containers. As a rule corrosion products were sampled from the most damaged sites of the corroded surface by scrapping. For microbiological analysis part of the collected corrosion products were resuspended in sterile phosphate buer. Prior to investigation the taken probes were stored at 4 C. Chemical composition of water was determined by atomic adsorption method. Chemical composition and morphology of corrosion deposits were detected by means energy dispersive spectroscopy (EDS) and scanning electron microscopy (SEM). To estimate the role of microorganisms in destructive processes several bacterial groups were selected as an index of biofouling and biocorrosion potential: heterotrophic aerobic bacteria (HAB), sulfate-reducing bacteria (SRB), iron-oxidizing bacteria (IOB) and fungi. These bacterial groups are dominant and most important microorganisms associated with bio-deposits formation and acceleration of corrosion processes. The isolation and count of the microbes was performed according to Standard Methods [3] as it was described in [46]. 3. Results and discussion 3.1. Case 1. Fouling of carbon steel heat exchanger caused by iron bacteria A carbon steel (CS) heat exchanger was installed along a fresh water line at the reverse osmosis unit at the Haifa Renery Plant, Israel. After 11/2 years from start-up the heat exchanger failed as a result of rust-colored deposits formation that clogged tubes, leads, tube sheets and connecting pipes. The goals of the study were to detect the causes of such fast clogging occurred under operation conditions, to estimate the bacterial eect on the process, and to evaluate the countermeasures. 3.1.1. Field conditions The heat exchanger was used to heat water from 15 to 25 C during the cold season of the year, feeding a reverse osmosis unit. During warm seasons, the heat exchanger was not active. Consequently, for several months the internal water was subjected to very low ow conditions or stagnancy. Feed water to the reverse osmosis unit owed through the tubes with steam on the shell side. The source water was a mixture of surface and potable well water stored in a large open air reservoir. 3.1.2. On-site observation Visual observation revealed that practically all parts of tested heat exchanger were plugged with brown rust deposits in the form of various dimension tubercles, which were strongly adhered to the steel surface (Fig. 1a and b). These deposits were accumulated from both sides of the heat exchanger (water inlet and outlet). The sediments layer thickness ranged from 1 to 6 cm. Shallow and dip pits (up to 10 mm) were detected on tube sheets and led surfaces following removal of the tubercles. Both ends of the tubes were severely damaged by corrosion. 3.1.3. Results of the investigations The analyses of incoming water (Table 1) showed that this chemical combination could not provide an extreme milieu that would cause the observed fast accumulation of rust detected on the internal heat exchanger surface and high corrosion rate of CS. Microbiological analysis conducted in water (planktonic bacteria) and in corrosion products scrapped from the corroded surface (sessile bacteria) revealed (Table 2) that most of the cultivable bacteria were HAB. The

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Fig. 1. (a) Tube sheet ends damaged by corrosion beneath deposits. (b) Corrosion slime sediments formed on inside surface of the pipe.

Table 1 Chemical composition of cooling water Parameters pH p-alkalinity Total alkalinity Cl SO2 4 Fe+2/Fe+3 (soluble) Fe (total) SiO2 Total hardness Ca hardness Mg hardness NO 3 NH 4 COD Chlorine TOC Conductivity Suspended solids Unit CaCO3 (ppm) CaCO3 (ppm) NaCl (ppm) SO2 (ppm) 4 ppm ppm ppm CaCO3 (ppm) CaCO3 (ppm) CaCO3 (ppm) ppm ppm MgO2/L ppm mg/L lS/cm ppm Value 6.97.4 0 80190 210350 4048 0.040.11 0.106 510 210230 110185 100125 811 0.10.4 38004700 0.20.7 2.8 9001100 14

cooling water carried a high concentration of iron bacteria and SRB. As expected, in the rust slime sediments the concentration of these bacteria was several orders of magnitude higher, especially for iron bacteria (IOB) and HAB. Physicochemical analysis (EDS) of rust deposits sampled from internal surface of tested heat exchanger showed that the examined slime contained up to 18% of organic substances. Elevated concentration of organic

J. Starosvetsky et al. / Engineering Failure Analysis 14 (2007) 15001511 Table 2 Bacterial count of tested bacteria in cooling water and slime sediments Microbial group type HAB (TPC) SRBc (total count) IOBd (total count)
a b c d b

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Planktonic bacteria (CFUa/ml) 2.2 104 52 4.0 102

Sessile bacteria (CFU/g) 4.5 109 5.4 103 4.9 107

CFU-colony forming units (viable cells). Heterotrophic aerobic bacteria (HAB), total plate count (TPC). Sulfate-reducing bacteria (SRB). Iron-oxidizing bacteria (IOB).

matter detected in slime rust indicated participation of isolated microorganisms in the process of slime formation. Despite of the fact that concentration of HAB in examined rust was the highest, this type of bacteria cannot be assumed to be responsible for accumulation of the large amounts of iron oxides and hydroxides, which led to the heat exchanger clogging. The isolated both in water and corrosion products SRB, presumably played certain role in localization of corrosion process occurred on heat exchanger surface under sediments, but also did not participated in slime deposits formation. Even sulfur compound traces were not found in scrapped deposits analyzed by EDS, despite the fact that H2S produced by SRB may react with metal ions present in water to form insoluble suldes of metals. The corrosion failure and rusty slime accumulation found on the inner surface of the heat exchanger may be attributed to iron bacteria activity. The EDS analysis revealed that sediments were comprised mainly of iron and oxygen (2:3 ratio). According to SEM examination, the rust deposit contained two dierent morphological forms: compact, dense particles, and crumbly, highly porous deposits with organic inclusions. After staining the deposit with crystal violet solution, numerous lamentous bacteria cells were found among the rust particles. The laments resembled the classical form of iron-oxidizing (iron-precipitating) bacteria of Leptothrix or Sphaerotilus genera. Microbiological analysis of iron bacteria mixed culture isolated from examined rusty slime showed that the culture consisted only of Sphaerotilus genera. It is well known that these bacteria may signicantly participate in rusty slime formation, producing large amounts of iron oxides and hydroxides precipitates in a very short period of time. It was shown that a biotic oxidation of rate of Fe(II) is at least one order of magnitude higher than an abiotic one. At a biotic oxidation of Fe(II) rusty deposits are usually very abundant in comparison with bacterial cells. Starkey [7] and Stephenson [8] calculated ratio iron-to-cell materials: it was 448500:1. Ironoxidizing bacteria generate energy for growth by oxidation of ferrous ions to ferric ions. Some types of iron bacteria may catalyze precipitation of preoxidized soluble ferric ions [9]. Iron bacteria were identied at high concentration both in the cooling water and particularly in corrosion sediments (Table 2). According to Cullimor and McCann [10], in running water iron bacteria proliferation could be observed if the ferrous ion concentrations were to exceed 0.20.5 mg/l. Iron bacteria also may acquire iron from equipment materials made of iron or CS (pipes, heat exchangers, etc.) In the present case concentration of soluble ferrous ions in tested cooling water (see Table 1) was insucient (<0.2 mg/l) to assist proliferation of iron bacteria. Nevertheless, a high corrosion rate of CS in fresh water can provide a high rate of ferrous ions transfer into the water phase, which can be used as additional energy source to iron-oxidizing and iron precipitating bacteria. Hence, it is fair to assume that the investigated water system had a high potential to carry iron bacteria activity, particularly through period of continuous ow. Under these favorable growth conditions, iron bacteria present in cooling water could stimulate deposition of Fe(III) on the heat exchanger inner surface, accelerating the corrosion rate of steel beneath deposits to cause plugging of the water system. This assumption is supported by experimental results, such as: An high ratio 1:5.5 between organic matter and inorganic iron-containing compounds, indicating that deposits were most likely a result of microbial activity. High numbers of iron-oxidizing bacteria found in source water and particularly in rust sediments.

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The tubercle-shaped morphology of deposits, which are typical for rust slime formed due to iron bacteria activity. Thus, on the base of conducted investigations it was concluded that failure of tested heat exchanger (clogging and severe localized corrosion) was directly related to the activity of iron-oxidizing bacteria detected in use cooling water. Heat exchanger made of carbon steel most likely served as a nutrient source for iron bacteria. Continuous leaching of ferrous ions into the running water coupled with good aeration of running water, resulted in corrosion of mild steel in fresh water encouraging aerobic iron bacteria growth and fast production of large amounts of biogenic rusts. Pitting corrosion observed under rust-slime layers (tubercles) on the parts of heat exchanger (tubes, sheets etc.) was probably caused by action of concentration cells formed on metallic surface due to creation of dierential aeration zones under primary deposits and accumulation of SRB, chlorides and other corrosive components in that zones. 3.2. Case 2. MIC of aluminum alloy oating roofs for storage tanks during hydro-test At Gadiv Petrochemical Company (Haifa, Israel) four steel tanks with aluminum alloy 5052 (USN A95052) oating roofs were erected to storage of aromatic solvents. Prior to use, these tanks were hydrostatically tested at ambient temperature for $3 weeks. The test revealed severe localized corrosion (up to full penetration) on the underside of the roofs. In order to determine why tested roofs were subjected to such severe corrosion so quickly, this study was performed. 3.2.1. Field conditions The tanks of 3000 m3 volume were made of mild steel. Test water came from the re water piping without any pre-treatment. The tanks were lled and exposed to ambient temperature ranging from $12 C (night) to 25 C (day) for 3 weeks. The oating roofs dimensions were 16.8 m in diameter and 0.48 mm. thick. Chemical composition of the roofs alloy was: (weight%): Mg 2.22.8; Si + Fe < 0.45; Cu max 0.1; Mn max 0.1; Al remainder. 3.2.2. On-site observation and sampling The roofs were inspected following drainage of water. Visual observation revealed that remarkable amount of white corrosion products had formed on the underside of the roofs (Fig. 2a). The entire roof surface in contact with water suered severe localized corrosion. Shallow and deep pits, and even holes of various shapes and dimensions, were found under the white deposits (Fig. 2b). Corrosion products were scraped from various locations for chemical and microbiological composition. Water samples for chemical and microbiological analysis were collected from the re water piping at the same tap that supplied the hydro-test water. 3.2.3. Results of the investigations Table 3 shows the chemical composition of water used for hydro-test. The susceptibility of aluminum and its alloys to localized corrosion is well known [11]. Chloride ions and pH are the main factors that determine the corrosion resistance of aluminum and its alloys in water. In the present study the pH of the water had a slightly basic value, which is not harmful to an aluminum alloy. The high chloride content could be considered a potential cause of pitting attack initiation of the roofs. However, the water parameters likely would not have caused the fast and severe corrosion attack observed during the hydro-test. The EDS analysis revealed that corrosion products taken from dierent parts of the corroded aluminum alloy roofs primarily contained aluminum and oxygen. Chlorides were detected in only one of the tested probes. Analytical determination of chlorides in the corrosion products showed: their chloride content: was 0.17%. The concentration of sulfur and sulfates was $0.24%. It was found only minute amounts of copper, silicon (alloying elements), carbon and calcium and no traces of magnesium (the main alloying element of the alloy) in the corrosion products. Water and corrosion product deposits were also tested for the presence of corrosion inducing microorganisms (Table 4).

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Fig. 2. (a) Corrosion products formed on the underside of the roofs. (b) Severe localized corrosion of the roof s inside surface.

Table 3 The chemical content of the re-extinguishing water Parameter pH p-Alkalinity Total alkalinity Cl SO2 4 Total hardness Ca hardness Mg hardness Iron Oil NO 3 TOC Conductivity Unit ppm CaCO3 ppm CaCO3 ppm ppm ppm CaCO3 ppm CaCO3 ppm CaCO3 ppm ppm ppm ppm S/cm Value 7.68.2 240 150200 400630 60180 250300 110160 130140 0.516 1 10 3.0 9001300

Results of microbiological analysis showed, that water used in hydro-test was contaminated with various types of microorganisms considered highly corrosive. The re water contained high concentrations of fungi (1.7 102 cells/ml) and HAB and HAnB (>103cells/ml). SRB and iron-oxidizing bacteria were also isolated from water samples, but T. thiooxidans was not detected. The number of isolated microorganisms in corrosion products was two to four orders of magnitude higher than detected in water.

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Table 4 Bacterial count of microorganisms in re-extinguishing pipelines water and corrosion products Microbial group type HAB (TPC) HAnBa (TPC) SRB (total count) IOB (total count) T. thiooxidans Fungi (TPC)
a

Water (CFU/ml) 2.4 103 5.1 103 2.2 3.2 Not detected 7 102

Corrosion products (CFU/g) 2.2 107 4.5 107 6.7 102 1.4 104 Not detected 8.0 106

Heterotrophic anaerobic bacteria (HAnB).

Microorganisms accumulation in the corrosion products indicates that biofouling processes occurred on roof surfaces during the hydro-test. As known, biofouling may initiate and accelerate corrosion attack [1,2]. The availability of corrosion inducing microorganisms in water and even their adsorption to a surface is required, but it alone is not a sucient condition for biocorrosion process development. This process heavily depends on metal or alloy type, physico-chemical parameters of the medium and microbial composition. A very important factor in biocorrosion initiation is bacteria metabolic activity; it depends on the suitability of the chemical compounds that are present in the water, which may serve as carbon and energy sources required for bacterial metabolism. Consequently, the chemical and microbiological results did not yield a denite conclusion on the role of microorganisms in the corrosion attack. At this stage, there was no way to separate the corrosion eect of chloride concentration from that of microorganisms. To clarify the role of microorganisms in this matter, laboratory corrosion tests were performed with untreated and membrane-ltration sterilized waters. In these experiments coupons made of aluminum alloy Al 5052 (rings with diameter 30 mm, thickness 1.7 mm, and width 10 mm) and pure aluminum Al 1100 (UNS A91100) (rectangular plates of 20 20 3 mm) were used. Chemical composition of tested aluminum was: (weight% ) Cu 0.06; Al-remainder Table 5 shows the results. No evidence of corrosion was detected on pure aluminum (1100) coupons exposed for 90 days in both untreated and sterilized by ltration waters. In addition, no signs of corrosion on Al 5052 aluminum alloy specimens exposed to sterilized water were observed during the entire experiment. The aluminum alloy coupons tested in untreated water revealed visual corrosion on the 14th day of exposure. The corroded areas exhibited a strongly localized character and were accompanied by the formation of aky, white corrosion products (Fig. 3). Corrosion tests showed conclusively that the microora in the water used for the hydrates played a very important role in producing corrosion on the roofs. Data show that microorganisms may severely damage aluminum and its alloys in a fairly short time period even in such relatively clean (from a microbiological point of view) but unsterile media. High susceptibility of aluminum and its alloys to localized corrosion makes it particularly vulnerable to MIC [12]. Hence, it is reasonable to expect a higher risk of MIC initiation when untreated water is contaminated with corrosioninducing microorganisms. The experiments demonstrated that in bacterially polluted water the aluminum-magnesium alloy coupons sustained strong corrosion attack, unlike pure aluminum. It should be emphasized that both waters had the same chloride concentration; this comparison indicates that an alloying element such as magnesium reduces the corrosion resistance of aluminum. Because the corrosion product probes detected no traces of magnesium, one can assume that magnesium forms soluble corrosion products. A likely scenario is that magnesium ions emitted from the corroded surface interact with some organic metabolites excreted by biolm bacteria, creating soluble complex compounds. Pitting initiation on aluminum alloys is usually attributed to the presence of chloride ions. The investigation revealed that the activity of microorganisms present in the surrounding
Table 5 Results of corrosion tests carried out for 90 days in untreated and sterilized re water pipelines Metal Al 1100 Al 5052 Untreated water No corrosion Pitting corrosion on the 14th day of exposure Sterilized water No corrosion No corrosion

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Fig. 3. Picture of Al 5052 alloy coupons exposed to original (left ask) and sterilized (right ask) waters on 14th day of corrosion test.

medium may substantially accelerate the corrosion process. It was demonstrated that strong localized corrosion of the aluminum alloy Al 5052 oating roofs that occurred during the hydrotesting was directly related to the activity of microora introduced with untreated water to tested tanks. 3.3. Case 3. Investigation of severe corrosion of aluminum parts from inoperative diesel engine cooling systems Diesel engines were placed in long-term storage in an operational status in a low-humidity controlled atmosphere to prevent corrosion. The engines were serviced every two years, a process that included the replacement of engine coolant. Severe corrosion occurred on some of the aluminum components of the cooling systems (Fig. 4). The analysis was done in order to determine the causes of the acute corrosion. 3.3.1. Field conditions and on-site observations The coolant was a non-commercial, tailor-made formulation used for long-term storage. It was composed of 99.4% ethylene glycol (EG) (to prevent freezing) and several corrosion inhibitors that were intended to pro-

Fig. 4. Corrosion damage in cooling system components made of A03560 cast aluminum alloy. (a) Radiator elbow. (b) Thermostat cover. (c) Radiator housing.

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tect the various metal components of the engine (aluminum, copper, steel, cast iron, etc.) against corrosion. The inhibitors consist of borates, nitrates, phosphates, silicates, and some supplementary organic inhibitors. The coolant is supplied by several vendors and each lot is tested according to ASTM D-1384 [13] requirements. Because the coldest winter temperature in Israel is only near freezing, and also to cut maintenance costs, the engine cooling systems were supplied with 20% coolant (diluted with tap water) instead of the usual 50% concentration. Field experience suggested that the concentration of EG might be lowered to a range of 2030%. During the scheduled replacement of the engine coolant, mechanics observed some leaks that were caused by corrosion attack on various aluminum A03560-T6 parts such as: elbows, pipes, covers, etc. (Fig. 4). The causes of observed corrosion failures were investigated. 3.3.2. Supplementary experimental procedure The coolant samples (duplicates) from ten systems were examined for presence of corrosion induced microorganisms. To evaluate the possible proliferation of micro-ora in the coolant, the activity and growth of HAB, which are naturally found in tap water, were monitored in coolant of various concentrations diluted with tap water. Experiments were carried out in 1%, 5%, 10%, 20% and 50% (v/v) aqueous EG solutions prepared from a stock coolant. With the aim of accelerating the process, 500 mL experimental solutions were maintained at 31 C. The monitoring interval was 100 days. The electrochemical behavior of cast aluminum alloy (A03560) specimens in coolant solutions was studied in a standard 1 L electrochemical glass cell controlled by a M263 potentiostat/galvanostat (EG&G, USA). The potentials throughout the text refer to a saturated calomel electrode (SCE). A platinum wire was used as a counter electrode. These experiments were carried out on 15 15 3 mm ag-type specimens that were cut of the damaged parts. Prior to measurement, the specimens were degreased in acetone, washed in distilled water, and air-dried. Potentiodynamic cathodic and anodic polarization curves were measured at a scan rate of 1 mV/s. The potentiodynamic measurements were initiated from an extra negative potential (250 mV) compared to steady-state Ecorr value of a working electrode. 3.3.3. Results and discussion To evaluate the possible microbial contribution to corrosion damage, a microbiological analysis of corrosion-inducing microorganisms was performed with coolant probes sampled from several cooling systems (Table 6). The coolant probes were originally contaminated with corrosive microorganisms capable of inducing biofouling and corrosion processes under appropriate conditions. MIC associated with contaminated diesel engine coolants was previously reported [14]. The isolated microorganisms were presumably introduced into the system through non-sterile tap water used to dilute the coolant. Chemical composition of the water was very close to that given in Table 1. An additional aspect was revealed during bacterial counting of the experimental probes: the higher the dilution of coolant, the higher the number of HAB detected. This phenomenon occurs when certain dilution of the coolant diminishes the biocidic eect of present inhibitors. The original combination of parameters such as: (a)
Table 6 Composition of corrosion-inducing microorganisms in the coolant probes (CFU/100 ml) Number 1 2 3 4 5 6 7 8 9 10
a

pH 8.40 8.20 8.90 8.50 8.61 8.44 8.43 8.46 8.78 8.46

HAB 48 1.2 105 1.1 107 26 22 2.5 105 3.6 102 1.1 103 2.4 106 2.0 102

SRB N.D. N.D. N.D. 1.8 102 5.5 102 N.D. N.D. N.D. N.D. 90
a

Iron Bacteria N.D. N.D. 57 N.D. N.D. 2.3 102 N.D. N.D. 9.5 102 N.D.

Fungi and Yeast 8 1.8 102 3.0 103 2 N.D. 1.3 105 N.D. N.D. 1.0 103 N.D.

N.D. not detected.

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basic pH (8.5) of coolant that is not optimal for microorganisms activity, (b) the presence of borates (with biocidic features), and (c) high concentrations of EG lead to the inhibition of bacterial proliferation. Further experiments done were to assess the role of these microorganisms and whether they could proliferate at different EG solution concentrations. The growth potential of HAB that were originally seeded into 1%, 5%, 10%, 20% and 50% (v/v) EG-containing solutions through dilution with non-sterile tap water was monitored for a 100 days interval. As shown in Fig. 5, during the rst two weeks of exposure in EG-containing solutions (concentrations 1%, 5%, and 10%) a sharp increase in HAB concentration was observed (two to four orders of magnitude) compared with the control (tap water) that revealed regrowth of only two orders of magnitude. Following this initial regrowth period, the number of HAB in control continuously decreased (due to luck of nutrients), while in EG solutions (1%, 5%, and 10%) bacterial cells continued to grow. Around the 20th exposure day, the increase in the number of bacteria in dilutions 1% and 5% EG solutions came to an end and persisted at the same level during the remaining exposure period. At 10% EG solution the HAB growth was slower, but it reached the same number as 1% and 5% solutions after 100 days. At EG concentrations of 20% and 50%, a decrease of one order of magnitude during the 14 days was observed, followed by an increase in HAB numbers of 3 1/2 orders of magnitude for the remaining time interval (approx. 85 days). The initial HAB number decrease may likely be attributed to the higher concentration of biocides in these samples. In due course, however, bacterial adaptation to toxic media can explain the re-growth and levels achieved. In this experiment, the kinetics of HAB growth revealed that bacteria could most probably utilize components of EG solutions for their metabolism and cell production. This conclusion is conrmed by the viable bacterial number reduction in the control sample (tap water with very low organic carbon content and without coolant solution).Throughout the preparation process of EG solutions with tap water, the formation of large white precipitates was observed. This result was not observed when experimental solutions were prepared with double distilled water. To determine whether the sediment formation aects the coolant corrosiveness on aluminum specimens, comparative electrochemical measurements were conducted in 20% EG solutions (eld concentration, as mentioned earlier) diluted with tap and distilled water (Fig. 6). The potentiodynamic polarization curves showed that in EG solution diluted with distilled water, the aluminum was characterized by deep passivity in a wide potential range (up to 1 V). No evidence of pitting corrosion was detected in this kind of solution. In contrast, the aluminum demonstrated high susceptibility to pitting corrosion with a breakdown potential around 0.05 V (SCE) in EG solution diluted with tap water. These results demonstrate that in tap water dilutions, the eciency of the coolants inhibitors sharply decreased compared to dilutions with distilled water. This eect could be attributed to chemical reaction between inhibitory compounds and bivalent ions such as Ca+2, Mg2+, and some other ions present in tap water that caused insoluble salts formation. Furthermore, Cl ions from tap water promote pitting corrosion.

Bacteria number (CFU/ml)

10 10 10 10 10 10 10

7 6 5 4 3 2 1
Tap water 1% EG 5% EG 10% EG 20% EG 50% EG

20

40

60

80

100

Time (day)
Fig. 5. Growth kinetics of HAB in dierent concentrations of EG in tap water at 36 C.

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0.5

A- 20% EG in dist. water B- 20% EG in tap water A

Potential (VSCE )

0.0 -0.5 -1.0 10-7 10-6

10-5

10-4

Current

(A/cm2)

Fig. 6. Aluminum potentiodynamic polarization curves measured in 20 v% EG solution diluted with double distilled water (A) and tap water (B). Scanning rate: 1 mV/s.

Thus, through simulation of dierent parameters that might be responsible for the strong corrosion attack on the experimental cooling systems, four major failure factors were determined: (1) Depletion of applied inhibitor additives because of the chemical reaction between inhibitors and ions present in tap water (i.e. Ca+2, Mg+2), leading to formation of insoluble salts. (2) Initiation of pitting corrosion by Cal ions introduced into coolant through tap water as diluent. (3) MIC by the proliferation of corrosion-inducing caused by three factors: (a) the dilution of the original coolant with tap water containing local bacteria and contamination, (b) the reduction in inhibitory compounds through dilution and (c) the successful utilization of EG or inhibitors (at lower concentrations) by introduced bacterial population. (4) Higher coolant concentrations (>20%) is less favorable for the development of corrosion-inducing microorganisms and, consequently, to MIC development, and they can be used as a threshold to prevent corrosion damages in such systems.

4. Conclusions The present study demonstrates that uncovering of MIC in technological equipment failures requires an individual approach of each case. These investigations also revealed that in certain cases, assessment of microorganisms present in surrounding medium role in corrosion destruction is possible only by simulation of the corrosion parameters found in the eld, which have a real eect on the process. Acknowledgements This work was accomplished with nancial support and facilities of the Oil Reneries, Ltd. (Israel). J.S. and D.S were partially supported by the Ministry of Adsorption. References
[1] [2] [3] [4] [5] [6] [7] [8] [9] Videla HA. Manual of biocorrosion. Boca Raton, New York, London, Tokio: Lewis Publishers; 1996. Borenshtein SW. Microbiologically inuenced corrosion handbook. Cambridge, England: Woodhead Publishing Limited; 1994. Standard Methods for the Examination of Water and Wastewater, APHA, 19th ed., Washington, D.C., 1996. Starosvetsky J, Armon R, Groysman A, Starosvetsky D. Mater Perform 1999;38:55. Starosvetsky J, Armon R, Groysman A, Starosvetsky D. Mater Perform 2002;41:50. Starosvetsky J, Armon R, Groysman A, Starosvetsky D. Mater Perform 2005;44:56. Starkey RL. Science 1945;102:523. Stephenson M. Bacterial metabolism. New-York: Longmann, Green & Co.; 1950. Ehrlich H.L. Geomicrobiology. M. Dekker, editor. New-York-Basel-Hong-Kong, 1996.

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[10] Cullimor DR, McCann AE. Aquatic microbiology. In: Skinner FA, Shewan JM, editors. London, New York, San Francisco: Academic Press; 1977. [11] Szklarska-Smialovska Z. Pitting corrosion of metals. An ocial NACE Publication; 1986. [12] Schmitt CR. Corrosion-case histories in biologically inuenced corrosion. In: Dexter SC, editor. NACE, Houston, TX. 1986. [13] ASTM D1384-04. Standard test method for corrosion test for engine coolants in Glasswarem. Annual book of ASTM Standards, West Conshohocken, PA: ASTM International, 2004. [14] Genner C, Hill EC. Br Corros J 1980;15:95.