Bacterial Corrosion

in Ships Tanks

Problem and Solution

MANAGING RISK

What is Bacterial Corrosion?

FACT OR MYTH?
Small animals eating steel is a myth. It is however a fact that local corrosion, occurring at very high rates and typically looking like clusters of pits, can be caused by chemical processes initiated by bacterial activity, i.e. bacterial corrosion exists. This phenomenon is sometimes described as microbial corrosion indicating that types of microbes other than bacteria may be involved in the process. The accepted technical term is microbially inuenced corrosion. Bacterial corrosion most frequently occurs on cargo oil tank bottom plating. It occurs also in water ballast tanks, primarily on up-facing, horizontal surfaces.

Small animals eating steel is a myth.

MICROBES ARE EVERYWHERE

Microbes or micro-organisms are living organisms so small in size that they can only be observed using a microscope. They include bacteria, microscopic algae, fungi and animals like amoeba. Microbes are found practically everywhere, in the oceans, lakes, rivers and any natural waters, and even in the air. The bacteria are frequently implicated in accelerated corrosion of steel and non-ferrous metals. They consist of one single cell only and are often shaped like tiny spheres or staves or are oblong and cigar-like.

MANY SPECIES
A large number of different species of bacteria and other micro-organisms normally co-exist in watery environments in some natural balance based principally on competition and cooperation. Under conditions which are especially suitable for one or a few species, this or these species will take precedence over others and start reproducing at a formidable rate.

Bacteria are frequently implicated in accelerated corrosion of steel.

CORROSION MECHANISMS
The common corrosion process occurring in marine, moist environments is electrolytic and is caused by local electric potential differences between anodic and cathodic sites on steel surfaces. Even on coated surfaces, local corrosion attacks such as pitting can occur at anodic sites of imperfections or damages in the coating. In stagnant water containing organic material (including oil), e.g. dirty ballast water or water settling on oil cargo tanks bottom plating, microbes may thrive, especially at pleasant, tropical temperatures. Bacterial corrosion often proceeds in two or three stages: 1. During initial microbial proliferation the oxygen that is normally dissolved in water is used up by aerobic bacteria and other microbes. Already at this stage, mildly acidic organic chemicals are produced by the microbial oxidation processes, which may accelerate ongoing electrolytic corrosion. The zone near the microbial growth becomes oxygen decient and anodic. 2. In some cases, conditions are such that a second stage occurs, where one or a few specialist species of anaerobic bacteria take over the scene, feeding on the acidic chemicals. The best known of these anaerobic species are the Sulphate Reducing Bacteria (SRB). Their characteristic property is that 22they utilise the oxygen in sulphates SO 4 for breathingand reduce the sulphates to sulphides S .

Hydrogen sulphide gas is also an end product of the SRB activity. The gas H2S with its well known rotten egg smell, also promotes corrosion. H 2S is also highly toxic and ammable and is believed to accelerate hydrogen embrittlement. 3. Strong acids such as sulphuric acid can be produced from sulphides by sulphur oxidising bacteria when oxygen becomes available again. The strong acids will further accelerate the ongoing corrosion process.

APPEARANCE
Typical signs of bacterial corrosion are: Clusters of pits several cm in diameter found under a cover of organic deposits, for example dirt and rust scale mixed with oil spills High local corrosion rates in pit clusters In oil cargo tanks, at bottomed pits may show a stepwise development with stairs at the pit edge Black colour of iron sulphides appearing during removal of cover (quickly disappearing when uncovered due to oxidation) Sulphidic smell, quickly disappearing after ventilation (watch out for pockets of poisonous H2S gas).

Bottom Pitting
CARGO OIL TANKS
Corrosion will occur in a watery phase or sludge settling out from oil cargoes on the tank bottom, if unprotected. The normal pitting corrosion rate may be dramatically increased if a bacterial corrosion process is superposed upon the common electrolytic process. Elevated temperatures in oil cargoes will be maintained for a longer time in double hull tankers than in single hull tankers due to the isolating effect of empty water ballast tanks (thermos bottle effect), implying that: micro-organisms including bacteria will thrive better for a longer time the electrochemical corrosion process will run faster for a longer time, e.g. 10C temperature increase may approximately double the chemical reaction rate. Both the electrolytic and the bacterial corrosion rate can thus be expected to increase in double hull ships. Stories told of severe corrosion in relatively new double hull tankers, especially cargo oil tanks pitting, conrm the expectations. In single hull tankers, pitting may represent a pollution hazard, if pits penetrate the bottom plating. In double hull tankers, pitting also represents a safety hazard, due to leakage of oil cargo and hydrocarbon vapours into ballast spaces.

Corrosion may occur in a watery phase or under sludge settling out from oil cargoes on the inner bottom of tanks.

WATER BALLAST TANKS

The common, electrolytic corrosion process predominates in water ballast tanks. Restrictions on deballasting and bilge pumping may, however, promote bacterial growth in oxygen-decient, stagnant water. Bacterial corrosion underneath sludge or dirt settling out from the water on bottom plating and other up-facing, horizontal surfaces may thus be superimposed on the electrolytic process, implying an increased total corrosion rate.

Low heat transfer in double hull tankers due to the thermos bottle effect.

The Solution
HOW TO AVOID BACTERIAL CORROSION
The best way of preventing corrosion in tanks, including bacterial corrosion, is to apply a high quality coating, preferably during newbuilding. Coating of cargo oil tank bottom plating and structures of existing ships is also carried out to stop pitting attacks. Epoxy based coatings, applied on a properly washed and blast cleaned surface have shown good results. The level of salt contamination on the surface should be kept as low as possible. Installation of sacricial anodes in cargo oil tank bottom and generally in water ballast tanks is recommended in order to avoid pittings at locations of coating imperfections. Keeping tanks as clean as possible, avoiding accumulation of dirt, sludge, and foul watery deposits, will reduce the risk. Using biocides for killing bacteria in commercial shipping is not realistic, considering the handling aspects and environmental impact.

Epoxy based coating on tank bottom.

VOLUNTARY CLASS NOTATIONS

COAT-1 and COAT-2 are new voluntary class notations available from July 1999. These notations deal with corrosion prevention of newbuidings and give reference to coating systems and to which category spaces they are to be applied. For tankers, the inner bottom is among the areas required to be coated.

DNV can assist you in solving your corrosion problems. Please contact your local DNV ofce or DNV at Hvik, Norway.
Text reviewed by ECHA Microbiology Ltd., Cardiff, UK. Pictures of coating with the courtesy of Sigma Coatings. The COAT notations give reference to coating systems and where they are to be applied.

Det Norske Veritas Veritasveien 1, N-1322 Hvik Tlf: 67 57 99 00 Fax: 67 57 99 11 Web site: www.dnv.com

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