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• Economics
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E i t
Cost of Corrosion
• $276B USD or 3.1% GDP – 35% of Costs Can Be
Mitigated Through Corrosion Control!
• $6.9B
$6 9B USD – Electric Utilities
NACE 2002 “Corrosion Costs and Preventative Strategies in the United States”
Cost of Corrosion (Based Upon Reject
Criteria)
Cost (USD) Reject Criteria (%) Sector
• Thi
Things that
th t are made
d off iron
i andd steel
t l began
b as ore
taken from the earth. Energy was added in the form
of heat to make it into the structure desired.
desired
STEEL PIPE
PIPE MILL
REFINING PROCESS
CORROSION PROCESS
• Anode
• Cathode
• Metallic Path
• Electrolyte
Corrosion cells are created when there is an imbalance or non-
equilibrium energy balance, causing a movement of energy from high
levels to lower levels.
Corrosion Cell Definitions
Anode Corroding structure ─ point where
current is discharged into electrolyte
Anode e
Catthode
Cath
hode
Corrosion Cell
What causes corrosion?
• Dissimilar Metals (Galvanic corrosion)
• De Alloying
De-Alloying
• Stresses
• Differential Moisture
• Temperature Differences in the Metal
or Electrolyte
y
• Dissimilar Soils
• yg Concentration Cell
Oxygen
• Metal Ion Concentration Cell
• Microbiological Influences
H ddoes the
How h environment
i influence
i fl
the rate of corrosion?
• Moisture Content
• Electrolyte Conductivity (ions)
• pH
• Oxygen Concentration
• Temperature
• Stress
• Aeration
• Agitation
What are the fforms off corrosion?
• General Corrosion
• Localized Corrosion
Pitting, Crevice or Filiform Corrosion
• Galvanic Corrosion
• Environmental Corrosion Cracking
• Flow Assisted Corrosion
Flow-Assisted
• Intergranular Corrosion
• Dealloying
• Fretting Corrosion
• High Temperature Corrosion
General Corrosion
0
35.75209746 35.7538992 35.75587739 35.75808995 35.75999111 35.76205017 35.7642443 35.7687765 35.7700929
-0.05
-0.1
-0.15
-0.3535 -0.3474375 -0.3609375
-0.3646875 -0.3743125
-0.2 -0.3885625
-0 422
-0.422 -0.43175
0 43175 -0.439
Substation (Alcoa
VDC
-0.35
-0.4
-0.45
-0.5
Latitude
S b
Subway Stray
St Current
C t
Stray
C
Currents
t
From
Subway
HVDC Stray Current
Pipeline Dc Stray Currents
-
0.8
Substation 3rd Harmonics
25,000
ures
20 000
20,000
Number of Structu
15,000
10,000
5,000
0
1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000
$
$2.3B S $4.2B
USD $ 20%
% Reject C
Criteria ((Transmission O
Only)
Only)
Corrosion Affects
ff You!
Your Environment
Your Company
Your Job
Your Safety
y
Your Pocketbook
Thank you!