PDF Review of the Bureau of Reclamations Corrosion Prevention Standards for Ductile Iron Pipe

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Corrosion, like a virus, has different forms. Each type of localized corrosion requires expensive prescriptions to help control the onset and spread of the disease. These expensive prescriptions increase maintenance, operations energy costs , and renewal and replacement capital budgets for a utility. The prescribed doses are based on the individual environment of a utility. Before procurement of a pipe material, the full life-cycle costs must be considered and compared against an alternative pipe material, because corrosion for metallic pipes may occur at any life-cycle stage.

Materials selection, fabrication, shape, and cost are all significant.

Corrosion-control measures must be able to reduce risk to a quantifiable and appropriate low level in situations in which the consequences of failure are serious. Corrosion control begins during the design process. Uncontrolled corrosion can lead to increased costs, premature failure and asset replacement, reduced safety, and negative environmental and public health effects.

Although it is unsightly, its predictability facilitates easy control, the most basic method being to make the material thick enough to function for the lifetime of the component. The spread of uniform corrosion can be slowed by slowing or stopping the movement of electrons; coat the surface with a nonconducting medium such as paint, lacquer, or oil; reduce the conductivity of the solution in contact with the metal in extreme cases to keep it dry.

Use a sacrificial coating that gives up its electrons more easily than the metal being protected; apply CP; use inhibitors; selecting a metal that forms an oxide that is protective and stops the reaction. Control and consideration of environmental and thermal factors are also essential in the management of corrosion. This epidemic is occurring all over the United States as corrosion claims victims of all ages of metallic, cement, and even clay pipes.

In the previous century the home remedy included making and installing a thick-walled cast-iron pipe to achieve a greater than year design life. Today the steel and ductile-iron pipe DIP walls are much thinner and as a result require the additional initial capital costs of corrosion-control measures and the expensive ongoing maintenance, monitoring, and operational corrosion activities.

Reports of early pipe failure caused by corrosion are occurring coast to coast affecting communities and creating the need for boil-water notices. One example out of hundreds in which cast-iron water pipes that were supposed to last as long as years are being corroded by soils just 17 years after they were installed is in upstate New York.

AWWA Dec 2011 the Epidemic of Corrosion Part 1 Examining Pipe Life

The clay soils in a particular subdivision there are reacting with the pipes and corroding them from the outside in, resulting in main failures even though the DIP was laid correctly and built to standards NACE, b. This occurs when two different metals are placed in contact with each other and is caused by the greater willingness of one metal to give up electrons than the other.

Three special features of this mechanism need to operate for corrosion to occur: the metals need to be in contact electrically, one metal needs to be significantly better at giving up electrons than the other, and an additional path for ion and electron movement is necessary. Break the electrical contact using plastic insulators or coatings between the metals. Select metals close together in the galvanic series. Prevent ion movement by coating the junction with an impermeable material, or ensure the environment is dry and liquids cannot be trapped.

Pitting corrosion. Pitting corrosion occurs in materials that have a protective film such as a corrosion product or when a coating breaks down. The exposed metal gives up electrons easily, and the reaction initiates tiny pits with localized chemistry supporting rapid attack. Select a resistant material and ensure a high enough flow velocity of fluids in contact with the material for frequent washing; controlling the chemistry of fluids and use of inhibitors; using a protective coating; maintaining the materials own protective film.

Pits can be crack-initiators in stressed components or those with residual stresses resulting from forming operations. Side effects can lead to stress corrosion cracking. Selective attack. This occurs in alloys such as brass when one component or phase is more susceptible to attack than another and corrodes preferentially, leaving a porous material that crumbles.

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This type of corrosion is best avoided by selection of a resistant material, but other means can help, for example coating the material, reducing the aggressiveness of the environment, and using CP. Stray current corrosion. This type of corrosion happens when a direct current flows through an unintended path and the flow of electrons supports corrosion.


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This can occur in both soils and flowing or stationary fluids. Microbial corrosion. This general class covers the degradation of materials by bacteria, molds, and fungi or their by-products. It can occur by a range of actions such as attack on the metal or protective coating by acid by-products, sulfur, hydrogen sulfide, or ammonia; and direct interaction between the microbes and metal that sustains the attack. Selection of resistant materials, frequent cleaning, control of chemistry of surrounding media and removal of nutrients, use of biocides, and CP.

Intergranular corrosion. This is a preferential attack on the grain boundaries of the crystals that form the metal.


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  5. It is caused by the physical and chemical differences between the centers and edges of the grain. Selection of stabilized materials, control of heat treatments and processing to avoid susceptible temperature range. Concentration cell corrosion crevice. If two areas of a component in close proximity differ in the amount of reactive constituent available, the reaction in one of the areas is speeded up. An example of this is crevice corrosion, which occurs when oxygen cannot penetrate a crevice and a differential aeration cell is set up. Corrosion occurs rapidly in the area with less oxygen. Avoiding sharp corners and designing out stagnant areas, using sealants, using welds instead of bolts or rivets, selecting corrosion-resistant materials.

    Thermogalvanic corrosion.

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    Temperature changes can alter the corrosion rate of a material. A good rule of thumb is that a 10oC rise doubles the corrosion rate. If one part of a component is hotter than another, the difference in the corrosion rate is accentuated by the thermal gradient, and local attack occurs in a zone between the maximum and minimum temperatures.

    The best method of prevention is to design out the thermal gradient or supply a coolant to even out the difference. Corrosion caused by combined actions.

    Polyethylene Encasement of Ductile Iron Pipe - Corrosion Protection from Aggressive Soils

    This is corrosion accelerated by the action of fluid flow, sometimes with the added pressure of abrasive particles in the stream. The protective layers and corrosion products of the metal are continually removed, exposing fresh metal to corrosion. Reducing the flow rate and turbulence, using replaceable or robust linings in susceptible areas, avoiding sudden changes of flow direction, streamlining or avoiding obstructions to the flow.

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    Corrosion fatigue. The combined action of cyclic stresses and a corrosive environment reduces the life of components below that expected by the action of fatigue alone. Coating the material, using a good design that reduces stress concentration, avoiding sudden changes of sections, and removing or isolating sources of cyclic stress.

    Fretting corrosion.

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    The relative motion between two surfaces in contact by a stick-slip action can cause breakdown of protective films or welding of the contact areas, allowing other corrosion mechanisms to operate. Designing out vibrations, lubricating metal surfaces, increasing the load between the surfaces to stop the motion, and applying surface treatments to reduce wear and increase the friction coefficient. Stress corrosion cracking. This is the combined action of a static tensile stress and corrosion that forms cracks and eventually causes catastrophic failure of the component.

    This is specific to a metal material paired with a specific environment. Reducing the overall stress level and designing out stress concentrations, selecting a suitable material not susceptible to the environment, using designs to minimize thermal and residual stresses, developing compressive stresses in the surface of the material, and using a suitable protective coating.

    Hydrogen damage. An active member of AWWA, limited to make any recommendations for their use at Baird also serves on the Economic Development this time. Despite these shortcomings in surface prepa- and Capital Planning Committee with the ration and in ensuring adequate CP, the committee Government Finance Officers Association for found that bonded dielectric coatings with CP may the United States and Canada. AWWA, June Report F. AwwaRF, Denver. Koch, G. NACE, b. Neigh- Elimination of corrosion. In modern medicine, disease borhood. As an industry we will not be able to eradicate corrosion in our distribution, transmission, and collec- NPL National Physical Laboratory , Beginners Guide to Corrosion.

    Sustainable water infrastructure. Sometimes, the best NPL, b. Corrosion Control Checklist. Research Topics.

    AWWA Dec 2011 the Epidemic of Corrosion Part 1 Examining Pipe Life

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