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CORROSION'MANAGEMENT'IN'PERFORMANCE'ASSESSMENT'AND'SYSTEMS'
HEALTH'MONITORING!!
Joe!H.!Payer!Na,onal!Corrosion!Center!(NCERCAMP)!
!Robert!Liang!and!Anil!Patnaik!
!Department!of!Civil!Engineering!!The!University!of!Akron!
Akron,!OH!44325!!!
NACE'Conference'RISK'MANAGEMENT'OF'CORRODIBLE'SYSTEMS'
June'18?20,'2013,'Washington'D.C.'
Benefits!of!beNer!corrosion!management!and!mi,ga,on!
• Increased!awareness!of!corrosion!risks!• Stronger!technical!basis!for!corrosion!mi,ga,on!
• Facilitate!implementa,on!of!sound!strategy/plan!
• Gain!fundamental!understanding!!
!
Corrosion!Risk!Management!jpayer@uakron.edu!
A!crucial!need!for!increased!safety,!reduced!risk!and!reduced!corrosion!costs!!
To!incorporate!corrosion!management!into!procedures!for!performance!assessment!and!systems!health!monitoring.!!Systems!Health!Monitoring!(SHM)!A. Monitor!!current!system!status!with!predic,on!
of!future!performance!and!failure!states!!B. Facilitate!ra,onal!decisionYmaking!regarding!the!
safety!and!reliability!of!a!structure!!C. Show!proper!ac,ons!(maintenance,!repair,!or!
retrofit,!etc.)!to!take!when!safety!or!performance!concerns!arise.!!
jpayer@uakron.edu! Corrosion!Risk!Management!
Great!opportuni,es!for!technological!advances!!
A. Bridge!the!detailed!knowledge!of!corrosion!damage!at!the!local!level!(pits!and!cracks)!to!full!systems!(vehicles,!ships,!bridges!and!power!plants)!
B. Mul,Ylevel!and!coupled!nature!of!degrada,on!processes!and!damage!evolu,on!are!important!
C. Bridging!methodologies!for!the!treatment!of!full!systems!and!specific!assets!
jpayer@uakron.edu! Corrosion!Risk!Management!
An!interdisciplinary!team!is!needed!!
To!assess!the!current!status!of!the!treatment!of!corrosion!in!SHM!and!to!undertake!ini,a,ves!for!technological!advances.!!
jpayer@uakron.edu! Corrosion!Risk!Management!
Na,onal!Corrosion!Center!(NCERCAMP)!Par,cipants!The!University!of!Akron!
!Joe!H.!PayerYCheif!Scien,st,!NCERCAMP!ScoN!LillardYCorrosion!Engineering!Homero!CastanedaYCorrosion!Engineering!Mariano!IannuzziYCorrosion!Engineering!Robert!LiangYCivil!Engineering!Anil!PatnaikYCivil!Engineering!Fred!ChoyYMechanical!Engineering!Shiva!ShastriYElectrical!and!Computer!Engineering!Ajay!MahajanYMechanical!Engineering!Mark!D.!SoucekYPolymer!Engineering!Jerry!YoungYTheore,cal!and!Applied!Mathema,cs!!
Comprehensive!approach!to!address!the!incorpora,on!of!corrosion!management!!
– Describe!Corrosion!Processes!in!Fundamentals!Relevant!to!SHM!– Translate!of!corrosion!science!and!technology!into!terms!relevant!to!SHM!(quan,fiable!and!measureable)!
– Link!Corrosion!Damage!PaNerns!to!Loss!of!Func,on!and!Serviceability!
– Assess!Current!SHM!Technologies!with!Emphasis!on!Treatments!Relevant!to!Corrosion!
– Assess!Current!Understanding!Computa,onal,!Simula,on,!and!Modeling!Capabili,es!for!Relevance!to!Corrosion!
– Assess!Tools!for!Linking!Corrosion!Damage!Detec,on!to!SHM!and!DecisionYMaking!
– Assess!Asset!Management!and!GIS!Based!Inventory!Databases!for!Corrosion!in!SHM!!
!
jpayer@uakron.edu! Corrosion!Risk!Management!
Goal!is!to!lower!the!risk!of!technological+hazards!due!to!corrosion!!Technological+hazard'YY!danger!origina,ng!from!technological!or!industrial!accidents,!dangerous!procedures,!infrastructure!failures!or!certain!human!ac,vi,es,!which!may!cause!the!loss!of!life!or!injury,!property!damage,!social!and!economic!disrup,on!or!environmental!degrada,on.!!!Present+benefits+in+these+terms;++everyone+understands+these.+A+measure+of+Consequence+is+corrosion+costs+of+$400+billion+per+year+to+US.+
jpayer@uakron.edu! Corrosion!Risk!Management!
Challenge!is!to!integrate!corrosion!knowledge!into!risk!management!
Requires!advances!!!YYfundamental!corrosion!science!!YYrisk!assessment!!YYmeans!to!couple!the!two!disciplines.!!
!! Translate!and!express!corrosion!knowledge!in!quan,ta,ve!terms!that!are!
useful!for!design!and!risk!analysis.!!! Develop!linkages!between!the!fundamental!understanding!and!
engineeringYbased!decisionYmaking!technologies!! Corrosion!control!in!risk!assessment!is!now!moving!toward!capabili,es!for!
other!degrada,on!modes,!e.g.,!deforma,on,!fa,gue,!and!fracture.!! Major!challenges!dealing!with!sequen,al!and!coupled!processes!
! Evolu,on!of!the!environmental!condi,ons!! Evolu,on!of!corrosion!damage!! Interac,ons!with!other!degrada,on!modes!
!
jpayer@uakron.edu! Corrosion!Risk!Management!
Three'Crucial'Areas'to'Reduce'Costs'and'Increase'Reliability'
(A)!Advance!Life!Predic,on!!(B)!Performance!Assessment!for!Exis,ng!and!New!
Systems!!(C)!Condi,on!Assessment!and!Life!Extension!of!Aging!
Infrastructure!
Power!plants,!wind!mills,!pipelines,!bridges!
Fuel!cells,!baNeries,!energy!storage,!electronics!
!
! How'safe?''How'long?''How'sure'are'you?''
From!!!“Corrosion!Costs!and!Preven,ve!Strategies!in!the!United!States’!!
Corrosion!Risk!Management!jpayer@uakron.edu!
Three!“Simple”!Ques,ons!
Sampling!of!Progress!
• Educa,onY!– UAkron!course!!on!Corrosion!Risk!Management!(mul,Ydisciplinary!enrollment)!
• Demonstra,on!of!Risk!Management!tools!– Fault!tree!analysis!– Markov!Analysis!
• Mul,Yscale!approach!– RC!Concrete!– Remaining!strength!of!steel!structures!
• Modeling!and!sobware!for!corrosion!analysis!– Galvanic!corrosion!– Design!and!materials!saelec,on!
jpayer@uakron.edu! Corrosion!Risk!Management!
Corrosion!Risk!Management!Course!Components!
Corrosion!Risk!Management!jpayer@uakron.edu!
1st'Order'C1'
1st'Order'D3'
1st'Order'D4' 2nd'Order'
D5.D6'
3rd'Order'D1.D2.E2'
3rd'Order'D1.D2.E1'
!!FTA!OF!PIPELINE!
FAILURE!Y!EXAMPLE!
!A!minimum!cut!set!(MCS)is!a!combina,on!of!basic!events!or!factors!necessary!and!
sufficient!to!cause!the!top!event!
!5!minimum!cut!sets!!1st!Order:!C1,!D3,!D4!2nd!Order:!D5.D6!3rd!Order:!D1.D2.E1,!D1.D2.E2!
OUTCOMES!• Iden,fica,on!of!MCS!• Probability!of!top!event!• Iden,fica,on!of!cri,cal!pathways!• Failure!contribu,on!and!importance!ranking!of!basic!events!
Fault+Tree+Analysis+for+Fungal+Corrosion+of+Coated+Aluminum Sandeep!Chawla!,!Joe!Payer,!Carla!Giai;!Corrosion!and!Reliability!Engineering,! Risk Management of Corrodible Structures Conference (NACE), June 19-20, 2013!
Corrosion!Risk!Management!jpayer@uakron.edu!
Markov!Analysis!for!Corrosion!Risk!Management!Risk Management of Corrodible Structures Conference (NACE), June
19-20, 2013!
dPi(t) = -λi(t)Pi + λi-1(t)Pi-1 , i = 2, 3, …, N dt
Predict'Damage'EvoluWon'and'Useful'Life'
Discrete'Stages'
TransiWon'Rates'Examine'Scenarios'
Corrosion'Threat'
Corrosion!Risk!Management!jpayer@uakron.edu!
MICRO'SCALE'Um’s'
MESO'SCALE''MESO'SCALE'(LAB)'
MACRO'SCALE'
MEGA'SCALE'
RELIABILITY?BASED'MULTI?SCALE'MODELING'APPROACH''IN!CORRODIBLE!SYSTEMS!
Ohio'County'Engineers'are'responsible'for'the'maintenance'of'nearly'26000'bridges'statewide'
System'Wide'
Remaining!Strength!of!Steel!Structures!
hNp://en.wikipedia.org/wiki/IYbeam!hNp://www.stlpipesupply.com/blog/whyYyouYshouldYbuyYiYbeamYsteelYandY304YstainlessYsteelYbars/!hNp://danit100.wikispaces.com/Bridges!!
MicroYscale!
MesoYscale!
MacroYscale!
MegaYscale!
SystemYwide!
Corrosion!Mechanism!
CrossYSec,on!
3!Dimensions!En,re!Framework!
Structural!Network!!
jpayer@uakron.edu! Corrosion!Risk!Management!
Galvanic!Modeling!
Aluminum/Steel!Fasteners!in!Marine!Atmosphere!
jpayer@uakron.edu! Corrosion!Risk!Management!
( a)
(b) Cd/Steel Fastener Cd/Rust Fastener
(c) (d)
Model!Output!GalvanicMaster,!Elsyca! 3YD!Reconsrucrion,!Alicona!–Infinite!Focus!G4!
Courtesy!of!Bill!AbbotYBaNelle!
ACES'Framework'Accelerated'Corrosion'Expert'Simulator' 1. Geometry!Analyzer:!
describes!local!area—lap.!Fastener,!…!
2. Materials!iden,fied:!steel,!CARC!(e.g.!galv!,!phosphate,!organic)!!
3. Define!environment!4. Material!degrada,on!
mode!• Organic!coa,ng!• Inorganic!coa,ng!• Metallic!coa,ng!(Zn)!• Base!metal!5.!!For!each!in!#4!need!
degrada,on!rate!!Corrosion'='[material]'x'[environment]'!EvoluWon'of'Damage'=![organic!coa,ng!life]!+![galv!ctng]!+![steel!in!mpy]!
Organic!coa,ng:!degrada,on!rate!with!,me!for!microenvironment!Galv!steel:!life!in!yrs!=!coa,ng!thickness!vs.!environment!table,!e.g.!ASHTO!Steel:!corr!rate!mpy!from!data!bases!for!atm!corr,!soils,!vehicle!tests!!
Example!for!useful!life!of!culverts:!organic!coa,ng,!galv,!steel!in!environment!
Courtesy!of!Tom!Savell,!GCAS,!Inc!
UAkron!par,cipa,ng!in!this!US!Army/TARDEC!!Program!!!!!
jpayer@uakron.edu! Corrosion!Risk!Management!
SUMMARYYGoal:!Assure!beNer!corrosion!management!and!mi,ga,on!at!each!stage!of!life!cycle!
So,+in+design:!avoid!“high!risks”!or!plan!mi,ga,on!So,+in+produc;on+and+manufacturing:!specify!prac,ces!to!avoid!detrimental!effects!or!mi,gate!So,+in+inspec;on+and+maintenance:!recognize!“high!risks”!and!use!effec,ve!tools,!techniques!and!prac,ces!So,+in+failure+analysis:!iden,fy!the!relevant!form(s)!to!guide!root!cause!analysis!and!correc,ve!ac,on!!
Corrosion!Risk!Management!jpayer@uakron.edu!
This+special+conference+on+Corrosion+Risk+Management+with+depth+and+breadth+of+topics+in+an+exemplar+of+excitement,+hope+and+promise+to+meet+this+goal.++
Acknowledgements!!
This!work!is!associated!with!the!Na,onal!Center!for!Educa,on!and!Research!on!Corrosion!and!Materials!Perfromance!(NCERCAMP)!at!The!University!of!Akron!
!and!!The!DoD!Technical!Corrosion!Collabora,on!supported!by!the!U.S.!Department!of!Defense!Office!of!Corrosion!Policy!and!Oversight.!!!The!research!is!administered!by!the!US!Air!Force!Academy!under!agreement!number!FA7000Y10Y2Y0013.!!
!
Corrosion!Risk!Management!jpayer@uakron.edu!
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