corrosion'management'in' performance'assessment'and ...€¦ ·...

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!!

!

[email protected]!

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.!!

[email protected]! 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!


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.!!


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!!

!


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.+


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!

!


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’!!

[email protected]!

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!


Corrosion!Risk!Management!Course!Components!

[email protected]!

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!

[email protected]!

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'

[email protected]!

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!!


Galvanic!Modeling!

Aluminum/Steel!Fasteners!in!Marine!Atmosphere!


( 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!!!!!


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!!

[email protected]!

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.!!

!

[email protected]!

corrosion'management'in' performance'assessment'and ...€¦ ·...

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