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SC-Compass®: Stray Current Corrosion and AC Corrosion - Idenficaon, Assessment and Predicon Version 9.18 Performance Funconality Usability Anyme Anywhere Any Device Any OS No USB dongles No installaon No Browser Plug-ins Home | Consulng | Training | Expert Witness | Failure Analysis | Design Review | Corrosion Test | Corrosion Soware | Coangs | Material Why WebCorr | Performance Guarantee | Unparalleled Funconality | Unmatched Usability | Any Device Any OS | Free Training Features and Funcons of SC-Compass Stray current corrosion refers to corrosion resulng from stray current - the current flowing through 1

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Page 1: SC-Compass®: Stray Current Corrosion - Identification, … · 2019. 5. 3. · Z } µ P Z Z } Z Z v Z ] v v ] µ ] X / v Z } } ] } v o ] µ U v } v r v u µ Ç } u µ Z } ] v o

SC-Compass®: Stray Current Corrosion and AC Corrosion- Iden�fica�on, Assessment and Predic�on

Version 9.18

Performance Func�onality Usability

Any�me Anywhere Any Device Any OSNo USB dongles No installa�on No Browser Plug-ins

Home | Consul�ng | Training | Expert Witness | Failure Analysis | Design Review | Corrosion Test | Corrosion So�ware | Coa�ngs | Material

Why WebCorr | Performance Guarantee | Unparalleled Func�onality | Unmatched Usability | Any Device Any OS | Free Training

Features and Func�ons of SC-Compass

Stray current corrosion refers to corrosion resul�ng from stray current - the current flowing through

1

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Page 2: SC-Compass®: Stray Current Corrosion - Identification, … · 2019. 5. 3. · Z } µ P Z Z } Z Z v Z ] v v ] µ ] X / v Z } } ] } v o ] µ U v } v r v u µ Ç } u µ Z } ] v o

paths other than the intended circuit. In the corrosion literature, non-standard terms used by some

authors include stray current electrolysis and electroly�c corrosion. Among the many different types

of corrosion, stray current corrosion is probably the most misused term by unqualified corrosion

consultants worldwide who literally refer to any corrosion phenomenon beyond their comprehension

as stray current corrosion. This mis-diagnosis o�en results in significant financial losses and safety

lapses for facility owners and operators.

Accurate iden�fica�on of stray current corrosion requires a sound understanding of all types of

corrosion. A qualified corrosion consultant (NACE cer�fied Corrosion Specialist) can tell the

differences among the different types of corrosion. Stray current corrosion is fundamentally different

from other (non-stray current) types of corrosion in that stray current corrosion is an electrolysis

process. In the electrolysis process, the external current (stray current) alone drives metal atoms into

electrolyte as water-soluble ions. The environmental factors such as oxygen concentra�on, cathode-

to-anode area ra�o, chloride, and pH that are so cri�cal to natural corrosion processes are no longer

relevant. The extent of damage or loss of metal is directly propor�onal to the magnitude of stray

current leaving the structure at the point of discharge. Stray current corrosion will be concentrated at

certain loca�on that leads to the lowest electrical resistance in the current circuit.

SC-Compass is developed by NACE cer�fied corrosion specialists with both BEng and PhD degrees in

corrosion. It is the only device and OS independent so�ware tool on the market for iden�fica�on,

assessment and predic�on of Stray Current Corrosion and AC Corrosion in underground pipelines,

rail transit systems, reinforced concrete structures, boats/ships/vessels, and other metallic structures

carrying electrical current. Designers, engineers, consultants, maintenance and inspec�on personnel

can quickly iden�fy, assess and quan�fy the impact of stray current corrosion and AC corrosion on the

remaining life of their structures/components any�me, anywhere, on any device running any OS

without the need to install or download anything. SC-Compass is developed in full compliance with

2

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the latest edi�ons of BS EN and NACE standards rela�ng to stray current corrosion and AC corrosion.

SC-Compass has answers to all the frequently asked ques�ons below and more:

Frequently Asked Ques�ons on Stray Current Corrosion:

What is stray current corrosion?

How is stray current corrosion different from other types of corrosion?

How to tell if my corroded structure is really due to stray current corrosion?

How to iden�fy stray current corrosion?

How to predict the level of stray current in my structure?

How to measure stray current?

How to assess stray current corrosion risk?

What interna�onal standards are relevant to the assessment of stray current corrosion?

What is the acceptable level of stray current specified in the latest edi�ons of BS EN and NACE

standards?

How to predict stray current corrosion rate for various metals and alloys?

How to calculate stray current corrosion rate for various metals and alloys?

Frequently Asked Ques�ons on AC Corrosion:

What is AC corrosion?

How is AC corrosion different from stray current corrosion and other types of corrosion?

How to tell if my corroded structure is really due to AC corrosion or stray current corrosion?

What are the unique features in AC corrosion?

How to iden�fy AC corrosion?

How to measure AC corrosion?

How to assess AC corrosion risk?

How does soil resis�vity affect the AC corrosion risk?

3

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What interna�onal standards are relevant to the assessment of AC corrosion?

What is the acceptable level of AC current specified in the latest edi�ons of BS EN and NACE

standards?

What is the acceptable level of AC Voltage to remote earth specified in the latest edi�ons of BS

EN and NACE standards?

What is the acceptable level of AC current to DC current ra�o specified in the latest edi�ons of

BS EN and NACE standards?

How to predict AC corrosion?

Overview and Applica�on Examples of SC-Compass

Figures below show the screen shots of SC-Compass. There are 6 modules in SC-Compass for 6 groups

of structures:

Underground Pipelines,

Rails,

Rail Fasteners,

Reinforced Concrete Structures,

Boats/Ships/Vessels,

Other Metallic Structures.

The main screen in SC-Compass has 5 zones:

Zone 1: Iden�fica�on of Stray Current Corrosion and AC Corrosion

Zone 2: Image Represen�ng the Corroded Morphology

Zone 3: Assessment and Predic�on of Stray Current Corrosion (BS EN 50162)

Zone 4: Predic�on of Stray Current Corrosion Rate

Zone 5: Assessment and Predic�on of AC Corrosion (BS EN 15280 / NACE SP21424)

4

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Figure 1 Overview of SC-Compass

Users of SC-Compass start by selec�ng the type of structure from the dropdown list:

Rails

Rail Fasteners

Reinforced Concrete Structures

Underground Pipelines

Boats, Ships and Vessels

5

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Other Metallic Structures

A�er selec�ng the structure, users simply click the corresponding Tab and select a case from the

built-in database that closely matches the users' circumstance based on the descrip�on and

morphology of the corroded structure as demonstrated below.

Figure 2 shows the database under "Others" Tab for "Other Metallic Structures". An user selected a

case closely matching his/her circumstance. Iden�fica�on of stray current corrosion and AC corrosion,

and relevant comments on the user selected case are displayed in Zone 1, with the representa�ve

image showing the corroded morphology displayed in Zone 2, as shown in Figure 3.

Figure 2 Stray Current Corrosion and AC Corrosion Iden�fica�on

6

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Figure 3 Iden�fica�on of Stray Current Corrosion and AC Corrosion for User Selected Case

SC-Compass determines that the selected case is NOT stray current corrosion and displays comment

on this case:

"Stray current corrosion is an electrolysis process and as such, it will not produce heavy rust scales,

pinhole type pi�ng, or any form of cracking."

7

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If an user cannot find a case closely matching his/her own situa�on in the database, the user can

email the photos with background informa�on to WebCorr. Our NACE cer�fied Corrosion Specialists

will then examine the photos and analyze the informa�on to determine if it is stray current corrosion

or AC corrosion. This consul�ng service is free of charge to licensed users of SC-Compass during the

en�re licensing period. The savings in consul�ng fee can be worth many �mes of the license fee.

Assessment and predic�on of stray current corrosion in SC-Compass are carried out in accordance

with relevant interna�onal standards such as BS EN 50162 for DC stray current corrosion, and BS EN

15280/NACE SP21424 standards for AC corrosion.

In Zone 3, users need to select the electrolyte from the dropdown list: Soil, Water, Concrete.

The electrical resis�vity (in the unit of Ω.m) of the selected electrolyte is then entered.

The structure to electrolyte poten�als with respect to a copper sulphate reference electrode are

required to assess the stray current status, stray current corrosion risk level and stray current

acceptability as per BS EN 50162 standard.

8

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Figure 3 Stray Current Corrosion and Assessment and Predic�on

In Figure 3 above, an user entered the following values as inputs:

Soil resis�vity: 120 Ω.m

Temperature: 10oC

Structure to electrolyte poten�al (OFF): -650 mV

Structure to electrolyte poten�al (ON): -550 mV

IR-compensated poten�al shi� ΔE: Not Available (if set to "Available", the entered value will be used

for the assessment)

9

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Based on the user inputs, SC-Compass predicts that stray current is entering the structure and

reducing the corrosion rate by a factor of 2.27. SC-Compass also computes the amount of stray

current in the structure and this is determined to be 0.029 mA/cm2.

The stray current acceptability as per BS EN 50162 is determined to be "Acceptable" and the stray

current corrosion risk level is determined to be "No SC Corrosion Risk as stray current enters the

structure".

In Zone 4, the stray current corrosion rate predic�on shows "No SCD", - meaning "No Stray Current

Discharge" and therefore no stray current corrosion. Stray current corrosion ONLY occurs at the point

of discharge. At the point of entry, there is no corrosion.

10

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Figure 4a Stray Current Corrosion Rate Calcula�on from Predicted SC Density

Note that in Zone 3 of Figure 4a above, the input for Structure to Electrolyte poten�al (ON) has

changed to "-550", as a result, SC-Compass predicts that stray current is leaving the structure and

increasing the corrosion rate by a factor of 60.29. The amount of stray current is predicted to be

0.779 mA/cm2.

Zone 4 is for the predic�on of stray current Corrosion Rate.

For the inputs parameters shown in Figure 4a, the stray current corrosion rate predicted by SC-

Compass is 9.044 mm per year for carbon steels. If an user measured the stray current in the

11

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structure and the surface area over which the stray current discharges, the measured data can be

entered for the calcula�on of the stray current corrosion rate by selec�ng "Use Measured SC in

Structure" from the dropdown list, as shown in Figure 4b below. Here, the user enter "7.750" mA as

measured stray current in the structure and "10" cm2 as the surface area over which the stray current

discharges. The calculated corrosion rate based on the measured data is 9.002 mm per year.

Figure 4b Stray Current Corrosion Rate Calcula�on from Measured Stray Current

12

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The stray current corrosion rate in mm per year is computed for about 200 metals and alloys (Figure

4c). If you cannot find the metal or alloy in the database, email us the grade of your alloy and we will

update the database within 24 hours a�er receiving your request.

Figure 4b Stray Current Corrosion Rate Calcula�on from Measured Stray Current

Zone 5 is for AC Corrosion Predic�on and Assessment

For underground pipelines under the influence of induced AC current, the risk of AC corrosion is

assessed in accordance with the latest edi�ons of BS EN 15280 and NACE SP 21424 standards. In

13

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Zone 5, users can select either AC current density or AC voltage with respect to remote earth from

the dropdown list (Figure 5a) for assessment and predic�on of AC corrosion. The DC current density is

required only if users selected "AC current density" from the dropdown list as the assessment criteria

(Figure 5b). SC-Compass takes into considera�on of the AC current density to DC current density ra�o

as per BS EN and NACE standards.

Figure 5a Assessment and Predic�on of AC Corrosion Using AC Current Density and DC Current Density

14

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Figure 5b Assessment and Predic�on of AC Corrosion Using AC Voltage to Remote Earth

The powerful applica�ons of SC-Compass in rail transit systems, civil structures, underground

pipelines, boats, ships and vessels are truly unlimited in engineering design, materials evalua�on and

selec�on, remaining life predic�on, trouble-shoo�ng and failure analysis. Contact us for licensing

details.

SC-Compass, giving you the right direc�ons in Managing Stray Current Corrosion

Home | Contact Us | PDF Copyright © 1995-2019. WebCorr Corrosion Consul�ng Services. All rights reserved.

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