Underdeposit corrosion

Localized corrosion, which occurs when the anodic sites remain stationary, is a more serious industrial problem. Forms of localized corrosion include pitting, selective leaching (eg, dezincification), galvanic corrosion, crevice or underdeposit corrosion, intergranular corrosion, stress corrosion cracking, and microbiologicaHy influenced corrosion. Another form of corrosion, which caimot be accurately categorized as either uniform or localized, is erosion corrosion. 

The three major forms of concentration cell corrosion are crevice corrosion, tuberculation, and underdeposit attack. Each form of corrosion is common in cooling systems. Many corrosion-related problems in the cooling water environment are caused by these three forms of wastage. The next three chapters—Chap. 2, Crevice Corrosion, Chap. 3, Tuberculation, and Chap. 4, Underdeposit Corrosion — will discuss cooling water system corrosion problems. 

Attack always occurs beneath a deposit. Cooling water system deposits are ubiquitous. Deposits can be generated internally as precipitates, laid down as transported corrosion products, or brought into the system from external sources. Hence, underdeposit corrosion can be found in virtually any cooling water system at any location. Especially troubled... 

Removing suspended solids, decreasing cycles of concentration, and clarification all may be beneficial in reducing deposits. Biodispersants and biocides should be used in biofouled systems. Simple pH adjustment may lessen precipitation of certain chemical species. The judicious use of chemical corrosion inhibitors has reduced virtually all forms of aqueous corrosion, including underdeposit corrosion. Of course, the cleaner the metal surface, the more effective most chemical inhibition will be. Process leaks must be identified and eliminated. 

Underdeposit corrosion is not so much a single corrosion mechanism as it is a generic description of wastage beneath deposits. Attack may appear much the same beneath silt, precipitates, metal oxides, and debris. Differential oxygen concentration cell corrosion may appear much the same beneath all kinds of deposits. However, when deposits tend to directly interact with metal surfaces, attack is easier to recognize. 

Ferrous sulfate was added to the condenser in hopes of retarding attack. A thick, tan deposit layer rapidly formed on tubes near inlets (Fig. 4.24). Corrosion continued unabated. Underdeposit corrosion caused localized areas of metal loss (Fig. 4.25). Corrosion product mounds contained up to 10% chloride. 

Some of the observed wastage was caused by past acid cleanings. However, much of the attack was caused by long-term underdeposit corrosion. 

Wastage was caused by classic long-term underdeposit corrosion. The combined effects of oxygen concentration cells, low flow, and contamination of system water with high chloride- and sulfate-concentration makeup waters caused corrosion. 

Corrosion resistance of stainless steel is reduced in deaerated solutions. This behavior is opposite to the behavior of iron, low-alloy steel, and most nonferrous metals in oxygenated waters. Stainless steels exhibit very low corrosion rates in oxidizing media until the solution oxidizing power becomes great enough to breach the protective oxide locally. The solution pH alone does not control attack (see Chap. 4, Underdeposit Corrosion ). The presence of chloride and other strong depassivating chemicals deteriorates corrosion resistance. 

See also Chap. 2, Crevice Corrosion Chap. 3, Tuberculation and Chap. 4, Underdeposit Corrosion. ... 

Passive attack involving underdeposit corrosion tends to involve large system surface areas and, hence, accounts for the greatest amount of metal loss, by weight, in cooling water systems. Active attack tends to produce intense localized corrosion and, as such, a greater incidence of perforations. 

Alter the environment to render it less eorrosive. This approach may be as simple as maintaining clean metal surfaces. It is well known that the chemistry of the environment beneath deposits can become substantially different than that of the bulk environment. This difference can lead to localized, underdeposit corrosion (see Chap. 4, Underdeposit Corrosion ). The pit sites produced may then induce corrosion fatigue when cyclic stresses are present. The specific steps taken to reduce corrosivity vary with the metal under consideration. In general, appropriate adjustments to pH and reduction or elimination of aggressive ions should be considered. 

The dezincification was caused by underdeposit corrosion. The fact that the brass was not an inhibited grade was a major contributing factor. Chemical cleaning had not been done since this exchanger was installed. No chemical treatment was used on either external or internal surfaces. 

The triggering mechanism for the corrosion process was localized depassivation of the weld-metal surface. Depassivation (loss of the thin film of chromium oxides that protect stainless steels) can be caused by deposits or by microbial masses that cover the surface (see Chap. 4, Underdeposit Corrosion and Chap. 6, Biologically Influenced Corrosion ). Once depassivation occurred, the critical features in this case were the continuity, size, and orientation of the noble phase. The massive, uninterrupted network of the second phase (Figs. 15.2 and 15.21), coupled... 

Many types of WT boiler are of a one-drum design, but where mud drums are fitted, these should also be inspected. As its name suggests, much of the mud, sludge, dislodged scale particles, and other general debris in the boiler ends up in the bottom or mud drum. This material should be removed and the drum inspected for underdeposit corrosion, wall thinning, erosion, and other problems. 

The relatively thick zinc hydroxide film can effectively prevent underdeposit corrosion and other problems. As a further example, in medium hardness waters, with careful control of the water chemistry, this thick Zn(OH)2 film can help offset risks of chloride-induced pitting corrosion with estuarine makeup water. 

Underdeposit corrosion - caustic gouging Underdeposit corrosion - hydrogen damage Underdeposit corrosion - phosphate corrosion Acid cleaning corrosion Internal deposit/corrosion product buildup Fireside wastage Fireside oxidation... 

Production of differential aeration cell. A scatter of individual barnacles on a stainless steel surface creates oxygen concentration cells. The formation of biofilm generates several critical conditions for corrosion initiation. Uncovered areas will have free access to oxygen and act as cathodes, while the covered zones act as anodes. Underdeposit corrosion (crevice corrosion) or pitting can occur. Depending on the oxidizing capacity of the bacteria and the chloride ion concentration, the corrosion rate can be accelerated. However, the presence of a biofilm does not necessarily mean that there will always be a significant effect on corrosion. (Dexter)5... 

Flow measurements showed flow rates lower than expected and backwashing was observed. The backwash contained brownish siliceous matter and other solid impurities. All three heat exchangers had silt and dirt deposits and partially plugged tubes. The tube ends were corroded and thinned down. Perforation of the tubes originated from inside (cooling water side). Pitting shows it to be underdeposit corrosion. 

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