CorrosionMeasure it, anticipate it,mitigate impacts and save money Examples in 2 industrial sectorsHow software solutions and predictive analysis can help Guillaume FERY http://orignal.blogspirit.com
Corrosion everywhere Source of risks, service disruption and high costs• Corrosion in various sectors – Costs and impacts – Anticipate to mitigate risks• The case of the water industry – Ageing networks – Corrosion impact – Examples• The case of wind turbines
The case of US bridges There are about 583,000 bridges in the United States. o 200,000 are constructed of steel o 235,000 are conventional reinforced concrete o 108,000 are constructed using prestressed concrete o 40,000 are made with other construction materials Approximately 15% are structurally deficient because of corroded steel and steel reinforcements.http://www.nace.org
2/ Example of Water networks in France Why corrosion is a threat for waterquality, service reliability and customer satisfaction
The water network equationType of water x type of pipe x age x type of soil = corrosion
WATER INDUSTRYWhat is corrosion? What consequences? Reactive? 1. Costs 2. Service disruption Sources SAUR
Most of the network was built in 60s 70sMostly using iron pipes (>40% = corrosion risk) FACTS 50% of the network >35 years 850,000 km, Value 100 billions euros 25% to 45% iron Renewal trend: 0,6% / year Source Beture Cerec 2002
Km to renew vs type of material Corrosion is a key criteria Source JM Cador 2002
The investment peakKM to reniew Investment (billions) Source JM Cador 2002
Why corrosion matters and how to get started to face the investment peak• Increased risk of • Risk of water quality • Operation threats to corrosion due to alteration (chlorine face supply predominant use of effect) disruption iron pipes • Risk of leakage • Cost of water• Increased risk of • Risk of major pipes wastage corrosion because of breakage • Customer aging network dissatisfaction (taste) = A need for anticipation and efficient asset management strategies 1. Asset management tool 2. Multi criteria analysis to locate risks (including corrosion model) 3. Predictive analysis to anticipate operations failure 4. Modern technologies and sensors to monitor the network 5. Investment plan to communicate and anticipate the water network investment cliff 6. Impact on operations: pression moderation, chlorine adjustment, etc.
3/ Example of Offshore wind turbines Why corrosion is a threat for renewables and how enable protection
Off shore win farms / facts• Seawater is a saline solution and a ionic conducting electrolyte.• Invokes electrochemical reactions that drive metalliccorrosion processes.• Salt spray/droplets• Flow corrosion• Type and concentration of salt, dissolved oxygen concentration, temperature, orientation of surface etc Source: university of Southampton
Current research• Develop robust sensing techniques and advanced signal processing methods for tribological applications, e.g. subsurface crack and lubrication regime detection using acoustic emissions and electrostatic sensing.• Develop low friction and wear resistant surfaces such as textured surfaces and self assembled monolayer.• Modelling of interfaces.
Why corrosion matters and how to get started to face the reliability issue• Using land-based • Prevention and • Major failure risks technology in the remote control are • Impact on business ocean leads to key model based on critical corrosion • In the new industry, reliable electricity ability to influence production threats design and • Costly reactive operations intervention vs smart maintenance• The bearing issues due increasing bearing sizes and extremely high and variable loads. Quality of the steel used is an issue.• The additional cost of providing unexpected maintenance and/orrepair significantly affects the cost of wind energy as a whole and undermines the reputation of this green energy source to produce reliable energy.• Current bearing and gearbox standards are not good enough to ensure the turbine works well.• Corrosion is a growing area of concern particularly corrosion induced but dynamically driven failures. Drastic reduction in bearing life associated with stand-still corrosion.• Condition monitoring has potential to predict premature failures.