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FOUNDATION POWER COMPANY DAHARKI LIMITED (FPCDL)

BRIEF ON CORROSION AND ITS CONTROL


Definition: Corrosion is usually defined as the deterioration of a metal or its properties
caused by a reaction with its environment. Most metals occur naturally in the form of oxides and are usually chemically stable. When exposed to oxygen and other oxidizing agents, the refined metal will try to revert to its natural oxide state. In the case of iron, the oxides will be in the form of ferrous or ferric oxide, commonly known as rust. Metallic corrosion generally involves the loss of metal at a particular location on an exposed surface. Corrosion occurs in various forms ranging from a generalized attack over the entire surface to a severe concentrated attack. In most cases, it is impossible or economically impracticable to completely arrest the corrosion process. However, it is usually possible to control the process to acceptable levels. Corrosion Terms Anode: An electrode at which oxidation of the surface or some component of the solution is occurring. Practically, this is the electrode at which corrosion occurs. Cathode: An electrode at which reduction is occurring. Practically, this is the electrode at which protection occurs in a Cathodic protection system. Electrolyte: The common environment with which both a cathode and anode are in contact. Practically, this is the soil or water to which a metal structure is exposed. Corrosion Process: Metallic corrosion is caused by the flow of direct current from one part of the metal surface to another. This flow of direct current causes the loss of metal at the point where current discharges into the environment (oxidation or anodic reaction). Control of Corrosion The five general method are used to control the corrosion. 1. Coating 2. Cathodic Protection, 3. Material Selection, 4. Environment Modifications 5. Design Practices. Control of underground corrosion is primarily achieved by two methods. Coating and Cathodic protection. An effective external coating can provide corrosion protection to over 99% of the exposed pipe surface. The protection coating is usually applied to pipe or tanks etc before burial. The coating serves to electrically insulate the metal from the soil. If the metal could be completely isolated, then the establishment of corrosion cells would be prevented and no corrosion current would flow. However, no coating can be considered a perfect coating. Damage to the coating as a result of handling, transportation, installation, thermal stresses and soil stress will eventually create defects or "Holidays" that expose the underlying steel to the environment.

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