CORROSION FORUM Industry Perspective Sheldon W. Dean 20 May 2003

Industry Perspective Issues Cost of Corrosion Communications Standards

Cost of Corrosion C C Technology Study % GDP Battelle Study – % GDP Industry View

Cost of Corrosion Industry View Cost of Corrosion Prevention Cost of Corrosion Failures Safety and Reliability

Cost of Corrosion Prevention Capital costs Operation costs Failure analyses - Key to continuous improvement Education, training & development - Culture change

Cost of Corrosion Prevention CAPITAL COSTS Upgrade to resistant alloys High performance coatings Cathodic protection systems Design improvements & analyses

Cost of Corrosion Prevention OPERATING COSTS Inhibitors Cathodic protection operation Maintenance - Repairs - Touch-up Inspections

Cost of Corrosion Prevention FAILURE ANALYSIS Failure analysis policy - What failures to examine? Responsible organization - Internal lab or outside lab? Follow up – Fix Who? When?

Cost of Corrosion Prevention EDUCATION, TRAINING & DEVELOPMENT Engineering – purchasing Operations Policy Communications

Cost of Corrosion Failures Loss of capital Cost of fix Inspection of similar equipment Related costs

Cost of Corrosion Failures Cascading effects - Many items fail in sequence Damage depends upon random factors Any analysis contains subjective elements

Safety & Reliability Safety and reliability are key issues Safety is not subject to cost analysis Consequence analysis Probability of failure Reliability is a key benefit of corrosion control

Communication – Key Issues Who needs to be involved? What level of communication needed? - Technical level? - How extensive? Who is responsible? What are the deliverables?

Communications Review of Air Products materials and corrosion programs Presented as an example of a successful activity Developed over 25 years - Evolutionary process - Designed to meet changing needs

Air Products M&C Program M & C Seminar M & C Workshops M & C Round tables A P University presentations Other

M & C Seminar Intended for new engineers (1 to 3 yrs) Featured different departments 10 to 20 presentations 30 to 45 minutes for each subject 1 to 2 days duration Presented annually Attendance: 60 to 100

M & C Seminar Presentation of technologies in M & C area Notebook with written papers College level assumed - Chemistry and basic engineering Responsibility rotated - senior M & C staff

M & C Workshops Local presentations at operating plants Small group of presenters, 2 to 4 - Include local specialists if possible Tailored to specific plant issues - e.g. sulfuric acid if used in plant - agenda negotiated with plant Arranged by request from plant

M & C Workshops Duration: ½ to 2 days Attendance: 15 to 40 Frequency: every 2 to 3 years Level: No technical training assumed

M & C Workshops Responsibility: - M & C Department sets agenda - Local management absorbs costs - Safety Department involved Program: - General topics - MTI videos - Specific plant topics ( Failure analyses)

M & C Roundtables Professional level group World wide participation Purpose: to share recent problems and results Encourage joint action and cooperation

M & C Roundtables Meeting 4 times a year or more Typical attendance: 10 to 20 Teleconference + web and video Responsibility: rotating among senior M & C engineers (2 year term)

A P University Wide range of technical topics covered M & C only small part of program 1 hr. presentation (lunch time) Topic: Recent developments with major technical impact Presenter: Responsible engineer

A P University Attendance: 30 to Wide range, engineers and managers Frequency: As needed (one per yr.) Policy level communication

Communications - Other Materials Technology Institute News Letter -Distributed world wide to engineers NACE & ASTM developments Liaisons: - Safety & Environment Dept. - Engineering Dept. - Management

Standards Corrosion Standards: - ASTM, NACE, ISO Voluntary consensus documents International scope Documents with wide usefullness

NACE Standards RP = Recommended Practices - Industry recognized practices MR = Material Requirements TM = Test Methods 5 year review Committee Reports – state of the art

ASTM Standards Test methods - Measure property or characteristic - Precision and Bias provided - Important in corrosion evaluations Practices - Procedure only - Does not give a result

ASTM Standards Specifications -Specific requirements for product - Important for purchasing Classifications - grouping of materials with similar properties Terminology -Definitions of terms in standards

ISO Standards Documents similar to ASTM ISO favors European members Voting based on one per country Negative votes require a majority ASTM now no longer supports ISO for corrosion standards

Wrap Up The cost of corrosion prevention is a necessary cost of being in business. Reducing this cost is not necessarily beneficial but may create significant problems.

Wrap up Safety and reliability are key issues in corrosion prevention. Corrosion control should increase safety and reliability if it is effective.

Wrap up Communication is an essential component of a successful corrosion control program. Communication should deliver the necessary information to the individuals responsible for corrosion control in a timely and understandable manner.

Wrap up The communication process must be tailored to the appropriate individuals at the level that will be most helpful. It should present new developments in a timely fashion.

Wrap up Standards provide a valuable resource for engineers and purchasing people to obtain proven results by the most reliable methods known to industry. Government people should be active in standards organizations to take full advantage of the expertise in these organizations.

Thank You! Questions please?