CORROSION ENGINEERS & DOCTORS Corrosion Engineers are akin to doctors - The patient calls when the problem is very serious or is on his/her’s death bed. Corrosion Engineers cannot replace lost metals but can prevent from more being lost. Build it, bury it and forget it is the normal philosophy. Penny wise, pound foolish.

COST OF CORROSION USA: 1.25% OF G.N.P.. 2002 NACE STUDY ESTIMATED DIRECT COST OF CORROSION IN USA TO BE $276 BILLION (3.1% GDP). IN 1975 BATELLE STUDY ESTIMATED THIS TO BE $70 BILLION (4.2% OF G.N.P.). 3.5% OF TOTAL US ENERGY DEMAND WAS GENERATED BECAUSE OF METALLIC CORROSION. U.K.: 3.5% OF G.N.P. (£1365m, 1969) INDIA: ESTIMATED TO BE AROUND $364 billion AS OF 2004. SWEDEN: 1.25% OF G.N.P. WEST GERMANY: 3% (DM 6 BILLION, 1969) PAKISTAN: AT 3% OF GNP, $107.28 BILLION (2005)-APPROX $3.2 BILLION

COST OF CORROSION INPUTS That part of the maintenance cost which arises because of corrosion damage The cost of inhibitors and other protective systems Consequential losses known to be caused by corrosion The cost of ‘conservatism’ in design due to uncertainties in operating conditions, properties of materials, etc. The cost of technical effort devoted to corrosion

22% CAN BE POTENTIALLY SAVED BY: SAVINGS 22% CAN BE POTENTIALLY SAVED BY: 1. BETTER DISSEMINATION OF INFORMATION ON CORROSION & PROTECTION 2. GREATER EDUCATION IN CORROSION & PROTECTION 3. INCREASED AWARENESS OF THE HAZARDS OF CORROSION

CORROSION – does it matter? YES - if it jeopardises human safety YES - if it causes waste of valuable resources YES - if it causes loss or contamination of product YES – if it causes reduction in equipment efficiency YES – if it means expensive maintenance YES – if it causes expensive over-design YES – if it causes customer alienation

LEGAL ASPECTS Negligence can be defined as ‘the causing of foreseeable damage’ and ‘is the omission to do something which a reasonable man, guided upon the circumstances which ordinarily regulate the conduct of human affairs, would do, or do something which a reasonable or prudent man would not do’. (Blyth v Birmingham Water Works Co. 1856 per Alderson, B.) It is known that steel will corrode, therefore a steel pipeline will leak in time if cathodic protection is not applied. It is now an accepted pre-requisite of good petroleum pipeline and high pressure gas line operations to prevent external corrosion, by a good external coating, properly applied, and supplemented by cathodic protection. Failure to apply cathodic protection to a coated, high pressure pipeline can reduce the leak free life to 18 months and, in the event of damage to property, leave the door open to court proceedings and consequent adverse publicity. Above quoted from “PIPELINE CORROSION: The Legal Aspects, Hatley, H.M., p6, Nov 1971.

CLASSIC CORROSION CASES

THE CASE OF FUEL STORAGE TANKS

THE CASE OF KDA

built-in obsolescence built-in/planned obsolescence: when a product is intentionally designed and made so that it will not last for a long time planned obsolescence: Planned obsolescence, also called built-in obsolescence, is the conception, design and production of a product, such as hardware or software , with the intent that it should be useful, functional or popular for a limited length of time. The term was coined in the 1950s by Brooks Stevens who suggested that new and improved products are in constant demand by consumers and that corporations can best respond by manufacturing items that don't last very long.

THE CASE OF SUKKUR BARRAGE

CH-517: Corrosion Introduction, definition of corrosion, forms of corrosion, cost of corrosion; Electrochemistry, oxidation/reduction reactions, corrosion as an electrochemical reaction; Reference Electrodes, Galvanic Series, Nernst Equation, Pourbix Diagrams; Faraday’s Law, area effects, Galvanic Corrosion, Active/Passive Cells, Thermogalvanic Corrosion. Environment-related corrosion; Physical and Chemical Soil Characteristics; Moisture effects; Electrical Resistivity; Engineering Materials, metals and non-metals; Forms of Corrosion, pitting, crevice corrosion, fill form corrosion, galvanic corrosion, environmental cracking, flow assisted corrosion, intergranular corrosion etc. Methods of Corrosion Control, material selection, modification of environment, protective coatings, cathodic and anodic protections; Corrosion Monitoring Techniques, interoduction, inspection methods, specimen exposure, cathodic protection monitoring.