Failure Investigation A pathway for Railways Safety

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Failure Investigation A pathway for Railways
Safety

• Corrosion related failure
• Paint perspective

RDSO Lucknow 5th December 2008 By Vasant
Kelkar Akzo Nobel Coatings India Private Limited
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Agenda

• Objective
• Corrosion theory
• Various factors governing the same
• Various methods adopted to check it
• Importance of painting amongst them
• Basis of system ISO12944
• Various options as per RDSO PCN spec
• What Akzo can / have offered
• How it can restrict corrosion and protect asset

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Objective

• Corrosion in steel and solution through various
  types of coating system
• RDSO-AKZO partnership to arrest and prevent
  corrosion related failures

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What is Corrosion?
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What is Corrosion?

• Two basic Definitions
• Corrosion is the deterioration of a material,
  (usually steel), because of a reaction with its
  environment
• The destruction of steel by an electrochemical
  process that is recognised by the formation of
  rust or pits
• These two definitions bring together the idea of
  an environment and an electrochemical process
  which are fundamental in understanding corrosion
  in terms of why it occurs and how it can be
  prevented.

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Summary of Corrosion process
High Energy
STEEL Iron Metal Chemically Unstable Structural
HEAT (By Man)
CORROSION (By Nature)
Chemically the same!
IRON ORE Iron Oxide Chemically Stable Non-Structur
al
RUST Iron Oxide Chemically Stable Non-Structural
Low Energy
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The Electrochemical Process
RUST FORMATION AT ANODE
ELECTROCHEMICAL PROCESS
ELECTROLYTE OXYGEN
METALLIC PATHWAY (STEEL)
CATHODE
ANODE
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The consequences of Corrosion

• Corrosion (Rust) Steel Metal Loss
• Steel Metal Loss Maintenance Costs
• Steel Metal Loss Reduced Structure Design Life
• Steel Metal Loss Revenue Loss
• Steel Metal Loss Catastrophic Failure
• Steel Metal Loss Loss of Life?

STEEL
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Steel?
...SO WHY USE STEEL?

• Iron ore is very widely available

• It is relatively easy to make steel from iron
  ore

• Steel is strong relative to its weight

• It is easy to fabricate with steel

• Steel is cheap!

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Corrosion How to control

• Adopting right technology at design stage
• Adopting suitable methods at fabrication stage
• Ensure no entrapment of Moisture and dirt
• Ensure proper insulation between different
  materials
• Applying metal coatings
• -Hot dip Galvanizing ( Limited performance )
• -Electroplating ( Limited performance )
• -Thermal Metal spraying
• Adding /changing chemical composition of coating
• -Weather resistance steel ( Incorporation of
  cu/cr/ni/p )
• Applying appropriate paint coatings

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Why Paint ?

• Protection from Corrosion (Asset protection)
• Control Fouling
• Provide good Cosmetic appearance
  (Aesthetics/Image)
• Prevent Cargo contamination
• Provide Abrasion resistance
• Provide anti skid property
• Superior Anti Graffiti property
• Provide Fire Protection or fire retarding
  property
• Provide Heat resistance
• Provide Radar Attenuation

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HOW COATINGS WORK ?

• Galvanic Protection Chemical Inhibition
  Barrier Protection

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Corrosion Protection
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Cosmetic Appearance
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Cargo Contamination Prevention
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Abrasion Resistance
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Fouling Control
Acorn Barnacles
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Skid Prevention
Good grip is essential to land a plane on a deck
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Radar Attenuation
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Heat Resistance
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Fire Protection
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Low Solar Absorption (LSA) Coatings

• Coatings protect decks, topsides
  superstructure from the harsh marine environment.
• These are GREY due to the need for visual
  camouflage.
• BUT.

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Solar Absorption
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Rail Wagon
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Rail Wagons
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Rail Wagons
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Rail Wagons
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Rail Wagons
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Rail Wagons
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Rail Wagons
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Rail Wagons
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Rail wagons
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The Environment Basic Definitions

• Atmospheric essentially the earths weather
  patterns!
• Underwater in rivers, oceans and seas
• Underground within the earths surface
• Manmade artificial environments such as storage
  tank internals, pipeline internals process
  vessel internals
• Steel Environment Potential for corrosion
• (Steel Environment) Coating Potential for
  protection

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The Environment Impact on Corrosion Rate

• The electrolyte has a big influence on the rate
  of corrosion
• It is the environment that supplies the
  electrolyte
• Therefore, the environment has an influence on
  the rate at which corrosion will occur
• Fast corrosion fast steel metal loss and vice
  versa
• Steel structure design life is directly related
  to the speed of steel metal loss
• An electrolyte with good electrical conductivity
  (i.e. plenty of ions) will provide the conditions
  for a high rate of corrosion
• i.e. it is MORE CORROSIVE !

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The Environment Impact on Corrosion Rate
Seawater, which contains the ions sodium and
chloride (salt), has greater conductivity than
drinking water which contains fewer ions.
A HIGHER CONCENTRATION OF IONS SUCH AS SODIUM
AND CHLORIDE INCREASE THE CORROSION RATE
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The Environment Impact on Corrosion Rate

• The degree of contact of the electrolyte with the
  steel surface also affects corrosion rate
• Intermittent electrolyte contact will switch the
  corrosion process on and off
• This idea of the corrosion process switching on
  and off is controlled by the environment in
  which the steel structure is in, i.e.
  temperature, rainfall, humidity, immersion,
  moisture, pollution and salinity etc
• Warm temperatures will influence the degree of
  electrolyte contact with the steel surface
• When the electrolyte evaporates, the corrosion
  process stops

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The Environment Impact on the Coating
THE COATING MUST BE ABLE TO WITHSTAND THE
ENVIRONMENT
STRESS
COATING
STEEL
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The Environment Impact on the Coating
Poor coating specification in a specific
environment can lead to early coating failure !
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Classification of Environments

• The ISO standard ISO 12944 Part 2
  Classification of Environments provides us with
  some very good guidelines on how to classify the
  corrosivity of a particular environment
• The idea of corrosion rate and steel metal loss
  is used to categorise the environments
• The greater the metal loss, the shorter the steel
  structure lifetime and vice versa
• The environment in which the steel structure is
  in, dictates the level of coating protection
  required
• Misunderstanding the environment can lead to
  incorrect coating specification and reduced
  coating lifetime due to early degradation and
  breakdown.

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Classification of Environments

• The ISO 12944 environment categories are shown
  below

Increasing Metal loss C1 to C5
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The Environment Examples
Inside an Airport terminal C1 Very Low
Corrosivity
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The Environment Examples
Inside an unheated warehouse C2 Low Corrosivity
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The Environment Examples
Stadia in urban atmospheres C3 Medium Corrosivity
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The Environment Examples
Construction Yards in industrial / coastal
atmospheres C4 High Corrosivity
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The Environment Examples
Chemical Plants in Industrial atmospheres C5-I
Very High Industrial Corrosivity
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The Environment Examples
Offshore Structures C5-M Very High Offshore
Corrosivity
Im2 Seawater Immersion
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System Selection Parameters

• Corrosion Properties Expected E.g. Salt Spray,
  Humidity
• Design Life Expectancy. Repaint after how many
  years of running.
• Dry Film Properties Expected E.g. Impact,
  Flexibility, Hardness, Abrasion resistance,
  Scratch resistance etc.
• Gloss Retention
• Overcoatability
• Ability to be coated Wet on Wet
• Cost per Sq Mtr/year
• Track record in similar industries
• Drying Times
• Technical service/Online Trouble shooting

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RDSO Specification coaches and wagons

• PCN 100 Epoxy primer ,polyester putty,PU
  surfacer and PU top coat
• Performance requirement - 500 hrs salt spray/750
  hrs QUV resistance
• Our Counter offer Interfine 878 polysiloxane
  top coat against PU top coat for better
  weathering resistance and better anti graffiti
  property.
• Advantage to RDSO Better paint life cycle time/
  better appearance
• PCN 102 specification for epoxy primer
• Performance requirement 500 hrs salt
  spray/humidity resistance
• Our Counter offer
• Intergard 251 High build epoxy primer having
  high DFT built up and
• Intercure 200 HS High vol. solid, fast drying ,
  high dft built up
• Advantage to RDSO Better paint life cycle time/
  faster production

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RDSO Specification coaches and wagons

• PCN 109 Specification for PU Top coat
• Performance requirement - 750 hrs QUV resistance
• Our Counter offer
• Interthane 990 high vol. solid ,high dft built
  up top coat
• Interfine 878 polysiloxane top coat against PU
  top coat for better weathering resistance and
  anti graffiti property.
• Advantage to RDSO Better paint life cycle time/
  better appearance/faster productivity
• PCN 104 specification for epoxy finishing
  paint
• Performance requirement 1000 hrs salt
  spray/humidity resistance over primer
• Our Counter offer
• Intergard 966 High build epoxy finish coat
• Intergard 345 High vol. solid, fast drying ,
  high dft built up top primer cum finish coat
• Advantage to RDSO No requirement of primer
  /faster productivity

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RDSO Specification coaches and wagons

• PCN 111 High build epoxy paint
• Performance requirement - 2000 hrs salt spary
  /humidity resistance
• Our Counter offer Interseal 670 HS
• Advantage to RDSO more dft built up/faster
  productivity
• PCN 123 High performance anticorrosion epoxy
  coating
• Performance requirement - 2000 hrs salt spary
  /humidity
• 
  resistance/chemical resistance
• Our Counter offer Interseal 547
• Advantage to RDSO better performance /single
  coat solution, Higher volume solids

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Special Coating

• Intergard 774 single coat fast curing epoxy
  finish for wagon external
• Advantage to RDSO single coat solution /faster
  productivity/less Inventory control
• Intershield 300 Universal abrasion resistance
  epoxy coating
• Advantage to RDSO Better corrosion protection
  /Prevention of weight loss due to erosion of
  steel owing high abrasion /Prevention of
  contamination of contents of wagons
• Interzone 954 Two component high solid epoxy
  barrier coat
• Advantage to RDSO Better corrosion protection
  /Prevention of weight loss due to erosion of
  steel owing high abrasion /Prevention of
  contamination of contents of wagons /Robust
  coating than intershield 300

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Product information
Interseal 670HS Surface tolerant epoxy mastic
coating Intergard 251 Epoxy zinc phosphate
primer Intergard 200HS Epoxy primer cum
intermediate coat with MIO,Zinc
phosphate Intergard 774 Single coat DTM epoxy
coating Intergard 345 Single coat epoxy primer
cum finish Interthane 990 PU finish Interfine
878 Polysiloxane finish Interfine 979
Polysiloxane finish Interline 399 Epoxy Novolac
tank lining Interline 850 Epoxy phenolic tank
lining Interzone 954 Modified epoxy barrier
coat Interzone 1000 Epoxy with glass flake
lining Intershield 300 Abrasion resistant
aluminium epoxy coating Interprime 741 Hot oil
resistant, weld able, etch PVB
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Recommended system choice for RDSO
Open wagons External Primer Interseal 670HS,
Intergard 251 Finish Interthane
990 Internal Interline 399, Interline 850,
Intershield 300, Interzone 954, Interzone
1000 Closed wagons External Primer Interseal
670HS, Intergard 251 Finish Interthane
990 Internal Interline 399, Interline 850
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Recommended system choice for RDSO
Stainless steel as a substrate External Primer
Intergard 251, Intergard 269 Finish Interthane
990 Internal If needed can be recommended We
have a system approval from Siemens (Test report
from Siemens / IIT) over stainless steel
Transformers External and Internal Standard 2
coat, 3 coat system as per classified
environment We have an approval from ABB (Job
being carried out at Cimotec) for transformers to
be used for DMRC
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Recommended system choice for RDSO
External anti graffiti paint for
coaches External Primer Intergard 251,
Intergard 269, Intergard 200HS Finish Interfine
878, Interfine 979 Internal If needed can be
recommended
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Partnering Progress

• We have ROHS compliant products.
• Ecotech/Low VOC initiative lesser solvent
  emissions.
• Coal Tar, Chrome and mutagenic solvent free
  products (PU)
• Isocynate free products
• Internationally banned solvents are not used.
• Upgrade systems to increase productivity
• Upgrade system to increase quality
• Train people on all aspects related to paint and
  its use
• Line audit / monitoring to be done
• Offer PFP (Passive fire proofing) OR fire
  retardant paints

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Advantages to RDSO

• Introduction of better paint systems
• Savings on cost by way of higher life, lower M
  R and increased productivity and better
  protection of asset over a longer period can be
  offered to Indian Railway
• Ensuring product aesthetics/corrosion protection
  with professional approach.
• Single point contact for supply, technical help
  for paints.
• Testing help from local and world wide
  laboratories of ANCIPL
• Contemporary products and application techniques.
• Increase visibility / image in market as quality
  manufacturer in this segment.

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Akzo Nobel RDSO

• Any Questions?

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Akzo Nobel RDSO

• Thank You