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FACWORLD EZINE
The Facilities, Mechanical, Electrical Resource Center

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November 2, 2005
Editor: Thomas Yoon

contact: http://www.free-marine.com/emailform.htm
Publisher: Facworld Ezine


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Publisher's Note
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Publisher's Note
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Hi there,


In the previous article, we found out the corrosion of iron
and steel occurs only when 3 conditions occur:

1. A potential difference exists.
2. The surfaces are covered by an electrolyte.
3. Oxygen is present.

Methods that are used to prevent corrosion are therefore aimed
at preventing the presence of an electrical potential
difference, using less active metals and removing the presence
of moisture and oxygen.

Painting
The most common method is to cover up the surfaces of bare
metal with a coating of paint. This prevents the flow of current
whenever the metal is in contact with water. To be effective,
the coating on the bare metal must have a very strong bond. This
first paint coat is called the primer coat.

The purpose of the primer paint coat is to protect the base metal
area and also have adhesion of the topcoat. Some examples of
primers are zinc chromate primer, red oxide and red lead primer.
For galvanized steel and light alloys you will need to use a
polyvinyl butyral-based, acid-catalyzed etching primer.

Some alkyd-based paint coatings pigmented with micaceous iron
oxide provides good protection for iron and steel surfaces and
are suitable for storage tanks, pipes, steel structures and
grills.

For heavy-duty paint coatings, the surfaces need to be cleaned
by sand-blasting. The idea of sand-blasting is to bombard the
surface with abrasives under high pressure to scrape it clean
to the bare metal.

Epoxy paints provide very good protection from corrosion. This
is because of the impervious nature of the epoxy coating layer.
These are excellent for protection against corrosive chemicals,
salt and fresh water abrasion and are ideal for steel piles,
marine structures, ballast tanks and sewage treatment plants.

Polyurethane paints are used in body paint and auto paint of
cars. These produce high gloss and are excellent body repair
paints with good durability.

Rubber and Plastic linings
By using rubber and plastic linings and laminates to coat the
bare metal, a chemical resistant elastomer layer can be
strengthened by the strong steel reinforcement underneath. Their
use is not so much to protect the steel but to use the steel for
support.

Cathodic Protection
Another way to protect steel is to coat the metal with a more
reactive metal. This can be found in galvanizing. This is the
coating of iron with zinc. The iron can be dipped in molten zinc
to coat it. Because the zinc is reactive, it forms a tough oxide
layer that prevents further oxidation and so protects the iron
underneath. Many outdoor structural parts are often protected in
this way. Some examples are cooling towers, air conditioning
ducting, sheet metal, pipes, street lamps, etc.

In some submerged steel installations, zinc is used as
sacrificial anodes. When zinc is placed together with iron, the
former is sacrificed in favor of the latter. An example of this
usage is in tube and shell heat exchangers where the presence of
copper tubes will cause an electrical potential to exist between
the steel shell and the copper tube nest. Sacrificial anodes of
zinc are often then placed at the shell end covers to protect the
iron from wasting away.

Impressed Current System
By putting the flow of current to the opposite direction, a way
has been found to counter the inherent electrical potential
caused by dissimilar metals placed together. By using noble
metals like titanium, platinized niobium or lead/silver alloy and
injecting electrical current in the opposite direction, the parent
steel metal can be protected from the effects of corrosion.

A typical impressed current system controls current so that the
inert anodes are made positive relative to the steel. When the
steel is immersed in seawater, the normal galvanic current is
counteracted by the supplied current. Different potentials are
also applied for newly painted steel and for clean bare steel. The
controller unit with its step-down transformer, rectifier, and the
reference electrode are essential components of this impressed
current system. The amount of current, and its evenly distribution
is very important in this system. Over potential can produce OH-
ions that can attack the surrounding paint.

Alkaline Chemical Treatment
Cement wash or alkaline chemical treatment for the water in contact
with the metal is used in tanks where no painting or coating is
allowed. Chemical treatment of water is also used in steam boilers
where any coating on the heat transfer surfaces will be disastrous.

Use of less active metals
It is difficult to replace steel in many applications where
strength is important. In applications where strength and low cost
is not so critical, alloys of cupro nickel, bronze and brass can be
used to substitute steel parts. Stainless steels containing iron
and chromium can also be used where higher cost is not a concern.

Painting to prevent corrosion does make our world a more colorful
place to live. We can prevent corrosion in so many different ways.
Corrosion need not be a dirty word. In most cases, just a coat of
paint will do.

Until next time...

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Thomas Yoon
Editor, Facworld Ezine
More information can be obtained at
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http://www.free-marine.com

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Article
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Marketing Successfully

Marketing keeps a business running by bringing in new
customers and building name recognition. Without a
marketing plan, a business is doomed to failure. Don't make
the mistake of developing a product or service and then
finding the market who will buy it.You can market your
business effortless if you find a need and then fill it.

Your best marketing begins with a product or service that
will solve a customer problem or need. If you did the
research on finding a need, then you already identified
your potential customers. This group becomes your target
market. Nothing more frustrating than trying to sell
something to a group of people who don't need it. Once you
identify a problem, develop a diverse product or service
line to solve the various needs and budgets of your
customers.

You can ensure that steady stream of customers by paying
attention to two areas. First, determine you can meet your
customer demands without a heavy upfront investments.
Second, never promise more than you can deliver. A good
rule of thumb... Over deliver and under promise.

Cash flow and marketing work together. Today's market
changes quickly and trying to anticipate customer needs far
in advance can quickly lead too much over head.Too much
inventory sitting on the shelves and not moving in a timely
manor will cut into your marketing budget and cash flow.
Keep it simple and plan for your customer needs for the
very near future.

When you have your marketing plan in hand of the need and
how you will fill it be sure not to over-inflate what your
company can do. Promising a customer a timeline that cannot
be achieved may get you the business the first time, but it
definitely will not lead to repeat business. It is always
better to have enough time built into a service to allow
for unforeseen problems and when it comes to products
they're as good as the name on them.

Over deliver, under promise and focus on knowing about your
target market and your customer needs. This approach gives
a better and more effective way to market your and gauge
your business growth.


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Contact Information
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Thomas Yoon, Publisher/Editor
4186 Bagan Luar Road
12000 Butterworth
Malaysia

Contact me at http://www.free-marine.com/emailform.htm


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