Salt Measurement Product Warren Neuburger President Louisville - PowerPoint PPT Presentation

Louisville Solutions Incorporated SaltSmart TM Salt Measurement Product Warren Neuburger President Louisville Solutions Incorporated

The Basics of Salt • There are many kinds of salts – A salt is a basic ionic compound – Chlorides, sulfates, Nitrates …. – Water solubility determines the specific mixture of – Water solubility determines the specific mixture of salts – As a result, sodium chloride is typically the largest contributor since it is the most soluble – Salts can be acidic, but can also be neutral or a base • Salt is everywhere and on every surface

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What is the Problem with Salt? • The nature of Salt is hygroscopic – When salts are exposed on the substrate, they attract moisture which can lead to flash rusting • Osmosis is a Property of solutions – All coatings permeable and in immersion service may – All coatings permeable and in immersion service may contain 1% to 3% water – Build-up of water between the substrate and the coating combined with soluble ions may create an electrolytic cell – leading to corrosion – Osmotic blistering exposes the substrate, accelerating corrosion and leading to possible premature coatings and structural failure

Rust • Flash rust on steel, sometimes evident in minutes, only occurs if surface contaminates are present • Bare clean steel does not flash rust • Bare clean steel does not flash rust • Need to remove salts prior to coatings application • Need to remove salts between layers of coatings 7 7

How to Remove Salt • Mitigation strategy is dependent on the AMOUNT of salt present • Small amounts of salt are tolerable for most coatings and does not typically change the rated lifespan of the coating lifespan of the coating • Heavier amounts of salt need to be removed or reduced – Abrasive blasting – DI waterjet • Sometimes the act of removal can make things worse!

Abrasives and Water Jet • Fresh abrasives may contain salts • Used abrasives always contain salts • Water Jet with water? • Water with De-ionized water? • Does act of removal imbed more contaminates? 9 9

Standards for Salt Detection • SSPC – Technology Guide 15 2005 – Updating guide is the subject of an active working group • NACE SP0508 • ISO 8502 – Part 2 Lab determination 1992 – Part 5 Measurement of chloride on steel prior to coating 1998 (ION) – Part 6 Extraction for analysis 1995 (Bresle) – Part 9 Field methods for conductometric determination 1998 – Part 10 Field method Titrimetric 1999 – Part 12 Field method water soluble ferrous ions 2003 • ASTM Work Item 3049 Standard Test Methods – To be published 2011 2

Extraction and Analysis • Soluble surface salt extraction methods – How do you get the contaminates off a known area to determine contamination levels and types – Collect a sample using highest efficiency – Collect a sample using highest efficiency • Analysis of the collected sample – Test by ion specific means (titration, kitagawa tubes, test strips/paper, colorimiter) – Conductometric testing 3

Older Extraction Methods • Swabbing method (cotton balls) • Latex cell (Bresle) • Latex sleeve (similar to Bresle) • Latex sleeve (similar to Bresle) • Saturated filter paper or pads (variant of swabbing) • Automated magnetic cell testing (variant of Bresle) 4

Extraction Efficiency Comparison (All numbers except SaltSmart come from published SSPC TU-4 Standard) Extraction Additional Notes Efficiency Notes Method Must be done over Swabbing 25-35% known surface area Over 10 minutes If repeated an Latex Cell 45 - 60% additional 10 minutes <90% Using acidic fluid, Latex Sleeve 65-75% over 6 minutes Expected to be Filter Paper unknown very low efficiency Automated latex Magnetic Cell 45-60% cell method SaltSmart TM Over 4 minutes Continuous Flow Up to 98% period Extraction Method 5

Salt Measurements • Nitrates and Sulfates Chlorides 14 14

SaltSmart Technology • Developed through US Navy funding, cost approx $2.0M • Navy spends $2.4B/year on corrosion, total USA spending is $276B/year • The Navy wants a 20 year coating • 5 year effort to find something better – Easier to use – Faster and labor saving – More accurate – More portable – Less operator-skill dependent • Development resulted in 2 US Patents, 6 foreign patents

What Makes SaltSmart TM Different? • Continuous Flow Extraction Method • SaltSmart TM is a system, and engineered as a system • Highest extraction efficiency of other methods tested • Supports parallel testing • Small contact area, provides broader coverage of large and small parts (gratings for example) • NO residue

What Makes SaltSmart TM Different? • Everything pre-measured • Eliminates chance of cross contamination • Readings are actual surface contamination with background contamination removed • Works in any orientation, magnetic or non- magnetic surfaces

Batch vs. Flow Extraction • Flow Extraction • Batch Extraction – Shower – Bath – Bresle Patch < 85% salt extracted > 99% salt extracted 3.0 mL H2O 0.8 mL H2O 10 minutes 3 minutes

Flow Extraction Demo QuickTime™ and a decompressor are needed to see this picture.

SaltSmart Work Flow DI Water Ampoule Sealed in Plastic Enclosure Salt Strip Unwrap Package 0:05 Unwrap Package 0:05

SaltSmart Work Flow Tack Strip Attach Tack Strip 0:13 Attach Tack Strip 0:13

SaltSmart Work Flow Attach DI Water Ampoule 0:20 Attach DI Water Ampoule 0:20

SaltSmart Work Flow Tack Strip to Work Surface 0:25 Tack Strip to Work Surface 0:25

SaltSmart Work Flow Other Samples May Be Started During Extraction Process Extract Salt into Reservoir 5:00 Extract Salt into Reservoir 5:00

SaltSmart Work Flow Other Samples May Be Started During Extraction Process Test Complete 6 Test Complete 6 - 8:00 8:00

SaltSmart Work Flow No “mess” to clean Remove Strip from Work Surface 8:00 Remove Strip from Work Surface 8:00

SaltSmart Standards Compliance • NAVSEA 009-32 – SaltSmart one of three approved methods • NACE – Compliant to SP0508-2008 • IMO – SaltSmart compliant to PSPC • SSPC – Supported in revised Technology Guide 15 • ISO 8502-9 • And a growing list of many others

How Much Salt is Safe • Various organizations are defining their own levels • As of yet, not yet converging on one number • As of yet, not yet converging on one number • US Navy has the most experience • Suggested that users need to develop Safe Limit, Fail Limit, and Alert Limit for their specific application

NAVSEA Standard Item 009-32: “Cleaning and Painting Requirements” 3.10.7. Conductivity or Chloride Measurement Chlorides Conductivity 3 µg/cm 2 (30 Immersed applications 30 µS/cm mg/m 2 ) mg/m 2 ) 5 µg/cm 2 (50 Non-immersed 70 µS/cm mg/m 2 ) applications • All critical coated surfaces • Test freshly prepared surface • 5 readings per 1000 sq.ft. • Use Bresle Method (or approved equivalent as SaltSmart TM )

IMO PSPC MSC.215(82) Performance Standard for Protective Coatings Total Salts Conductivity 50 mg/m 2 Primary Surface 42 µS/cm Preparation 50 mg/m 2 Secondary Surface 42 µS/cm Preparation • Seawater ballast tanks of all ship types • Double-side skin spaces in bulk carriers >150m long • Use ISO 8502-9 (Bresle Method) or equivalent

SaltSmart • Safe, Clean, Easy • Fast – Disposable, no cross • High efficiency extraction contamination possible process – Compact • Accurate – No needles, bottles, solvents, – Minimum training calibration solutions – Insensitive to technique – Insensitive to technique – No residue or cleanup – No residue or cleanup – Re-wet strip to audit results • Cost Effective • Robust – Cost approx ISO 8502-9 Patch – Any substrate, any – 20X faster curvature, any orientation – Supports testing in parallel • Independent lab tested for accuracy • Made in USA

Questions? Louisville Solutions Incorporated www.louisvillesolutions.com www.SaltSmartOnline.com