Preservation of Parts, Equipments and Assets

during Storage, WIP and Shipment using VpCI

NIGIS – SZ Training Program, IIT Chennai, Nov 13, 2014

 Copyright 2005, Cortec Corrosion Solutions India Private Limited. All rights reserved.
 Corrosion – Silent Killer !!
• About 75,000 Crores of Rupees are lost
every year in India due to Corrosion
during manufacture, shipping and
storage

• 30 % of these is avoidable, related to the

failure to use the best practices and
products available
Areas where Industry faces
the problem
Storage

Work-in-Process

Domestic and Export Shipment

During operation & lay-up of Plant
and Equipment
 Lets face Reality
Corrosion can neither be stopped nor
prevented!!!
What is the solution?

Protection
How?
by Shielding the Metal for a pre-defined duration
Under a given set of Conditions
 Methods of Protection by
Shielding

• Material Selection
• Barrier Bag + Desiccant
• Petroleum based RP Oils
• Contact Inhibitors such as epoxy and grease
• Use of Vapor Phase Corrosion Inhibitors
 Vapor-Phase Corrosion
Inhibitors
Definition:

• Organic Chemicals that vaporize

• These vapors have corrosion inhibiting

properties

• They condition an enclosed atmosphere with

a protective vapor that condenses on all
metal surfaces, including recessed areas and
cavities
 How do they work?

Metal

Enlarged view of metal

surface
VpCI vaporizes and ionizes
VpCI Ions dissolve in the electrolyte (Moisture)
VpCI Ions always travel towards the metal
VpCI Migrates to recessed areas and cavities
VpCI Ions form a thin monomolecular protective
film on the metal surface
VpCI re-heals and self-replenishes
 H2O
O2

VpCI molecule

VpCI Metal

H2S
• Light Blue: oxygen molecules
• Dark Blue: water molecules
• Black: VpCI

Metal
Contaminants Oxygen Water

VpCI VpCI VpCI VpCI VpCI

Metal
VpCI VpCI VpCI VpCI VpCI

Metal
 Different Carriers used for
liquid products
• Solvent - Dry Film
• Water - Dry Film
• Oil - Wet Film

Carrier does not protect metal. It only

transports the inhibitor to the metal.
It is the inhibitor that protects metal
 3 Phase Action of VpCI

Inside a Pipe Inside a closed

container
 Industry expectations
• Safety
• Cleanliness
• Surface Preparation
• Removal and Cleaning prior to use
• Disposal, reuse and recyclability
• Reliability
• Cost effective
 Other Industry Issues and
Myths on Preservation
• Desiccants and de-humidifiers
• Vacuumising and Nitrogen Filling
• SS and higher metals do not corrode
• “Raining” inside the container
• More the barriers and microns, better the
protection?
• Holidays in barrier coatings, paints
• Protection during monsoon only?
• Water carry over on metal during machining
 VpCI Forms and Industry
Categories
• Packaging including biodegradable and compostable plastics
• Metal Working
• Products for Electrical & Electronic Industry
• For Process Industry, Water Treatment, Cooling Water
• For the Defense and Steel Industries
• Liquids, Coatings, Aerosols, Powders
• Additives to oil, water, paint, ink, polymers, etc
• Water-based cleaners/degreasers with flash rust protection
• Rust Removers with flash rust protection
• Products to protect rebar and concrete in construction industry
 Packaging Products
Extruded PE Film, Woven fabric, Bio-degradable &
compostable film, with and without inhibitor,

Stretch, Shrink & Anti-static films, Coated, reinforced and

laminated paper, Linerboards, Impregnated Foam

Emitting devices, Tablets, Pouches and Powders that

release corrosion inhibiting vapors into the enclosure, etc

Common Principle : Ionic action between opposite poles

Application : Wrap/ Insert and Seal
Protects : Multi-metal
Protects up to : 2 years - storage and shipment
Films and Bags
Some Popular Applications
Weaponry Protection and
Storage
Stretch Film

Video: Corpak VpCI Stretch Film

Shrink Film
•

32
33
Static Dissipative Film
Coated Paper
Reinforced Paper
Linerboard
Impregnated Foam and bio-based
non woven pad
Pouches and Tablets
Emitters for the Electrical and
Electronic Industry
“Integrated Solution”
Cocooning the equipment
Few more examples of cocooning
Biodegradable & Compostable
film with & without inhibitor
 Oil based corrosion
inhibitor concentrates
• Additive to lubricants, cutting oils and
hydraulic, stamping and drawing oils
• For gear boxes, differentials, engines and
equipment internals, lubricating and hydraulic
oil systems, etc.
• During storage, operating and intermittent use
• Effective for mineral and synthetic oils
• Protects machinery, equipments & parts, Cold
Rolled Steel Coils and Sheets, stamped and
pressed parts, etc.
 Solvent based corrosion
inhibitor concentrate
• Dry,Waxy Film protects CS, SS, CI, Cu &
Al. up to 2 years
• Used in Moth balling of plant and
equipment
• Protection of machinery and bi-metallic
components, during storage and export
• Protection of turbine blades and
components, crank shafts, plates and pipes
in outdoor conditions, bi-metallic bearings,
etc.
• Protection of Aircrafts and spares
 Water based corrosion
inhibitor concentrates
• Dry and clear film protects multi-metal
• Protects spare parts, tubular parts, pumps, components,
castings & forgings during storage and export
• Excellent in process metal protector
• Additive to Standing water and rinse water systems
• Can be added to water based coolants
• Edge spray for coils and sheets stock
• Fog void spaces, enclosures, packages, tanks & containers
• Protects internal surfaces of equipments, parts and tools
 Concentrates for Metal
Working/Machining/Cutting Operations

• Mutli-functional corrosion inhibitor

• Protects ferrous and non ferrous metal
• Excellent lubricant and coolant properties
• Resistant to rancid attack by bacteria
 High Performance Coatings
with inhibitor
• Water borne coatings that leave a dry and semi-dry
film
• Can be used as Primer/Top Coat. However
compatibility with other coatings must be checked
• Suitable for outdoor uncovered structures and
equipments, including marine and in acidic
atmospheres
• Some of them work even in immersed conditions
 Rust Converters
• Unique water-based formulation converts
the surface rust into a protective primer
• Suitable for rusty or poorly prepared steel
• Can be top coated with solvent and water
based coatings
• Low VOC, High salt spray rating
• Works in presence of acid fumes
• Ideal for marine and outdoor applications,
including immersed
Inhibitors for preservation in
the Process Industry
 Corrosion inhibiting Powders
• For dry and wet applications
• Its unique VCI action can protect metal in all three
phases ; viz., Liquid phase, Inter phase and Gaseous
phase.
• For protecting internal surfaces of Pipes, Vessels,
Compressors and other enclosed surfaces, etc. during
storage and shipment
• Additive to water used in closed circuit cooling
systems.

• Additive to standing water & hydro test water

Application of Powder inside Pipes
and Vessels
 Water based cleaners and
degreasers with inhibitor
• Cleans hydrocarbon deposits, grease, drawing and buffing
compounds,and mill and machinery oils
• Dilutable with water – increases economy

• Inhibitor present prevents flash rusting, while it cleans

• Nontoxic, non-hazardous, nitrite free, cost-effective

• Used via dipping tank, cleaning equipments, washing or
spraying systems
 Water based Rust Removers with
inhibitor in liquid, gel & powder forms

• Removes rust, cleans and protects against flash

corrosion
• Specific product removes paint
• Hard on rust but mild on metal
• Adhesion promoter. Top paintable.
Clean, Preserve, Protect
Program that can incorporate
liquids and packaging
 Migrating Corrosion Inhibitors for
the Construction Industry
• To protect rebar in concrete against
corrosion
• For new concrete: MCI Admixtures to
concrete, to be added before casting.
• For repair and rehabilitation of existing
structures: MCI Surface coatings and related
products to prevent further corrosion of
rebar.
• Also coatings for rebar during storage
Few Applications of VpCIs in the
Industry
• Bulk packaging of automotive
components in crates lined with VpCI
film
• Storage of service parts in VpCI films
and bags
• Install VpCI emitting devices into
electrical, electronic and telecomm
equipments for protection during transit
as well as in service
 Few VpCI Applications
(continued)
• Preserve military assets in a readiness
state outdoors (and indoors) by adding
VpCI to all functional fluids and then
simply wrapping in VpCI shrink film
• By adding VpCI additives to existing
coolants or by using VpCI - based Cutting
Fluids, secondary dips in RP Oil can be
eliminated because the protection is now
built-in to the machining
 Few VpCI Applications
(continued)
• Semi finished parts are protected against
work-in-process corrosion by exposing
them to VpCIs. Parts need not be
cleaned or prepared for the next
operation
• Rusted parts and equipments can be
salvaged by using rust removers and
cleaners containing VpCI
 Few VpCI Applications
(continued)
• Fog heat exchangers with VpCI powder
or liquid to eliminate subsequent shipping
and storage corrosion problems
• Spray or coat valve flanges and stems
with outdoor VpCI coatings for extended
protection
• Boost the protection of lubricating oils
with VpCI additives for multi metal
systems.
 Few VpCI Applications
(continued)
• Three phase protection for gear box
internals during storage and service by
using VpCI additive to the existing oil
• Protect tank bottom plates by injecting
VpCI powders or liquids under the tank
• Protect metal under insulation by
injecting migrating VpCIs at
predetermined intervals
 Few VpCI Applications
(continued)
• Use VpCIs as additive to hydrotest fluid
to protect internal surfaces even after
the fluid is drained off
• Protection of coils, sheets and sections
produced in a steel plant
• Repair and Protection of structural steel,
equipments and pipelines
• Protect rebar in concrete as well as
during storage at open sites
 FAQs on VpCI
– Is VpCI safe?
• Yes, it is safe to humans and the
environment
– Is it expensive?
• No, it is cost effective
– Is it user friendly?
• Yes, it can be used in a variety of
friendly and convenient ways
 FAQs on VpCI (contd)
– How does VpCI differ from traditional
methods and coatings?
• While they try to keep the moisture and
environment away from the metal by
creating a barrier/shield and thus
protect, VpCIs protect metal in the
presence of moisture
 FAQs on VpCI
– Is skill required for proper use of VpCI?
• As VpCI works by itself once it the
right VpCI is deployed at the right place
and in the right dosage. However
application knowledge will help
– How to choose the right VpCI?
• This is dictated by the application and
the customer expectations. If in doubt,
ASK the VpCI expert or NIGIS - SZ.
•
THANK YOU

QUESTIONS?
For further details contact NIGIS–SZ:

Advisor: kamachi@igcar.gov.in
President: pk.mathew@cortec-india.com
Vice President: dr.r.venkatesan@gmail.com
Vice President: tianode@gmail.com
Secretary: srangs@rocketmail.com
Joint Secretary: tmsridhar@yahoo.co.uk
Treasurer: rani@igcar.gov.in