CHEMICAL ENGINEERING DEPARTMENT

(Branch:Pollution) (Stage:Four)

((Report In Corrosion))

Erosion-Corrosion in Copper Pipes in Hot Water

&
Other Material

Supervised by
Asst. Prof. Dr. Basheer Ahmed

A Cademic Year
2019-2020

1
 Erosion-Corrosion of Copper Pipes in Hot Water
&
Other Material

TABLE OF CONTENTS
1. Introduction .................................................................................................................................. 3
2. Theory of Erosion-Corrosion........................................................................................................ 4
3. Erosion Incidence of Erosion-Corrosion in Australian Buildings ............................................... 5
4. Erosion-Corrosion Steps .............................................................................................................. 6
5. Erosion-Corrosion Maps .............................................................................................................. 6
6. Other Examples on Erosion Corrosion ....................................................................................... 7
7. Possible Causes of Erosion-Corrosion ........................................................................................ 9
7.1 (a) Water Velocity .............................................................................................................. 9
7.1.1 General Considerations......................................................................................... 9
7.1.2 Specific Observations ............................................................................................ 9
7.1.3 Published Literature ............................................................................................ 10
7.1.4 Historical Development of Guidelines ................................................................ 10
7.2 (b) Elevated Water Temperature ..................................................................................... 10
7.3 (c) Turbulence Due to the Joint Profile ............................................................................ 10

8. Measurement of erosion-corrosion .......................................................... ………………11

9. Test on Erosion-Corrosion ........................................................................................................12
10. Preventive Methods ..................................................................................................................13
11. Discussion & Conclusion ...........................................................................................................14
12. References .................................................................................................................................15

2
 1- Introduction

Corrosion: Removal of metal from the surface of the pipe by the mechanism of a
chemical reaction between the metal pipe wall and the fluid in the pipe. The chemical
reaction results in direct dissolution of metal ions into the fluid and/or formation of a film
of reaction products (e.g. oxides, carbonates, sulphates etc).

Erosion: Removal of metal from the surface of the pipe by a mechanism of

physical/mechanical wear, under the influence of the flowing fluid and of any particulate
matter carried in the fluid stream. Small (possibly microscopic but larger than atomic
sized) fragments of solid material are physically removed from the surface and carried
away by the fluid stream.

Erosion– corrosion: complex interaction of erosion, (mechanical driven

process), and corrosion, (electrochemical driven reaction) at the surface
resulting in material loss. Both processes occur at the surface with their
interaction being commonly referred to as synergy.
Synergy: Difference between Erosion‐Corrosion Rate and the sum of Erosion
Rate alone and Corrosion Rate alone

S = VEC -- ( VOC + VOE ) ,,, S = ΔVC + ΔVE

VC can be split in
• Cf : Effect of erodent damage of a passive film leading to
corrosion of the underlaying surface
• Ce : Effect of erodent deforming the surface leading to increased
corrosion activity
• VE can be split into 3 parameters

• Ep: enhancement of wear from corrosion between metallic phases

• Em: influence of corrosion on the mechanical properties of the surface
material
• Es: Enhancement of wear by oxide layer formation

Overall synergy:
S = ΔCf + ΔCe + ΔEp + ΔEm + ΔEs

Pitting: A form of Corrosion in which the metal removal is localised (rather than
uniformly distributed over the surface), resulting in development of distinct depressions
(pits) in the surface, surrounded by relatively flat, relatively un-attacked surface.

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 2- Theory of Erosion-Corrosion
Erosion-Corrosion is a mode of material surface damage in which corrosive attack by the
chemical environment and mechanical wear by a flowing fluid (with or without entrained
solids or gas bubbles) act conjointly to increase the rate of material loss. In general terms,
Erosion-Corrosion can occur by a spectrum of mechanisms, between the extremes of:
Corrosion-dominant — where the fluid flow merely aids ion transport so as to
increase the rate of corrosion; and
Erosion-dominant — where for example selective corrosion might reduce
the erosion resistance of the material surface.
In the specific case of Erosion-Corrosion of copper pipes in potable water, the
mechanisms are as follows:
The copper initially undergoes some general (uniform) corrosion, forming a layer
of corrosion products, known as scale. The scale may be comprised of copper
oxides, carbonates, sulphates etc. This scale has the effect of limiting transport of
oxygen and other aggressive species to the metal substrate, hence may have a
protective effect, reducing the rate of subsequent corrosion.
The flowing water dislodges portions of the protective scale from the surface,
exposing patches of bare metal.
In terms of the electrochemistry of corrosion, the protective oxide scale is
“cathodic” (noble) while the exposed metal is “anodic” (reactive). The
configuration of small anodic patches surrounded by a larger area of cathodic
material gives rise to acceleration of the corrosion
rate by “galvanic action”.

The corrosion rate of the patches of exposed metal remains high because the flowing
water provides a continuous supply of dissolved oxygen and flushes away the dissolved
copper ions, and possibly also because of galvanic action.
A feature of Erosion-Corrosion is the phenomenon of the critical velocity, also known as
the breakaway velocity. The critical velocity is the flow velocity at which there is a distinct
transition from low corrosion rates (when the protective scale remains largely intact) to
high corrosion rates (when significant portions of the protective scale are dislodged by the
flow).

4
 3- Incidence of Erosion-Corrosion in Australian Buildings
In the last decade UQMP has investigated at least two cases of premature failure (leakage)
of copper pipes in hot water reticulation systems in commercial buildings in Australia. In
both cases the observed features of the attack on the pipes indicated that Erosion-
Corrosion was the operative phenomenon. This diagnosis was unambiguous, due to the
following features which are characteristic of Erosion-Corrosion (both E-C in general and
specifically E-C of copper pipes by potable water) and not consistent with the other two
phenomena:
The corroded regions (pits) showed bright metal surfaces, free from oxide scales;
Numerous examples of horseshoe-shaped pits with their open ends facing
downstream;
The remaining surface covered with oxide scale, under-cut at the boundary with the
corroded areas;
Preferential occurrence at bends and downstream from non-smooth joints (due
to water turbulence at these features);
Relatively high ratio HCO 3/SO4, of approximately 4 — hence unlikely to cause Type
2 Pitting.
The photographs reproduced in Figure 1 to Figure 7 below are from a case investigated in
2008, from a building constructed in 2000.

Figure 1: Overview of pipe samples suffering from

Erosion-Corrosion

5
4- Erosion Corrosion Steps:

5- Erosion Corrosion Maps:

6
6- Other Examples on Erosion Corrosion

7
8
 7- Possible Causes of Erosion-Corrosion
A systematic analysis of the evidence in the above-described cases of Erosion-Corrosion
indicated that there were three contributing factors that led to the premature failures:
(a) Excessive water velocity in the pipes;
(b) Elevated water temperature;
(c) Turbulence due to the joint profile.

(a) Water Velocity

7.a.1- General Considerations

A necessary condition for Erosion-Corrosion is water velocity sufficient to disrupt the
protective copper oxide scale and hence permit active corrosion of exposed bare metal
surfaces. In a water distribution system there are two factors that can lead to water
impinging on and moving across a surface at velocities high enough to disrupt the
protective oxide scale:
High general flow velocity;
Turbulence, causing high local impingement velocities.
It is possible for turbulence to cause Erosion-Corrosion when the general flow velocity is
moderate and within industry guidelines. However turbulence cannot occur under zero-
flow conditions, and for a given pipe profile significant turbulence is more likely when
the general flow velocity is high.

7.a.2- Specific Observations

In one of the investigations described above, unambiguous Erosion-Corrosion was
observed in a straight section of pipe remote from bends and joints (some 500 mm
upstream of the leaking bend) — see sample in upper-right of Figure 1. This observation
constituted compelling evidence that there was a systemic problem, as opposed to a
problem restricted to regions of local turbulence. Although the attack did not occur in all
parts of the system, it was evident that the conditions were so close to critical that any
number of local factors could trigger the Erosion- Corrosion.

At face value these observations and system specifications indicated that a water velocity of
1.5 m/s was sufficient to cause:
Some Erosion-Corrosion in straight sections (borderline conditions);
Severe Erosion -Corrosion, sufficient to cause pipe perforation in a relatively short
time, in the vicinity of pipe features promoting turbulence (local conditions clearly
exceeding breakaway velocity.

9
7.a.3-Published Literature
There exists a considerable amount of published information about the effects of water
velocity and temperature on the tendency for Erosion-Corrosion. The original research in
this area has led to various industry guidelines and national standards. Some relevant
publications are listed below, with recommendations for maximum water velocities where
given.

7.a.4- Historical Development of Guidelines

There is significant variation between the guidelines given in the various publications
listed above. It is important to bear in mind the difference between a critical velocity (also
called breakaway velocity), above which Erosion-Corrosion can be expected to occur, and
a recommended maximum velocity, which provides some factor of safety. Note also that
the requirements for continuously recirculating systems are more stringent than those for
intermittent-use systems, since in the latter there might be time for protective scales to re-
form.

(b) Elevated Water Temperature

The quantitative guidelines presented in section 3.1 above indicate that water temperature
has a significant influence on the tendency for Erosion-Corrosion to occur. Several of the
guidelines imply that for a given velocity, water temperatures above 60°C are more likely
to cause Erosion- Corrosion than are temperatures below 60°C. Equivalently we may say
that increasing temperature causes a significant decrease in the critical velocity for
Erosion-Corrosion to occur.

(c) Turbulence Due to the Joint Profile

It is well publicised that turbulence created by rough joint profiles can promote Erosion-
Corrosion, in systems otherwise free from this problem. In the 1993 paper previously
cited,
A. Cohen states the opinion that “Too often, erosion-corrosion is the direct result of
improper workmanship. Unreamed cut tube ends, globules of solder … dents/dings in
tube …”.
Figure 1 and Figure 7 show clear evidence of the promotion of Erosion-Corrosion by
turbulence at the step in the inner wall profile at a joint. On the other hand, there was direct
evidence that Erosion-Corrosion had occurred in response to the general water velocity
and temperature, in a straight section of pipe where there were no turbulence-promoting
features. It follows that, regardless of the probable contribution of rough joint profiles to
a majority of leak sites, it was clear that this system had a systemic susceptibility to
Erosion-Corrosion due to excessive water velocity and elevated temperature.

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 8- Measurement of erosion-corrosion

To control the adverse effects of erosion-corrosion, it is very important to accurately

measure the amount of corrosion that has occurred. The technological advancements
provide us with a variety of techniques to clearly predict the corrosive situation and the
amount erosion-corrosion. Corrosion measurement is a quantitative technique by which
the usefulness of avoidance techniques can be evaluated to have feedback to the
optimization of corrosion control. The ultimate objectives of conducting corrosion
measurements are to find the safe working life of an equipment or plant and also to initiate
action against corrosion without upsetting the cost of the life-cycle. The corrosion
monitoring techniques will provide an early warning signal against corrosion-induced
breakdown. The proper diagnosis of the warning signals will lead to the identification of
the root cause of the problem. The selection of the method depends upon the use and the
purpose of performing it. The simplest method of inspection is visual inspection that can
be performed when there is physical access to the object. The proper analysis of the
sketches and photographs will explain the degree and the type of corrosion. Boyd et al.
(2004) explained the importance of ultrasonic testing methods to investigate the corrosion
rates by measuring the physical parameters of the components. Nowadays, automated
ultrasonic methods have been successful in detecting subsurface corrosion and cracking in
components. The modern spectroscopic methods such as electron microscopy studies are
mainly used in the study of the corrosion characteristics by analyzing the thickness and
nature of the surface layers. The erosion-corrosion resistance of engineering materials at
various test conditions is shown in Figure

11
 9- Test on Erosion-Corrosion

Photos of the wire beam electrodes (WBEs) and coupons after 20 h of

exposure to different flow-accelerated corrosion (FAC) (a,b) and erosion-
corrosion (c) conditions, and local three-dimensional (3D) surface
profilometry images of typical coupon areas , adapted from, with
permission from Elsevier 2019.

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 10- Preventive Methods

Methods are used to prevent erosion corrosion:-

1. Design
2. Alteration of Environment
3. Coatings
4. Cathodic Protection
5. Better material

1. Design ;

• Design involves change the shape, geometry of part.

• Design of inlets & outlets should be streamlined to prevent turbulence.
• It also involves redesigning the flow of the fluid to ensure there is less turbulence.

2. Alteration of Environment ;

• Settling & filtration to remove solid particles.

• Temperature of environment should be reduced.

3. Coatings ;

• Coatings are utilized but they are not much effective.

• Welded overlays & hard facing are applied at times.
• Repair of attacked areas is done by welding.

4. Cathodic Protection ;

• Helps to reduce attack.

• Not much used in erosion corrosion.
• Steel plates are used on condenser head for cathodic protection.
• Zinc plugs are used for water pumps.

5. Better material ;

• Use that material which is more corrosion resistant than the previous one.
• It is an economical solution of erosion corrosion.

13
 11- Discussion & Conclusions

UQMP has investigated failures of copper pipes in hot water reticulation systems
in Australian commercial buildings, in which the failure was unambiguously due
to the phenomenon of Erosion-Corrosion.

In the failed installation described in section 2.5 of this report the water velocity was
believed to be 1.5 m/s, well within the limit of 3.0 m/s specified by AS/NZS 3500.4.

It has been known and published in water distribution industry literature since the mid
1980s that, in recirculating hot water systems, in order to prevent Erosion-Corrosion of
copper pipes the water velocity should not exceed 0.5–0.6 m/s.

In principle it is quite plausible that Erosion-Corrosion of copper pipes upstream

from a polypropylene pipe could be the source of copper found to have deposited
on the polypropylene.
This hypothesis could be verified by one or both of two means:

o Physical examination of copper pipes from the affected installation,

especially at joints and bends (assuming the affected copper pipes have not
already been replaced)

o If it is a recirculating hot water system with water temperatures above 60 C

and water velocities known to exceed about 1.2 m/s in any of the copper
pipes, then Erosion- Corrosion is almost inevitable.

There would seem to be an urgent need for AS/NZS 3500.4 to be updated with respect
to its specifications for maximum permissible water velocities, in order to conform with
known principles of corrosion protection and to come into line with international
standards.

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