The examples and perspective in this article deal primarily with the United Kingdom and do not represent a worldwide view of the subject.(December 2010) |
Cold water pitting of copper tube occurs in only a minority of installations. Copper water tubes are usually guaranteed by the manufacturer against manufacturing defects for a period of 50 years. The vast majority of copper systems far exceed this time period but a small minority may fail after a comparatively short time.
The majority of failures seen are the result of poor installation or operation of the water system. The most common failure seen in the last 20 years is pitting corrosion in cold water tubes, also known as Type 1 pitting. These failures are usually the result of poor commissioning practice although a significant number are initiated by flux left in the bore after assembly of soldered joints. Prior to about 1970 the most common cause of Type 1 pitting was carbon films left in the bore by the manufacturing process.
Research and manufacturing improvements in the 1960s virtually eliminated carbon as a cause of pitting with the introduction of a clause in the 1971 edition of BS 2871 requiring tube bores to be free of deleterious films. Despite this, carbon is still regularly blamed for tube failures without proper investigation.
Copper tubes have been used to distribute potable water within building for many years and hundreds of miles are installed throughout Europe every year. The long life of copper when exposed to natural waters is a result of its thermodynamic stability, its high resistance to reacting with the environment, and the formation of insoluble corrosion products that insulate the metal from the environment. The corrosion rate of copper in most potable waters is less than 2.5 μm/year, at this rate a 15 mm tube with a wall thickness of 0.7 mm would last for about 280 years. [1] In some soft waters the general corrosion rate may increase to 12.5 μm/year, but even at this rate it would take over 50 years to perforate the same tube. Despite the reliability of copper and copper alloys, in some cold hard waters pits may form in the bore of a tube. If these pits form, failure times can be expected between 6 months and 2 years from initiation. The mechanism that leads to the pitting of copper in cold hard waters is complex, it requires a water with a specific chemistry that is capable of supporting pit growth and a mechanism for the initiation of the pits.
The pits that penetrate the bore are usually covered in a hard pale green nodule of copper sulfate and copper hydroxide salts. If the nodule is removed a hemispherical pit is revealed filled with coarse crystals of red cuprous oxide and green cuprous chloride. The pits are often referred to as Type 1 pits and the form of attack as Type 1 pitting.
The characteristics capable of supporting Type 1 pits were determined empirically by Lucey after examining the compositions of waters in which the pitting behaviour was known. [2] They should be cold, less than 30 °C, hard or moderately hard, 170 to 300 mg/L carbonate hardness, and organically pure. Organically pure waters usually originate from deep wells, or boreholes. Surface waters from rivers or lakes contain naturally occurring organic compounds that inhibit the formation of Type 1 pits, unless a deflocculation treatment has been carried out that removes organic material. Type 1 pitting is relatively uncommon in North America and this may be a result of the lower population density allowing a significant proportion of the potable water to be obtained from surface derived sources. In addition to being cold hard and organically pure, the water needs a specific chemistry. The effect of the water chemistry can be empirically determined though use of the Pitting Propensity Rating (PPR) a number that takes into account the sulfate, chloride, nitrate and sodium ion concentrations of the water as well as its acidity or pH. A water with a positive PPR has been shown to be capable of propagating Type 1 pits.
Many waters in both the UK and Europe are capable of supporting Type 1 pitting but no problems will be experienced unless a pit is initiated in the wall of the tube. When a copper tube is initially filled with a hard water salts deposit on the wall and the copper slowly reacts with the water producing a thin protective layer of mixed corrosion products and hardness scale. If any pitting of the tube is to occur then this film must be locally disrupted. There are three mechanisms that allow the disruption of the protective deposits. The most well known, although now the least common, is the presence of carbon films on the bore. Stagnation and flux residues are the most common initiation mechanisms that have led to Type 1 pitting failures in the last ten years.
Copper tubes are made from the large billets of copper that are gradually worked and drawn down to the required size. As the tubes are drawn they are heat treated to produce the correct mechanical properties. The organic oils and greases used to lubricate the tubes during the drawing processes are broken down during the heat treatment and gradually coat the tube with a film of carbon. If the carbon is left in the bore of the tube then it disrupts the formation of the protective scale and allows the initiation of pits in the wall. The presence of deleterious films, such as carbon, has been prohibited by the British Standards in copper tubes since 1969. [3] [4] All copper tubes for water service are treated, usually by sand (or other nonferrous medium) blasting or acid pickling, to remove any films produced during manufacture with the result that Type 1 pitting initiated by carbon films is now very rare.
If water is left to stand in a tube for an extended period, the chemical characteristics of the water change as the mixed scale and corrosion products are deposited. In addition any loose scale that is not well adhered to the wall will not be flushed away and air dissolved in the water will form bubbles, producing air pockets. These processes can lead to a number of problems mainly on horizontal tube runs. Particles of scale that do not adhere to the walls and are not washed away tend to fall into the bottom of the tube producing a coarse porous deposit. Air pockets that develop in horizontal runs disrupt the formation of protective scales in two areas: the water lines at the sides, and the air space at the top of the tube.
In each of the areas that the scale has been disrupted there is the possibility of the initiation of Type 1 pitting. Once pitting has initiated, then even after the tube has been put back into service, the pit will continue to develop until the wall has perforated. This form of attack is often associated with the commissioning of a system. Once a system has been commissioned it should be either put immediately into service or drained down and dried by flushing with compressed air otherwise pitting may initiate. If either of these options is not possible then the system should be flushed through regularly until it is put into use.
In plumbing systems fluxes are used to keep the mating surfaces clean during soldering operations. The fluxes often consist of corrosive chemicals such as ammonium chloride and zinc chloride in a binder such as petroleum jelly. If too much flux is applied to the joint then the excess will melt and run down the bore of a vertical tube or pool in the bottom of a horizontal tube. Where the bore of the tube is covered in a layer of flux it may be locally protected from corrosion but at the edges of the flux pits often initiate. If the tube is put into service in a water that supports Type 1 pitting then these pits will develop and eventually perforate the sides of the tube.
In most cases Type 1 pitting can be avoided by good working practices. Always use tubes that have been manufactured to BS EN 1057. Tubes greater than 10 mm in diameter made to this standard will always be marked the number of the standard, the nominal size, wall thickness and temper of the tube, the manufacturer's identification mark and the date of production at least every 600 mm. Tubes less than 10 mm in diameter will be similarly marked at each end.
Once a system has been commissioned it should be either put immediately into service or drained down and dried. If either of these options is not possible then the system should be flushed though regularly until it is put into use. It should not be left to stand for more than a week. At present stagnation is the most common cause of Type 1 pitting.
Flux should be used sparingly. A small quantity should be painted over the areas to be joined and any excess removed after the joint has been made. Some fluxes are marked as water-soluble but under some circumstances they are not removed before pitting has initiated.
Stainless steel, also known as inox, corrosion-resistant steel (CRES) and rustless steel, is an alloy of iron that is resistant to rusting and corrosion. It contains iron with chromium and other elements such as molybdenum, carbon, nickel and nitrogen depending on its specific use and cost. Stainless steel's resistance to corrosion results from the 10.5%, or more, chromium content which forms a passive film that can protect the material and self-heal in the presence of oxygen.
Plumbing is any system that conveys fluids for a wide range of applications. Plumbing uses pipes, valves, plumbing fixtures, tanks, and other apparatuses to convey fluids. Heating and cooling (HVAC), waste removal, and potable water delivery are among the most common uses for plumbing, but it is not limited to these applications. The word derives from the Latin for lead, plumbum, as the first effective pipes used in the Roman era were lead pipes.
Reinforced concrete, also called ferroconcrete, is a composite material in which concrete's relatively low tensile strength and ductility are compensated for by the inclusion of reinforcement having higher tensile strength or ductility. The reinforcement is usually, though not necessarily, steel bars (rebar) and is usually embedded passively in the concrete before the concrete sets. However, post-tensioning is also employed as a technique to reinforce the concrete. In terms of volume used annually, it is one of the most common engineering materials. In corrosion engineering terms, when designed correctly, the alkalinity of the concrete protects the steel rebar from corrosion.
The term chloride refers to a compound or molecule that contains either a chlorine ion, which is a negatively charged chlorine atom, or a non-charged chlorine atom covalently bonded to the rest of the molecule by a single bond. Many inorganic chlorides are salts. Many organic compounds are chlorides. The pronunciation of the word "chloride" is.
Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials by chemical or electrochemical reaction with their environment. Corrosion engineering is the field dedicated to controlling and preventing corrosion.
Tap water is water supplied through a tap, a water dispenser valve. In many countries, tap water usually has the quality of drinking water. Tap water is commonly used for drinking, cooking, washing, and toilet flushing. Indoor tap water is distributed through indoor plumbing, which has existed since antiquity but was available to very few people until the second half of the 19th century when it began to spread in popularity in what are now developed countries. Tap water became common in many regions during the 20th century, and is now lacking mainly among people in poverty, especially in developing countries.
Brazing is a metal-joining process in which two or more metal items are joined by melting and flowing a filler metal into the joint, with the filler metal having a lower melting point than the adjoining metal.
In metallurgy, a flux is a chemical cleaning agent, flowing agent, or purifying agent. Fluxes may have more than one function at a time. They are used in both extractive metallurgy and metal joining.
A water supply network or water supply system is a system of engineered hydrologic and hydraulic components that provide water supply. A water supply system typically includes the following:
Pitting corrosion, or pitting, is a form of extremely localized corrosion that leads to the random creation of small holes in metal. The driving power for pitting corrosion is the depassivation of a small area, which becomes anodic while an unknown but potentially vast area becomes cathodic, leading to very localized galvanic corrosion. The corrosion penetrates the mass of the metal, with a limited diffusion of ions.
A pipe is a tubular section or hollow cylinder, usually but not necessarily of circular cross-section, used mainly to convey substances which can flow — liquids and gases (fluids), slurries, powders and masses of small solids. It can also be used for structural applications; hollow pipe is far stiffer per unit weight than solid members.
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Boiler feedwater is an essential part of boiler operations. The feed water is put into the steam drum from a feed pump. In the steam drum the feed water is then turned into steam from the heat. After the steam is used, it is then dumped to the main condenser. From the condenser, it is then pumped to the deaerated feed tank. From this tank it then goes back to the steam drum to complete its cycle. The feedwater is never open to the atmosphere. This cycle is known as a closed system or Rankine cycle.
Crevice corrosion refers to corrosion occurring in occluded spaces such as interstices in which a stagnant solution is trapped and not renewed. These spaces are generally called crevices. Examples of crevices are gaps and contact areas between parts, under gaskets or seals, inside cracks and seams, spaces filled with deposits and under sludge piles.
Corrosion engineering is an engineering specialty that applies scientific, technical, engineering skills, and knowledge of natural laws and physical resources to design and implement materials, structures, devices, systems, and procedures to manage corrosion. From a holistic perspective, corrosion is the phenomenon of metals returning to the state they are found in nature. The driving force that causes metals to corrode is a consequence of their temporary existence in metallic form. To produce metals starting from naturally occurring minerals and ores, it is necessary to provide a certain amount of energy, e.g. Iron ore in a blast furnace. It is therefore thermodynamically inevitable that these metals when exposed to various environments would revert to their state found in nature. Corrosion and corrosion engineering thus involves a study of chemical kinetics, thermodynamics, electrochemistry and materials science.
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Copper has earned a respected place in the related fields of architecture, building construction, and interior design. From cathedrals to castles and from homes to offices, copper is used for a variety of architectural elements, including roofs, flashings, gutters, downspouts, domes, spires, vaults, wall cladding, and building expansion joints.
SAE 304 stainless steel is the most common stainless steel. It is an alloy of iron, carbon, chromium and nickel. It is an austenitic stainless steel, and is therefore not magnetic. It is less electrically and thermally conductive than carbon steel. It has a higher corrosion resistance than regular steel and is widely used because of the ease in which it is formed into various shapes.
The durability design of reinforced concrete structures has been recently introduced in national and international regulations. It is required that structures are designed to preserve their characteristics during the service life, avoiding premature failure and the need of extraordinary maintenance and restoration works. Considerable efforts have therefore made in the last decades in order to define useful models describing the degradation processes affecting reinforced concrete structures, to be used during the design stage in order to assess the material characteristics and the structural layout of the structure.