Salt Measurement Product Warren Neuburger President Louisville - - PowerPoint PPT Presentation

SaltSmartTM

Louisville Solutions Incorporated

Salt Measurement Product

Warren Neuburger President Louisville Solutions Incorporated

• There are many kinds of salts

– A salt is a basic ionic compound – Chlorides, sulfates, Nitrates …. – Water solubility determines the specific mixture of

The Basics of Salt

– 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

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• Bare clean steel does not flash rust
• Need to remove salts prior to coatings

application

• Need to remove salts between layers of

coatings

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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

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• Water Jet with water?
• Water with De-ionized water?
• Does act of removal imbed more contaminates?

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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

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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

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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)

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Extraction Efficiency Comparison

(All numbers except SaltSmart come from published SSPC TU-4 Standard)

Extraction Method

Efficiency Notes

Additional Notes

Swabbing 25-35%

Must be done over known surface area

Latex Cell 45 - 60%

Over 10 minutes If repeated an additional 10 minutes <90%

Latex Sleeve 65-75%

Using acidic fluid,

• ver 6 minutes

Filter Paper unknown

Expected to be very low efficiency

Magnetic Cell 45-60%

Automated latex cell method

SaltSmartTM Up to 98%

Over 4 minutes period Continuous Flow Extraction Method

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Salt Measurements

• Chlorides

Nitrates and Sulfates

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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 SaltSmartTM Different?

• Continuous Flow Extraction Method
• SaltSmartTM is a system, and engineered as a

system

• Highest extraction efficiency of other methods

tested

• Supports parallel testing
• Small contact area, provides broader coverage
• f large and small parts (gratings for example)
• NO residue

What Makes SaltSmartTM 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

• Batch Extraction

– Bath – Bresle Patch

• Flow Extraction

– Shower

< 85% salt extracted 3.0 mL H2O 10 minutes > 99% salt extracted 0.8 mL H2O 3 minutes

Flow Extraction Demo

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

Sealed in Plastic Enclosure DI Water Ampoule

SaltSmart Work Flow

Salt Strip

Unwrap Package 0:05 Unwrap Package 0:05

Tack Strip

SaltSmart Work Flow

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

Extract Salt into Reservoir 5:00 Extract Salt into Reservoir 5:00

Other Samples May Be Started During Extraction Process

SaltSmart Work Flow

Test Complete 6 Test Complete 6 - 8:00 8:00

Other Samples May Be Started During Extraction Process

SaltSmart Work Flow

Remove Strip from Work Surface 8:00 Remove Strip from Work Surface 8:00

No “mess” to clean

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 Immersed applications 3 µg/cm2 (30 mg/m2) 30 µS/cm

• All critical coated surfaces
• Test freshly prepared surface
• 5 readings per 1000 sq.ft.
• Use Bresle Method (or approved equivalent as

SaltSmartTM) mg/m2) Non-immersed applications 5 µg/cm2 (50 mg/m2) 70 µS/cm

IMO PSPC MSC.215(82)

Performance Standard for Protective Coatings

Total Salts Conductivity Primary Surface Preparation 50 mg/m2 42 µS/cm Secondary Surface Preparation 50 mg/m2 42 µS/cm

• 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

• Fast
• High efficiency extraction

process

• Accurate

– Minimum training – Insensitive to technique

• Safe, Clean, Easy

– Disposable, no cross contamination possible – Compact – No needles, bottles, solvents, calibration solutions – No residue or cleanup – Insensitive to technique – Re-wet strip to audit results

• Robust

– Any substrate, any curvature, any orientation

• Independent lab tested for

accuracy

• Made in USA

– No residue or cleanup

• Cost Effective

– Cost approx ISO 8502-9 Patch – 20X faster – Supports testing in parallel

Questions?

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