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Ssc-348 Corrosion Experience . Data Requirements

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Ssc-348 Corrosion Experience . Data Requirements ,., .- -- —. SSC-348 CORROSION EXPERIENCE . DATA REQUIREMENTS Thiscklmmtlmkcilajpval forpublicml- ad salqiu distciilicmiaUnlimitul SHIP STRUCTURE COMMITTEE 1991 The SHIP STRUCTURE COMMllTEE is constitutedto prosecutea rsearch pqram to improvethe hull Wucturee of shipsand othermarinestructuresby en extensionof knowtedgepertainingto design, matetials,and methodsof construction. RADM J. D. Sims, USCG, (Chairman) Mr. H. T. Hailer Chief, Offioeof Marine Safety, security _ie Administratorfor Ship- and EnvironmentalProtection buildingand Ship Operations U.S. Coast Guard MaritimeAdministration Mr. Alexandw Malaldmff Mr. ~omas W. Allen Director,Stwcturat Integrity EngineeringOfiicer (N7) Su roup(SEA 55Y) MMtatySealiit Command NavaY Sea SystemsCommaruf Dr. DonafdLiu CDR Miihael K Parrnelae,USCG, Senior~~e President Secretary,Ship StructureCommittee ~erican Bureauof Shipping U.S. Coast Guard CONTRACTING OFFICFR T=HNIP. REPRFSENTATWS Mr. William J. Sikierka Mr. Greg D. Weds SEA 55Y3 SEA 56Y3 Naval Sea SystemsCommand Naval Sea SystemsCommand SHIP ST17JCTURFWRCWMIIJEE The SHIP STRUCTURE SUBCOMMlllEE acts forthe Ship StructureCommitteeon technicalmattersby providingtechnicalcoordinationfor determinatingthe goalsand objectivesof the programand by evaluatingand interpretingthe resultsin termsof structuraldesign,corrstrudlon,and oparatiin. AMERICAN OUREAU OF SHIPPING NAVALsEhSYSTEMS COMMAND Mr. Stephen G. Arntson(Chairman) Mr. Rokt A Sielski Mr. John F. ConIon Mr. CharlesL Null Dr. John S. E@noer Mr. W. ~omae Paokard Mr. Glenn M. Aeha Mr. Atlen H. Engle Mr. Altwt J. Attermeyer CAPT T. E. Thompson Mr. Michael W. Touma CAPT DonaldS. Jensen Mr. JefferyE, Baaoh CDR Mark E. tdoli Mr. Frederickseibold Mr. NormanO. Hammer Mr. Chao H, Lin Dr. Walter M, M=l=n SHIP SIEL!CTURF SURCQIMMITTFF I WSON MFldE!EKS US. COMT’E!JMD AmFMy - LT BruceMuaW”n Mr. AlexanderB. Stavovy u.s.MERCHANT MARINE ACADEMY f4AT10W ACADIEMYOF SCIFNcsE - Dr. C, B. Kim S u.s.NAVAIACADEMY Mr. Stanley G. Stii Dr. RamsWarBhattacharyya SOCIEIYOF Iw VAL ARCHITECTS AND MARINE ENGINEERS - Dr. VMlliamSandbarg Dr. W. R, Porter mERKAN IRON AND STEEL INSTITUTE WELDING RESEARCH COUNCIL Mr. Akrwtder D. Wilson Dr. MartinPrager .- Membr Agencies: Address Corre~ndence to: UnitedStates@as? Guaud Secretary, ShipStructure Commiltee Naval &a Systems bmmand U.S.CoastGuard (G-MTH) Manlime Administration Ship 2100 Semnd StreetS.W. AmericanBureau of Sh@ping Washington, D.C. 20593-0001 MilitaySealifl~tnmand Structure PH: (202)267-03 Committee FAX (202)257-0025 An InteragencyAdviemyCommittee DedicatedtotheImprovementofMarineStniwtures SSC-348 January 31, 1991 SR-1306 CORROSION EXPERIENCE DATA REQUIREMENTS The detrimental effect of corrosion on marine structures is well known. Assessing the extent of corrosion damage and predicting corrosion rates, however, can be difficult. The purpose of this project was to develop a corrosion survey methodology that could be used in assessing vessel structures. This report contains the methodology and data collection requirements that could be used to assess corrosion rates, damage, and margins. ‘G!/%- Rear Admiral, U.S. Coast Guard Chairman, Ship Structure Committee TmchnicalReptirt DocumentationPage 1. R-part w. 2. Government Acc-ssion No. 3. Rocipiont’s C*telog No. SSC-348 L Titlo ond $ubtitlo 5. Report Dot. 1 ~88 I CORROSION~PERIENCE DATA REQUIREMENTS 6. Pmrfoming Orgnnj;otion Cod. I 8. Por{ormino Oreonization Ropott No. ?. Author/s) Karl A. $tambaugh, John C. Knecht SR-1306 y. Prtfoming Or#mizotion Namomd Address , 10. Work Unit No. (TRAIS) Giannotti & Associates, Inc. 703 Giddings Avenue, Suite U-3 11.Contract or Gront No. DTCG23-86-C-20064 Annapolis, Maryland 21401 13.Typ*of Roportond Pm,iod Cow.r.d 1 It. Sponsoring AgoncYNomc mdAddr*x8 Technical Report U.S. Coast Guard 10/86 - 5/88 Office of Merchant Marine Safety Washington, DC 20593 Ii.Sponsoring Agency Ctid- G-M 15. Supplmm~ntory Not-g The USCG acts as the contracting office for the Ship Structure Committee. 16. Abcfroci A corrosion survey methodology is presented to obtain corrosion data from ships. The corrosion data will be used to develop’s rational method for assessing cor- rosion margins. The project included a survey of ship operators for corrosion data to define data collection and analysis requirements to characterize the -corrosion rates that affect strtictural integrity of ships. The techniques used to predict corrosion r’atesand assess the strength of corroded structure were also reviewed to determine data requirements. The methodology consists of a data collection procedure ,,with recommended instrumentation. Forms were developed for documenting the measurements. Finally, an outline of the database was deve- loped that includes an Expert Syst,em -interface for data input, analysis and retrieval. .. 17. K-y Wotd~ 18. Di sfiibution Stotem.nt corrosion This document is available to the U.S. ship structures public through the National Technical corrosion data Information Service, Springfield, VA, 22161 lg.SocuritY Clo$rif. (of this ropart) 20. $ocurity Clo=sif. (of thi r poet) 21. No. of PESOS 22. Pric* UNCLASSIFIED UNCLASSIFIED 102 ..— — .-..- Form DOTF 170Cf.7 (8-72) Reproduction of completed poge euthorizod : .—.—.— ,.. ... —-.. ...._ . .._ ,. ..”___ ,-. .. .. T* Find Svt LENSTtl LENGTH m millinwtws 0,04 inch.z in cm Cnmmmlwa 0,4 inc%an ill IImlnIs 3.3 1! inclms .2.6 cm tinmtms cm km km m mme13 1.1 Vtis “d I*#t 30 Cemllmmm cm km kilmmatws 0.6 m Vtim 0.9 nwters m mil*s mi hs 1.6 k,#mtm, km AREA d in2 inz squm !m4m 6,S *W. Cmtirmtua cd m’ # m’ oqwrm htt 0,09 qun Im31mrn ma ~? mi2 Squnm “do 0,8 Zqumm maws Vda m’ ha d fquma mihs 2.8 qlm* Ititmwtffs km’ mcros O.* I14clmmm tm 01 01 o lb lb h9 t VOLUME mil!itilerc ml millililws 0.03 1102 miI!ilil*r3 ml #itars 2.7 P millilil*ls ml lilm~ t.m ql liter * I Iilms 0.26 Il!ws I cubicnnlms 36 Iitw I cubicmalws 4,3 Ilws I cubuc meters m’ cubic metnrs m’ “c Falw+touit % fmprrnum “F Fshmnh*it 6/9 Iaftm “c tnmpmamrc ntiaf acting ‘F 321 ‘F 32 93.6 az -40 0 40 80 120 I*O 200 , 1,1,, ,i,:i,i,,lj -1 8,, : Y,;4 ,.,.4, ,4”,. I r,, ,,,1,,., ,..,,, 4 , ,“,,,.,,,,,,,. ,,8>,1,,,,., $ ,Wu.,, ,,,31 1,,1]1,.,. ,,,,. WBS h?,.,,1>,,1,, .hfi[,. l’; 1 1 1 # 1 I 100 U41,L.!,1 W,.,ot!l. ,,,,1 Mm.,,,... P,>,,. S:..Is, m Cau,,loq, N,,. C1,I.l UMU, - g: -20 0 20 40 50 ‘ 60 s? Oc TABLE OF CONTENTS 1.0 INTRODUCTION. .1 2.0 BACKGROUND AND PREVIOUS CORROSION SURVEY. 2 2.1 Corrosion Surveys of Ship Structure. 2 2.2 Corrosion Survey Results . 3 3.0 CORROSION DATA REQUIREMENTS . .13 3.1 Corrosion Margin Assessment. .13 3.2 Corrosion Rate Prediction and Survey Techniques. .16 3.3 Summary of Data Requirements and Recommended Corrosion Rate Survey Technique. .22 4.0 DATA COLLECTION REQUIREMENTS. .25 4.1 Types of Corrosion to Survey . .25 4.2 Corrosion Locations. .28 4.3 Correlation Parameters . .32 4.4 Sample Size and Accuracy . .34 4.5 Instrumentation Requirements . .39 5.0 CORROSION SURVEY METHODOLOGY. .40 5.1 Data Acquisition . .40 5.2 Data Recording. .54 5.3 Data Analysis. .. .70 5.4 Program Implementation . .84 6.0 CONCLUSIONS AND RECOMMENDATIONS . .87 7.0 REFERENCES. ● - . .83 i LIST OF FIGURES 2-1 Gauging Measurement History for the M/V CHESTER Poling Before & After Hull Failure . 7 2-2 Ultrasonic Measurements of a Transversely Framed Containership with Corrosion Fatigue Cracks. 9 2-3 Weld Detail Used on the Converted Containership Showing Corrosion Fatigue Cracks . .10 2-4 Result of Plate Thickness Gauging and Corrosion Distribution of Girder Web Slot. .12 2-5 Number of Cases of Damage by Ship Type 13roken- Down into Types of Damage Between 1976-1984. .12 4-1 Simplified Schematic of Uniform Corrosion. .26 4-2 Schematic of Formation of a Pit. .27 4-3 Typical Bottom Shell Loss Patterns . .29 4-4 Typical Bottom Structure Defects . .31 4-5 Normal Distribution Curve. .36 5-1 CRT Display Equipment. .44 5-2 Thickness Measurement Through a Coating Layer. .45 5-3 Digital Display Equipment. .46 5-4 Single Transducer Pulse Echo–Pattern . .49 5-5 Twin Transducer Pulse-Echo Pattern . .50 5-6 Focused Transducer Concept Showing the Diverging Beam from the Point of Focus as it Enters Parallel into the Steel Plate . .. .51 5-7 Spurior Signal S1 Caused by a Sidelobe . .52 5-8 Effect of Acoustic Mask. .53 ii LIST OF FIGURES (continued) 5-9 Pitting Intensity Diagrams . .55 5-1o Ship Designations. .53 5-11 List of Compartment Designations . .60 5-12 List of Ship Structures. .61 5-13 Ship Information Sheet . .65 5-14 Compartment Correlation Parameter Sheet. .66 5-15 PanelDataSheet. .69 5-16 Example Panel Gauging Patterns . .71 5-17 Database Configuration . .72 5-18 Data Input Sequence. .74 5-19 Sample Data Input Sequence . .76 5-20 Data Editing Sequence. .81 5-21 Sample Data Analysis Output. .83 5-22 Data Analysis Sequence . .85 LIST OF TABLES 2-1 Corrosion Rates. .4 3-1 Correlation of Corrosion Data Requirements and Failure Modes Relevant to Structural Integrity . .23 iii 1.0 INTRODUCTION Ship structure design involves a thorough application of scientific and engineering approaches. In many instances where there are no rational theories or methods, it becomes necessary to develop this knowledge as an extrapolation of existing technology. Most often, new techniques and methods are developed from survey of structural systems to obtain empirical data. This approach would improve the analysis of corrosion in ship structures. Currently, corrosion margins are applied based on past experience and most maintenance efforts are guided by trial and error experiences. To improve on current practice and develop a rational method for assessing corrosion margins, it is necessary to survey corrosion in ship structures, develop a corrosion rate data base to predict corrosion rates accurately and determine the time frame a given corrosion margin will be depleted.
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