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Corrosion and corrosion protection of wind power structures in marine environments
This book focuses on corrosion and corrosion protection measures for wind power structures in marine environments. It is part of the Elsevier Wind Energy Engineering Series, which covers various aspects of wind energy engineering, including scientific and technical content that supports research and application stages. The book explores material selection, constructive design, corrosion allowances, and cathodic corrosion protection specifically for marine wind structures. It offers insights into the types of materials used, their corrosion resistance, and the engineering principles necessary for protecting wind power structures in harsh marine conditions. The intended audience includes engineers, researchers, and professionals in the wind energy and marine engineering sectors.
Front Cover -- Corrosion and Corrosion Protection of Wind Power Structures in Marine Environments -- Copyright Page -- Contents -- Foreword -- 4 Material selection -- 4.1 General recommendations -- 4.1.1 Selection criteria -- 4.1.2 Corrosion and alloying -- 4.2 Low-carbon (unalloyed) steel -- 4.2.1 Selection -- 4.2.1.1 Corrosion management program -- 4.2.1.2 Material groups -- 4.2.1.3 Atmospheric corrosion index -- 4.2.1.4 Strength requirements for high-strength low-alloy steel -- 4.2.1.5 Linear assessment equations -- 4.2.1.6 Comprehensive index value -- 4.2.1.7 Interaction between alloy elements and carbon -- 4.2.1.8 Interaction between alloy elements and corrosive environment -- 4.2.1.9 Sn-bearing steel -- 4.2.1.10 Pitting corrosion in mild steel -- 4.2.2 Weathering steel -- 4.2.2.1 General relationships -- 4.2.2.2 Regression equations -- 4.3 Stainless steel -- 4.3.1 Selection -- 4.3.1.1 General relationships -- 4.3.1.2 Material groups -- 4.3.1.3 Corrosion resistance classes -- 4.3.2 Pitting corrosion resistance -- 4.3.2.1 Pitting resistance equivalent number -- 4.3.2.2 Critical pitting index -- 4.3.2.3 Alloying resistance number -- 4.3.2.4 Effects of microstructure -- 4.3.2.5 Effects of temperature -- 4.3.3 Crevice corrosion resistance -- 4.3.3.1 Rating of crevice corrosion resistance -- 4.3.3.2 Crevice corrosion index numbers -- 4.3.3.3 Incubation time -- 4.3.3.4 Critical crevice temperature -- 4.3.4 Stress corrosion cracking -- 4.3.5 Surface quality -- 4.3.6 Surface condition -- 4.4 Aluminum alloys -- 4.4.1 Types of corrosion -- 4.4.2 Material groups -- 4.4.3 Protection of aluminum and aluminum alloys -- 4.5 Zinc -- 4.6 Copper and copper alloys -- 4.6.1 Types of corrosion -- 4.6.2 Material groups -- 4.6.3 Copper-nickel alloys -- 4.6.4 Pitting corrosion potential -- 4.6.5 Dezincification and dealumunization -- 4.7 Nickel and nickel alloys.
4.8 Welds and weld overlays -- 4.8.1 Welds -- 4.8.2 Weld overlays -- 4.9 Fiber-reinforced composites -- 4.9.1 Corrosion phenomena -- 4.9.1.1 Types of corrosion -- 4.9.1.2 Electrolytic corrosion -- 4.9.1.3 Galvanic corrosion -- 4.9.2 Degradation in seawater -- 4.9.2.1 Degradation of adhesives -- 4.9.2.2 Degradation of glass fiber-reinforced epoxy -- 4.9.2.3 Degradation of glass fiber-reinforced polyester -- 4.9.2.4 Degradation of carbon-epoxy laminates -- 4.9.2.5 Degradation of Al-CFRP compounds -- 4.9.3 Galvanic corrosion -- 4.9.4 Environmental stress corrosion -- 4.10 Bolts and screws -- 4.10.1 Types of corrosion -- 4.10.2 Fasteners -- 4.11 Concrete -- 5 Constructive design -- 5.1 General -- 5.1.1 Design basis document -- 5.1.2 Basic rules -- 5.2 Sealing and climatization -- 5.2.1 General methods -- 5.2.2 Oxygen control -- 5.2.2.1 Background -- 5.2.2.2 Airtight sealing -- 5.2.3 Control of humidity -- 5.2.3.1 Estimation of dew point temperature -- 5.2.3.2 Technical solutions -- 5.2.4 Overpressure and air treatment -- 5.3 Accessibility -- 5.3.1 General requirements -- 5.3.2 Access openings -- 5.4 Avoidance of gaps, joints, and overlapping connections -- 5.5 Precautions against deposits and the accumulation of electrolyte -- 5.6 Steel preparation -- 5.6.1 General aspects -- 5.6.2 Weld seams -- 5.6.2.1 General aspects -- 5.6.2.2 Weld seam quality -- 5.6.2.3 Effects of weld seam quality on corrosion -- 5.6.2.4 Effects of weld seam quality on coating performance -- 5.6.3 Free edges -- 5.6.3.1 General aspects -- 5.6.3.2 Edge rounding -- 5.6.3.3 Hard surface layers -- 5.6.3.4 Effects of cutting fume -- 5.6.3.5 Edge rounding and coverage -- 5.6.3.6 Coating corrosion protection performance over edges -- 5.6.4 Surface quality -- 5.6.4.1 Initial rust degree -- 5.6.4.2 Surface imperfections -- 5.6.5 Stripe coating -- 5.7 Bolted connections.
5.7.1 Types of bolted connections -- 5.7.2 Slip-resistant connections -- 5.7.3 Preloaded bolted connections -- 5.7.4 O-ring gaskets -- 5.8 Bimetal coupling -- 5.8.1 General aspects -- 5.8.1.1 General requirements -- 5.8.1.2 Specific metals in contact -- 5.8.1.3 Exposure conditions -- 5.8.1.4 Galvanic corrosion of metals in seawater -- 5.8.1.5 Bolted connections in seawater -- 5.8.2 Corrosivity evaluation -- 5.8.2.1 Corrosivity evaluation measures -- 5.8.2.2 Electrolyte layer -- 5.8.3 Area factor -- 5.8.4 Modeling of bimetallic corrosion -- 5.8.5 Constructive solutions -- 5.8.6 Coating of bimetallic couplings -- 5.8.6.1 General relationships -- 5.8.6.2 Conducting polymers -- 5.9 Handling, transport, and assembling -- 5.9.1 General requirements -- 5.9.2 Temporary protection during storage -- 5.10 Vapor corrosion inhibitors -- 5.10.1 Practical applications -- 5.10.2 Types of vapor corrosion inhibitors -- 5.10.3 Protective mechanisms of vapor corrosion inhibitors -- 5.10.4 Efficiency of vapor corrosion inhibitors -- 6 Corrosion allowances -- 6.1 Basics -- 6.1.1 General considerations -- 6.1.2 Splash zone -- 6.1.2.1 General considerations -- 6.1.2.2 Secondary structural parts -- 6.1.2.3 Floating wind turbine structures -- 6.1.3 Boat landings -- 6.1.4 Scour zone -- 6.1.5 Internal compartments -- 6.1.6 Chains -- 6.1.6.1 Corrosion allowance -- 6.1.6.2 Corrosion and wear allowance -- 6.1.7 Machinery and systems -- 6.2 Calculation of corrosion allowance -- 6.2.1 Splash zone -- 6.2.1.1 General offshore structures -- 6.2.1.2 Offshore wind power structures -- 6.2.1.3 Structure design lifetime -- 6.2.1.4 Coating system lifetime -- 6.2.1.5 Corrosion rate -- 6.2.2 Corrosion allowance period -- 6.2.3 Mobile offshore units -- 6.2.4 Corrosion allowance models -- 6.2.4.1 Steel structures -- 6.2.4.2 Offshore structures -- 7 Cathodic corrosion protection -- 7.1 Basics.
7.1.1 Electrochemistry -- 7.1.2 Cathodic protection methods -- 7.1.2.1 Cathodic corrosion protection concept -- 7.1.2.2 Requirements for cathodic protection -- 7.1.2.3 Methods of cathodic protection -- 7.1.2.4 Environmental zones and levels -- 7.1.2.5 Design factors -- 7.1.3 Protection potential -- 7.1.3.1 Reference electrodes -- 7.1.3.2 Parameter effects on protection potential -- 7.1.3.3 Recommendations for protection potentials -- 7.1.3.4 Protection potential for stainless steels -- 7.1.3.5 Protection potentials for high-strength carbon steels -- 7.1.3.6 Effects of seawater quality on protection potential -- 7.1.3.7 Effects of seawater flow conditions on protection potential -- 7.1.3.8 Effects of pH value on protection potential -- 7.1.3.9 Effects of seawater aeration on protection potential -- 7.1.3.10 Effects of seawater temperature on protection potential -- 7.1.3.11 Effects of seawater hydrostatic pressure on protection potential -- 7.1.3.12 Effects of seawater conductivity on protection potential -- 7.1.3.13 Effects of seawater depth on protection potential -- 7.1.3.14 Effects of meteorological data on protection potential -- 7.1.3.15 Effects of fouling on protection potential -- 7.1.3.16 Effects of bacteria films on protection potential -- 7.1.3.17 Decay of protection potential with exposure time -- 7.1.3.18 Potential drop -- 7.1.3.19 Protection potential design issues -- 7.1.4 Protection current density -- 7.1.4.1 Initial electrical current density -- 7.1.4.2 Maintenance electrical current density -- 7.1.4.3 Final (or repolarization) electrical current density -- 7.1.4.4 Design recommendations for protection current density -- 7.1.4.5 Effects of seawater temperature on protection current density -- 7.1.4.6 Effects of seawater oxygen concentration on protection current density.
7.1.4.7 Effects of seawater conductivity on protection current density -- 7.1.4.8 Effects of seawater flow velocity on protection current density -- 7.1.4.9 Effects of seawater depth on protection current density -- 7.1.4.10 Effects of rock dump on protection current density -- 7.1.4.11 Effects of meteorological data on protection current density -- 7.1.4.12 Effects of fouling and MIC on protection current density -- 7.1.4.13 Effects of exposure time on protection current density -- 7.1.4.14 Effects of buried depth on protection current density -- 7.1.4.15 Effects of surface condition on protection current density -- 7.1.5 Electrolytes -- 7.1.5.1 Seawater -- 7.1.5.2 Soils and sediments -- 7.2 Cathodic protection with galvanic anodes -- 7.2.1 Anode materials -- 7.2.1.1 General requirements for galvanic anode materials -- 7.2.1.2 Material composition of galvanic anodes -- 7.2.1.3 Limitations with respect to galvanic anode materials -- 7.2.1.4 Performance characteristic of galvanic anodes from performance data -- 7.2.1.5 Composite galvanic anodes -- 7.2.1.6 Galvanic magnesium anodes -- 7.2.1.7 Alloyed galvanic aluminum anodes -- 7.2.2 Galvanic anode geometries -- 7.2.3 Design criteria for cathodic protection with galvanic anodes -- 7.2.4 Current demand of galvanic anodes -- 7.2.5 Driving voltage -- 7.2.6 Galvanic anode parameters -- 7.2.6.1 Galvanic anode current capacity -- 7.2.6.2 Galvanic anode weight -- 7.2.6.3 Number of galvanic anodes -- 7.2.6.4 Current output of galvanic anodes -- 7.2.6.5 Galvanic anode (circuit) resistance -- 7.2.6.6 Galvanic anode lifetime -- 7.2.6.7 Current demand of galvanic anodes -- 7.2.6.8 Galvanic anode consumption -- 7.2.6.9 Autocorrosion effect on anode consumption -- 7.2.7 Effects of water flow velocity on galvanic anode performance -- 7.2.8 Galvanic anode size.
Corrosion and corrosion protection of wind power structures in marine environments. Volume 2, Corrosion protection measures