cibse approved cpd on corrosion monitoring rev3...– bsria ,bg29/2012, bg50/2013 – bs 8552:2012...

Welcome Everyone

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CIBSE accredited Presentations by Paul Ashby of Geberit UK & Gordon Pringle HASL – UK & Ireland Risycor Distributors since

Jan 2018

Presented by: Paul Ashby07912 [email protected]

Thursday 30th April 2020BESA Training, Rotherwick House, 3 Thomas More St, St Katharine's & Wapping, London E1W 1YZ

PRECISION CARBON STEEL:MAKE IT RIGHT– TRUTH OR RUMOUR?

GEBERIT AIM: MAPRESS CARBON STEELCHANGE AN INDUSTRY FROM THE INSIDE

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MAKE IT RIGHT - TRUTH OR RUMOUR?

To educate and instil changewithin the Building Services industry on how to address theroot cause of corrosion and stop the rumour mill

201120122001

CARBON STEEL TIMELINE

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1950’s

INVENTIONPressfitting invented by Gunna-Larsson

RANGEExternally galvanised carbon steel pressfittingslaunched

CORROSIONRoyal Victoria Hospital Belfast hits the headlines

1969CARBONCarbon steel system introduced by Mannesmann

COPPER Copper prices reach an all time high

INITIATIVEIncreased UK adoption within smaller installers

CARBON STEEL TIMELINEFIRST MAJOR REPORT OF INTERNAL CORROSION

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2012

“Delay to full opening of Royal Victoria Hospital critical care building branded a 'disgrace’”

Belfast Telegraph , March 2018

“Problems with the pipework have been ongoing and concern is rising as to whether the problems

will be properly addressed”Belfast Live, March 2015

“Corrosion has been

found in the building's

new heating system.

BBC, July 2015

“The opening of the new £150m critical care unit

at the Royal Victoria Hospital in Belfast is to

be delayed further because

of a problem with the pipework”

BBC, March 2014

WHAT WENT UNREPORTED…

Corroded products within the system included:

• Black iron 1387• Precision carbon

steel• Valves• Boilers….

REALITY:CHANGING AN INDUSTRY FROM WITHIN

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Project: Mater HospitalDesign and Product Specification: R&F Mechanical

Pipe System Installer: September 2001

• In 2013, sections of the Mater Hospital plastic coated carbon steel system were removed and viewed• The precision carbon steel had been installed some 12 years prior, revealed corrosion free pipework• System remained as effective as it was the day it was commissioned

“…Mater Hospital is an excellent example of good practice; as a consequence, the building’s carbon steel pipework will remain corrosion free for many years to come”

David FlemmingR&F Mechanical

REALITY:CHANGING AN INDUSTRY FROM WITHIN

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Project: Omagh HospitalDesign and Product Specification: R&F Mechanical

Opened: May 2017

• Geberit Mapress Carbon Steel 15-108mm used in full across 9 plant rooms: 50km of pipe and 250 thousand fittings• At it’s busiest there were 150 M&E’s on site at one time, all of which had received training on Geberit Mapress Carbon Steel• Positive communication has seen an upturn in sales for precision carbon steel and R&F Mechanical

“…20 years installing into hospitals and we’ve never had an issue. Mapress Carbon Steel is our product of choice”

William FlemmingR&F Mechanical

20182015/16201120122001

CARBON STEEL TIMELINE

07/05/2020


1950’s

INVENTIONPressfitting invented by Gunna-Larsson

RANGEExternally galvanised carbon steel pressfittingslaunched

CORROSIONRoyal Victoria Hospital Belfast hits the headlines

1969CARBONCarbon steel system introduced by Mannesmann

COPPER Copper prices reach an all time high

COPPER Copper prices fall dramatically

INITIATIVEIncreased UK adoption within smaller installers

NHSGuidance document is issued

2013MATER12 year old system still good as new

TRUTHA need to re-educate the industry

2015

OMAGHNine plant rooms all precision carbon steel

FOUR SIMPLE RULES:CHANGING AN INDUSTRY FROM WITHIN

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GOOD PLANNING & BEST DESIGN

TRANSPORT AND STORAGE

PROFESSIONAL INSTALLATION

COMMISSIONING AND MAINTENANCE

Training• Correct training & best design• Accredited• On site

Closed System• Closed systems with closed expansion tanks• Mindful of continuous over-pressurisation• System ventilation

Suitable Piping Materials• Application• Not used outside

Effective Corrosion Protection• Barrier against diffusion• Closed-cell insulation / corrosion protection• Mass loss monitoring system

ADDING VALUEFALSE ECONOMIES

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‐1.2‐1‐0.8‐0.6‐0.4‐0.20

Zinc

Mild Steel

Low Alloy Steel

Copper

Stainless Steel (410,416)

80/20 Copper/Nickel

Stainless Steel (302, 304, 321, 347)

A MATERIAL SWITCH MOVES THE PROBLEM WITHIN THE SYSTEM

ANO

DIC

CATH

OD

IC


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GOOD PLANNINGTRANSPORT AND STORAGE



Method according to plan• Manufacturers guidelines• Train all contractors• Management process

Protect Product Material• Protective caps

No Rusted Parts• No visible red rust• White powder (Zinc Oxide)

Recommended Pressure Test• Test with compressed air• Water quality for pressure testing• Replenish the operating system


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GOOD PLANNINGTRANSPORT AND STORAGE



Fill to Original Plan• Leave it filled• Completely ventilate the system• Do not empty commissioned systems

If Refilling…• Within 24 hours at most• Approved quality

Important Handover Information and Testing• Corrosion knowledge transfer• BSRIA test intervals• Training on mass loss monitoring system

No Unsuitable Additives• Manufacturers instructions on dosing

BSRIA ARE WORKING ON NEW VERSIONS OF BOTH BG29 AND BG50 FOR 2020 AND 2021 RESPECTIVELY

ADDING VALUENEW TECHNOLOGIES – MONITORING SYSTEMS

MASS LOSS MONITORING

Under utilised

Now cost effective

Early warning detection system

Option of complex data or simple data

F&M handover peace of mind

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Devices sited through the system

A quantity recommendation (BG/29 guidelines for water sampling)

Coupons sit within the system reacting to changes in the water make up

Changes activate an alarm to a downloadable

dashboard

Each device has a 15 year lifespan within a clean

system

Devices can be removed and

replaced WITHOUT draining down

Devices monitor the whole system, not just carbon steel

EN HASL

CIBSE accredited Presentation by Gordon Pringle HASL – UK & Ireland Distributors Jan 2018

Preventing Corrosion by Continuous Monitoring

Contents• Why do heating and cooling systems corrode• The cost of corrosion• What is corrosion and what causes it• The role of oxygen and how it enters the system• Methods for monitoring• Why monitor for corrosion• Summary• (Real life examples how monitoring can save

systems)

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Why do heating systems corrode?

• Sealed systems are designed to prevent corrosion• In addition most systems in the UK are treated with

corrosion inhibitors.• There are many UK standards and guidelines all aimed

at minimising corrosion.– BSRIA ,BG29/2012, BG50/2013– BS 8552:2012 Sampling CoP, BS2486:1997,

BS7593:2019*– ICOM Commercial Htg Systems Guide– CIBSE AM14:2010, Commissioning Code W, Guide B

& M– Other European Standards are relevant i.e. VDI2035

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Despite these standards EVERYONE in the business has come across this

…this..

UK Carbon Reduction Policy• Heat networks are a crucial aspect of the path

towards decarbonising heat.• 17000 Heat Networks in the UK• 90% of all connections are Residential• Currently 2% of UK Heat Demand• Cost Effectively 14-20% by 2030 & 43% by 2050• In 2015 CCC est. 18% needs to be met for UK CRP• Ambient Temp Loops inc. Heat Pump also driving

forward development of these networks• Greaves4 illustrated that 15% of the 185 UK heat

networks studied had suffered failures as a result of issues around water quality.

• Potentially 2573 Systems at risk now!

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…this

…or indeed this..

The real problem often remainsinvisible from the outside until it is far too late

If systems are so well protected from corrosion why has a whole industry developed around Powerflushing and system cleaning?

700000 hits on Google for the term Powerflushing

Sales and variety of filters / magnetic dirt separators have exploded.

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Which of the following may be contributing to corrosion problems?

• System design?• Choice of materials?• Modern high efficiency components?• Cost cutting?• Poor training?• Poor maintenance?• Incorrect / Poor chemical treatment regime?• Implication of Mixed Metals?

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All of these can lead to corrosion problems

There are many types of corrosion

• Uniform Corrosion• Galvanic Corrosion• Crevice Corrosion• Pitting Corrosion• Under Deposit Corrosion• Microbiological Induced Corrosion (MIC)• Intergranular Corrosion• Erosion Corrosion• Stress Corrosion

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What is corrosion?

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Corrosion

Oxygen

Without one of these components (uniform) corrosion cannot take place

Eliminating one component (eliminates corrosion)

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Corrosion

Oxygen

• Do not use steel or other metals e.g. plastics

• Do not use water. E.g. Thermal oil

• Eliminate oxygen from the system and keep it out

Implication of Mixed Metals

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Eliminating oxygen is key- Initial fill

• Oxygen is held in solution in the water. How much can be dissolved depends on temperature and pressure. (Henry’s Law)

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Drinking water contains approximately 10mg/l of O2.

- Initial fill cont.

• When the system is filled under high pressure dissolved oxygen levels will also be higher.

• Trapped air pockets after filling get absorbed• Repeated draining and filling during pre-

commission cleaning and commissioning adds more oxygen = more corrosion.

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Danger! After pressure testing and / or cleaning a system must never be left empty !

O2 is consumed shortly after filling in an untreated system.

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How much corrosion is created?

Cause CorrosionBy weight (g)

CorrosionBy volume (cm³)

First fill (10,000 l) 396 775% Remaining air pockets 540 105Gas charge expansion vessel(1000 l) 3750 728

Caused by negative pressure:

1 Cool down at night (70°-20°) 400 76

1 Heating season (70°-20°) 36kg 7000

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What is an acceptable level of corrosion? No standard exists!

How does O2 enter the system?

• Poor pressure control accounts for 90% of all corrosion problems. Lack of understanding of EN12828.– Expansion Vessel too small– Pre-charge pressure too high– Pre-charge pressure too low– Loss of pre-charge pressure and lack of maintenance.– Incorrect Pump position (neutral point)– Defective bag or membrane (pump or compressor pressurisation*)

• Leaks– Automatic topping up with fresh water.– Compensation for water loss through Safety Valve. Usually due to

incorrect pressure control!• Diffusion

– Rubber fan coil hoses (EPDM is highly permeable)– Non-barrier plastic pipes. Is the barrier 100% barrier?

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Position Matters

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Size Matters

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Methods of corrosion monitoring

• Traditional– Water sample testing– Corrosion Coupons– Removeable pipe sections

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Methods of corrosion monitoring

• Advanced– Linear Polarisation Resistance (LPR method)– Sensors (PH, conductivity,O2 ,etc.)– Corrosion Sensor (Electronic coupon method)

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pH Sensor Conductivity Sensor LPR SensorCorrosion Sensor

Continuous monitoring & recording with the ‘Electronic coupon’ method

• Direct corrosion measurement through loss of material mass. Not water chemistry

• Continuous measurement and recording• Recording corrosion rate in micron/year• Lifetime analysis of corrosion activity possible• Instant warning when corrosion rates rise to

damaging levels• Temperature recording and can test HBV• Graphic output to assist with cause finding

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Detailed logging of every change in corrosion rate(s) and temperature since commissioning

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Recording corrosion history

Example 4 Perth Crematorium

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Example 4 Crematorium

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80/60C F&R Htg & DHWS400kW Boiler refurb 2017Expansion Vessel LinePH1 2PE

Example 4 Crematorium

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Example 4 Crematorium cont..

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Example 5 Newbyres Care Home

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80/60C F&R Htg & DHWS400kW Boiler refurb 2017119 Elderly residentsEH23 4TZ

Example 5 Newbyres Care Home

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NBS Source April 2020

NBS Plus provides designers and specifiers with product information in just one click, helping them to specify quickly, accurately and with the most relevant and up to date information at the time of specification. Corrosion Monitors 90 65 55 475

1st May 2019

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We need to improve….

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CPLS2020 Digitisation

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Productivity growth 2005‐'14 CAGR, %

Let’s get started #Risycord

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Summary• Despite many good standards and guidelines corrosion is still a problem. Not just PCS!• Modern system components are much more susceptible to corrosion sludge.

Therefore the problem will get worse not better.• Corrosion inhibitors are not a universal miracle cure in isolation.• By reducing O2 levels it is possible to achieve very low levels of corrosion even without

inhibitors.• Corrosion caused by the first fill is minimal and not detrimental. Frequent refill is to be

avoided. • Correct pressure control and minimising topping up is vital for enhanced corrosion

control. Vacuum degassing make up water can only be advantageous if affordable.• Monitoring corrosion should be mandatory to warn for sudden changes in the system.

BG29/2020 has yesterday introduced Real Time Monitoring & Data Retrieval. We commend BSRIA for this adoption to provide transparency. BG50/2013 Already had p76 6.6.4!

• Smart sensors such as the Risycor corrosion sensor sends alarms upon increased corrosion and records the entire corrosion history of the system.

• Greater consideration should be given to Northern European Standards DE VDI 2035 & pending* 2021-03 VDI 6044, Austrian ONORM H5195-1, ISSO NL Publication 13 and the Swiss SWKI for Hot & Cold Water plus Cooling Circuits, BE WTCB.

• Heard of the Golden Thread! Why it Matters….Transparency is required as Condition based maintenance will improve TMon and Cx in delivering predictive maintenance.

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Thank you

Any Questions?On behalf of HASL/RESUS & GEBERIT, we would like to thank you for attending this

collaborative CIBSE Accredited CPD’s.

Gordon Pringle [email protected] Ashby [email protected]

Feel free to connect with me on or follow me on Twitter @jugtastic67

Technical Due Diligence is coming more into focus!

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Optimum Corrosion Monitoring

• Monitor circuits that reach to the top of the system and / or futhermost extremities i.e. Index legs.

• Monitor close to cold feed (topping up) i.e. Shunt return*

• Monitor circuits containing plastic pipes or EPDM hoses which are not diffusion tight

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Shunt return - Example

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Index Point - Extremities

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cibse approved cpd on corrosion monitoring rev3...– bsria ,bg29/2012, bg50/2013 – bs 8552:2012...

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