Comfit's Proactive Approach to Resolving Corrosion Issues at Control Valve Manufacturer

Introduction:

In the world of industrial manufacturing,  corrosion  can be  a  significant  concern,  leading  to    equipment failure,  downtime, and  costly repairs. When the  client encountered corrosionissues   with  their  fittings,  they  reached  out  to  Comfit,  their  trusted  supplier,  for  assistance. Comfit's proactive approach and thorough investigation led to the identification and resolution ofthe root cause of the corrosion problem.

The Complaint:

Client lodged a complaint with Comfit regarding corrosion of the fittings supplied by Comfit.The fittings, made of SS 316 material, were intended to be used for connecting air in controlvalves. Given the compatibility of the material with the application, corrosion was not expected to occur.

Comfit's Swift Response:

Recognizing the severity of the issue, Comfit's team immediately visited client's factory to assess the situation firsthand. They collected samples of the corroded fittings and brought them back for analysis. Comfit assured client that they would investigate the problem and provide a resolution within two weeks.

Investigation and Analysis:

Comfit sent the corroded fitting samples for IDX analysis to determine the composition of the corrosion. The results revealed a high level of sodium(Na) in the rust,  indicating  that  the corrosion was likely caused by an external factor rather than the material itself.

Comfit's team reached out to client to gather more information about their installation and testing processes. client confirmed that the corrosion appeared only after installation and that they performed pneumatic tests using a soap solution to check for leaks. Additionally, they mentioned that the corrosion was present on both the fittings and the tubing.

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Identifying the Root Cause:

Based on the information provided by client, Comfit suspected that the soap solution used for testing might be  the  source  of the  corrosion.  Upon  further  inquiry, client revealed that they were using bore water instead of demineralized (DM) water for their testing process.

Comfit's team concluded that the high sodium content in the bore water was the likely cause of the corrosion. The sodium from the bore water, combined with the soap solution, created an environment conducive to corrosion on both the fittings and the tubing.

Implementing a Solution:

Armed with this knowledge, Comfit advised client to change their testing process and switch to using DM water instead of bore water. By eliminating the  source  of sodium, the corrosion issue could be resolved. Client  promptly  implemented  Comfit's  recommendation   and   changed  their  testing process  .As a result, the corrosion problem was successfully resolved, ensuring the long-term integrity of the fittings and tubing.

Lessons Learned:

The client's case study highlights the importance of thorough investigation and root cause analysis when addressing quality issues. Comfit's proactive approach, including on-site visits, sample analysis, and open communication with the client, was instrumental in identifying the source of the corrosion problem.

Moreover, this case study emphasizes the significance of considering external factors, such as the testing process and environment, when troubleshooting quality issues. By looking beyond the material and examining the entire system, Comfit was able to pinpoint the root cause and provide an effective solution.