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M. Zee, PhD, FNACE, FASMPeyman Tahri, PhD, Peng
Tara WockenfussAnil Chikkam
05 September, 2018Matergenics.com
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CorrosionandFatigueareLifeLimitingMechanisms
CorrosionandFatigue
MaterialsFollowLawsofPhysicsandChemistryPerfectly,FailuresareDuetoHumanError
• 2,900,000milesofagingpipelines• 500,000agingbridges• 80,000agingstoragetanks• 20,0000agingT&Dstructures
Foragingstructurespastisnotindicationoffuture
AgingInfrastructure
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Allentown(2011):CorrosionConsequences:HCA
Corrosion related accident resulting in serious fatalities in Pennsylvania:Corrosive Soil, Aging Pipeline and Graphitization. Considering soil corrosivityand Age (84 years in corrosive soil), this accident could have been prevented.
GRAPHITIZATION
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Conditions for Accelerated Corrosion and Corrosion Accidents
• Aging Pipelines: Baby boomer pipes and tanks >20-30 years
• Corrosive Soils
• Inadequate cathodic protection: “On” vs “Off”
• CP Shielding in General
• Coatings that Shield Cathodic Protection
• AC /DC Interference
• MIC
• Stress Corrosion Cracking
• Over Protection
ConditionAssessment
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Corrosion Risk Assessment
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Documentationofthesite including- SiteCharacterisitics,Straycurrentsourcesidentification,…..
IndirectAssessment including:- SoilCorrosivity Determination(Barneslayeranalysis)- ElectrochemicalAssessment(CIS),(DCVG)…- CurrentMeasurements- CoatingResistivityMeasurements
DirectAssessment including- On-sitefocusedmeasurements- In-labinvestigations
CorrosionMitigation including- CathodicProtectionDesign,installation,andmonitoring- CoatinginconjunctionwithcathodicprotectionPost-Assessment including- PotentialandCurrentReads- Lifeexpectancymodelingbasedonsoilcorrosivity andpotentialreads
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DirectandIndirectAssement
Presence of:
Accelerated Corrosion
SCC
Coating Defects
Coating Delamination
MIC
HE
DC Stray Current
AC Interference
ACInterference
DCCorrosion
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Corrosion Mitigation
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• Materials Selection
• Cathodic Protection
• Protective Coating
• Corrosion Inhibitors
• Non-Corrosive Environment
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Belt
Suspenders
Suspenders & Belt Approach Pump Electrons!
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CORROSIONMONITORING
Pipeline /Tower Leg Integrity is mostly managed by
1-Close Interval Survey AND (CP potentials)
2-Remote coating surveys: DCVG, ACVG, Pearson survey, coating conductance,
3-Corrosion Monitoring by Test Coupons
False Sense of Security
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CorrosionConsequences:HCA
Corrosion related accident resulting in serious damage in Pennsylvania
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AcceleratedCorrosionResultedinAnotherExplosioninaYearEarlierDuetoSameMechanism(CPshielding)
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CoatingThatShieldsCathodicProtectionCanResultInExplosions
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AcceleratedCorrosionResultedinExplosioninWestmorelandCountyInPennsylvania
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CoatingThatShieldsCathodicProtectionAcceleratedCorrosion,Perforation,LeaksAndExplosions!
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Cathodic Protection Shielding
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CathodicProtectionShielding
• Definition (NACE SP0169): Preventing or diverting the cathodic protection current from its intended path
• Why Cathodic Protection shielding is important?
• Regulatory Reasons
• CFR192.112 : to operate at alternative MAOP:
• The pipe must be protected against corrosion by Non-shielding coating
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ShieldingvsNon-shielding
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FBE-NonShielding
Nocorrosion
PH>9
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CathodicProtectionShielding
Theexplosionhappenedataround8:30amFridaymorningApril28th 2016,about200yardsbehindahomeinSalemTownship,whichlies30mileseastofPittsburgh.Itdestroyedthathome,torchedafieldanddamagedseveralhomesnearby.
Why Cathodic Protection shielding is important?
Accelerated Corrosion, Perforation, Leaks, Explosions
Recent Failure Case
PrimaryCauseofFailureThepipelinefailedduetodis-bondment ofthecoatingthatshieldedcathodic protectioncurrents.
“Thepipelineruns 9,096milesand carriesnaturalgasfromtheGulfCoasttothenortheasternU.S.Thesectionofpipethatexplodedwasbuiltin1981.“aninlineinspectionin2012revealednoareasrequiringrepairorremediationbeforethenextinspection.”
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• Corrosivesoilsiscommononalloftheabove
• Corrosionsoilmappingcanassistinidentifyinghotareasofcorrosiontherebyreducingpossibleincidentsandaccidents
• Corrosionsoilmappingshouldbeanessentialtoolinplanninganddevelopmentofundergroundassetintegrity
• AllentownExplosion• WestmorelandExplosion• StressCorrosionCrackingExplosions• MICRelatedCorrosionDamage
CorrosiveSoil
CorrosiveSoilsandCorrosionSoilMapping
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Corrosion Risk Assessment
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Is this soil corrosive?Is it reducing?Is it oxidizing?What is the corrosion rate?Predictive Modeling, Remaining Life?What type of cathodic protection should be applied?Is backfill important?
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Soil Corrosivity
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KeyParametersinSoilCorrosivity:
§ SoilResistivity
§ Soilresistivitymeasurement- ASTMG57:Four-pinmethodandBarneslayeranalysis (on-site measurement)- ASTMG57:Soil-boxmethod(in-labmeasurement;as-receivedandsaturatedtests)
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SoilResistivity
r = 2 p a R* a is in cm
Barn’sLayerAnalysisDeepBurialCorrosivity
SaturatedSoil
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Corrosion Parameter
Low Moderate Severe
pH 6.5-7.5 5.5-6.5 <5.5
Resistivity (ohm-cm) >10,000 2,000-10,000 <2,000
Conductivity (mS/cm) <0.2 0.2-0.4 >0.4
Chloride (ppm) <50 50-150 >150
Sulfates (ppm) <150 150-1150 >1,150
Sulfides (ppm) <1 1-5 >5
% Moisture (% wt) <20% >20% >20%
Redox (mV Std. H) >200 100-200 <100
Rules of Thumb to Help Determine Corrosion Activity
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Effects of Soil Characterises on Corrosion Rate
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Corrosion Rate Predictive Model
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Soil Maps
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SoilpH SoilSalinity(ElectricalConductivity) SoilWaterStorage
Source:UCDavis,CaliforniaSoilResourceLab
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Corrosion Risk Maps Can Be Used To Identify Sites At Risk
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Summary
A) Most pipeline, T&D tower/tank coatings are physical barriers by design, which isolate the metal pipeline from the surrounding environment conductive electrolyte
B) A risk for corrosion exists at locations where (1) the coating dis-bonds and (2) corrosive electrolyte is able to enter between the pipe surface and the coating.
(D) EIS and PH Can Provide Information On Coatings that Shield Cathodic Protection
(E) Soil Corrosivity Mapping will Identify Areas at High Corrosion Risk. Direct Assessment will Determine if the Coating/Tape Shields Cathodic Protection.Corrosionmitigationstrategycanbeestablishedbasedontheresults
Corrosionsoilmappingshouldbeanessentialtoolinriskanalysis,planninganddevelopmentofundergroundassetintegrityprogram.
(C) The most challenging factor for CP shielding is that it can exist for decades and will not be recognized, detected, or mitigated until an incident (Corrosion/SCC) occurs.
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Questions?Thank you for your attention!
Questions