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Atmospheric
. . .First
A
Little
History. . .
Edited 9/2/98 1
Corrosion - History
a little
Edited 9/2/98 2
Lets talk
about
b t
what
it
is
Corrosion - What it is
Edited 9/2/98 3
Corrosion - What it ain’t
An actual, unretouched photo of the famous …..
“ OHMITES”
Corrosion - What it is
Edited 9/2/98 4
Cathode - the area or material being
protected (area receiving electrons)
Edited 9/2/98 5
Corrosion - an example
Bulb
Carbon rod
cathode
Zinc Casing
anode
Edited 9/2/98 6
Now lets take any piece of metal, add in an anode, I
BUT now lets put in a power source between the metal am
an
and the anode - just to make it work faster anode
Cathode
magnesium Anodos
zinc Anodes
- Greek for “way up”
galvanized steel
aluminum alloys As we go down the
low carbon steels Cathodes list, the metals get
wrought iron more cathodic
cast iron
Kathodos
stainless steels
- Greek for way down
copper alloys
silver
Titanium Occur naturally,
graphite only subject to
gold (most of this derived by good old atmospheric
platinum Sir Humphrey Davies) corrosion-
tarnishing
Edited 9/2/98 7
Please…
Before
we
Go
Any
Further..
Corrosion
…a common myth...
W ONG!!!!!!!!!!!!!!!!!!
WRONG!!!!!!!!!!!!!!!!!!
Edited 9/2/98 8
What breaks first????
Hmmmm never hear much about service breaks, do ya!!
magnesium
zinc
aluminum
iron
steel
copper
etc.
Copper Services
Houses
Copper
Steel Tank
ank
Now you know why you should only use covered copper wire for your test leads
Edited 9/2/98 9
How can we stop this?
We have 3 choices:
2 U plastic
2.Use l ti
insulator
Steel Tank
or pipe
192.467: Elec. Isolation
Edited 9/2/98 10
Corrosion - What it is
Edited 9/2/98 11
Corrosion Control
Part 192, Subpart I
External
Internal
Atmospheric
Definition of Corrosion
The Deterioration of a Material,
Usually a Metal, that Results from a
Reaction with its Environment.
Edited 9/2/98 12
Galvanic Series of Metals
Edited 9/2/98 13
Basic Corrosion Cell
Fe
Fe
Fe
Pipe Corrosion
Metallic Path
Edited 9/2/98 14
Corrosion on Pipelines
Dissimilar Metals
steel/copper
Dissimilar Soils
pH In/Out Concrete
Differential
Aeration
b tt
bottom n compacted
t ds
Mill Scale
Corrosion
Oh - cm
Ohm Description
Edited 9/2/98 15
Soil pH
ACIDIC ALKALINE
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Cathodic Protection
The
Decrease of
Corrosion of
a Metal by
Forcing
Current to
Fl
Flow to
t the
th
Metal from a
Solution
(Electrolyte).
Edited 9/2/98 16
Cathodic Protection
Galvanic
Sacrificial Anodes
Impressed
Current Systems
Edited 9/2/98 17
“OQ” Qualified Person
Operator Qualification
requires that an
unqualified person must
be under the direct
observation of a
qualified person.
Date of Installation
Transmission or
Distribution
Coated
C t d or B Bare
Edited 9/2/98 18
CP Required
CP Required
Edited 9/2/98 19
CP Not Required
Pipelines in
NON-CORROSIVE
environments
(§192.455(b)).
Edited 9/2/98 20
Non-Corrosive Environment
Tests Needed to Demonstrate:
Soil
S il R
Resistivity
i ti it M
Measurements
t
Corrosion Accelerating Bacteria
Leak Frequency
Soil Composition
pH
Bell Hole Examinations
Internal
I t l Inspections
I ti
463 Requires
§192.463
§192 R i Cathodic
C th di
Protection to a Level that Complies
with Appendix D.
Edited 9/2/98 21
Corrosion
Edited 9/2/98 22
The Cell - a definition used by chemists for an electro-chemical SYSTEM consisting
of: an anode; a cathode; and an electrolyte
Some commercially
available “cells“
Anode cathode
Salt
solution
or
electrolyte
under
g
ground
It does corrode - eventually
Galvanic Series
magnesium
zinc
i
(as soon as all of the zinc is steel
consumed by the corrosion cell, etc.
well, “all gone”)
Edited 9/2/98 23
The Cell
..a Half Cell...
Anode cathode
Salt
Cu/
solution
CuSulfate
or
Solution
electrolyte
Copper rod
Things to remember:
1. It’s a electrical connection to the soil (a way of getting a consistent
reading)
2. Copper/ Copper-Sulfate is E X T R E M E L Y poisonous !!!!!
Cu/CuSO4 Reference
Electrode
Edited 9/2/98 24
Cathodic Protection Criteria
850 mv
100 mv Polarization
Decay
E log I (Gas)
neg pos
Half cell
I take a reading..
What am I getting a reading of??
Edited 9/2/98 25
A typical Pipe to Soil Connection The “average” of the
Pipe to soil voltages
Through the holidays!
neg pos
Half cell
IF I had a “Perfect”
Coating – What
Would my reading be??
0 - ZERO
Is that sufficient
-.65
-1.05
.05
To protect all
------- Holidays??
-.85
Edited 9/2/98 26
Components of IR Drop
Electrolyte (soil)
Edited 9/2/98 27
Cathodic Protection & IR Drop
Edited 9/2/98 28
C. P. CRITERIA (850 mv)
Protected Levels Considering
P/S
1050 IR Drop
1000
950
900
850
800
P t ti Level
Protection L l
750
ON
OFF
Current
C
Interruption
Cu/CuSO4
Reference
Edited 9/2/98 29
100 MV Polarization Decay
P/S
Adequate protection
850
800 demonstrated
750
700
650
600
550
0 6 18 30 42
Measured with
Current Applied
Consider IR Drop
Cu/CuSO4 Reference
Does NOT Apply to
Structures with
Different Anodic
Potentials
Edited 9/2/98 30
300 mv Shift
P/S
900
800
Protected
770 770 770 770 770 770 7
700
600 Native
500
Potential
450 460 450 470 450 4
430
400
At Predetermined Anodic
Areas
Edited 9/2/98 31
Cathodic Protection Criteria
E Log I
Tafel Slope
Cu/CuSO4
Reference
Edited 9/2/98 32
Monitoring ~ §192.465(a)&(c)
Cathodically Protected
Zones
Isolated Sections
< 100 ft. (Gas Mains
or Transmission)
10% Sampling Per Yr.
Non-Critical Bonds
Monitoring ~ §192.465(b)&(c)
Rectifiers
R tifi
Critical Bonds
Reverse Current
Switches
Diodes
6 x year - Intervals
Not Exceeding
2 1/2 Months
Edited 9/2/98 33
Monitoring ~ §192.465(e)
Monitoring ~ §192.465(e)
Edited 9/2/98 34
Monitoring ~ §192.465(e)
Reevaluation of Unprotected Lines
Every 3 Years not to exceed 39 Months
Active Corrosion
Continuing corrosion which, unless
controlled, could result in a condition that
is DETRIMENTAL to PUBLIC SAFETY --
§192.465(e)(1) [was 457(c)]
Edited 9/2/98 35
Detrimental to Public Safety
Considerations
Pipeline Location
Population Density
Road Crossings
Pressures
Corrosion Rate
(3 Year Intervals)
Electrical Survey
Edited 9/2/98 36
Electrical Surveys
What’s Impractical
Common Trench
Pipeline Environment
Soil Contaminants
Edited 9/2/98 37
Monitoring ~ §192.459
Check
Condition of
Coating and
Pipe
Exposed Pipelines
Investigate to determine whether
corrosion or coating deterioration
exists
If corrosion found, investigate beyond
exposed area (visual or other means)
Repair any problems
Keep records
Edited 9/2/98 38
Remedial Actions
§192.465(d)
“Within
“Withi Monitoring
M it i Period”
P i d”
“Prompt”
Consider:
Population Density
Environmental
E i t lCConcerns
Rate of Corrosion
Climatic Conditions
Availability of Materials
From Casings
Effective
Insulation
Protection From
Arcing
Edited 9/2/98 39
Shorted Casings
P/S reading ESSENTIALLY
th Same
the S as C
Casing
i
reading
Shorted Casings
Remedial Measures
3) If 1 or 2 Impractical,
Monitor with Gas
Detection Equipment at Intervals
Specified in .705 & .721, or Smart Pig
Edited 9/2/98 40
Test Stations/Test Leads
§192.469 & 471
Must Have SUFFICIENT Test Stations
or Other
Oth C Contact
t tP Points
i t tto D
Determine
t i
the Adequacy of Protection.
Edited 9/2/98 41
Test Leads ~ §192.471
Attach to Minimize Stresses on Pipe
Maintain Mechanically
Secure & Electrically
Conductive
Corrosive
C i P Product
d T
Transported
d
Test to Determine Effect on Pipeline
Take Steps to Minimize Effect
Edited 9/2/98 42
Internal Corrosion Control
Monitoring ~ §192.477
When Corrosive Product is
Transported
Must Be Monitored
For I.C.
2x Calendar Year
N.T.E. 7 ½ mos.
Coupons
Water Analysis
Microbiological Analysis
Inhibitors
Unless Non-Corrosive
Environment or Only
Light Surface Oxide
Edited 9/2/98 43
Atmospheric Corrosion Control
§192.479
Non-Corrosive
Environment not applicable
to Offshore Splash Zones
or Soil-to-Air Interfaces
Onshore
Every 3
Calendar
Years at
Intervals not
exceeding 39
Months
Edited 9/2/98 44
Atmospheric Corrosion Control
Monitoring ~ §192.481
Offshore
Every Calendar
Year Not To Exceed
15 mos
mos. Intervals
At Soil-to-Air Interfaces
Under Thermal Insulation
Under Disbonded Coatings
At Pipe Supports
In Splash Zones
At Deck Penetrations
In Spans Over Water
Edited 9/2/98 45
Remedial Measures ~ General
§192.483
Pipe that Replaces Pipe because of
External Corrosion
Cleaned
Coated
Cathodically
Protected
Remedial Measures
Transmission §192.485
General Corrosion
Replace
Lower
MAOP/MOP
Repair
Localized
Corrosion
Replace
Repair
Reduce Operating Pressure
Edited 9/2/98 46
Remedial Measures
Transmission §192.485
General Corrosion
Closely Grouped Pitting Affecting
Overall Strength of the Pipe
Remedial Measures
Gas Distribution (exc. CI & DI) ~ §192.487
General Corrosion or W.T. <30%
Remaining
Replace
Repair
Localized
C
Corrosion
i
Repair
Replace
Edited 9/2/98 47
Remedial Measures (Gas)
Cast & Ductile Iron ~ §192.489
Graphitization General
If Fracture May Result -
Replace
Localized-If Leakage Might
ResultMight Result
Repair
Replace
Seal Internally
Records or Maps
Location of Protected Piping
Cathodic Protection Facilities
Galvanic Anodes
Bonds to Other
Structures
Edited 9/2/98 48
Corrosion Control Records
§192.491(b)
Edited 9/2/98 49
Corrosion Control Records
§192.491(c)
Edited 9/2/98 50