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AUGUST 2014

VOL. 53, NO. 8IN THIS ISSUE

CORROSION PREVENTION AND CONTROL WORLDWIDE MATERIALS PERFORMANCE

A 36-in (914-mm) diameter natural gas pipeline was recently recoated in the feld with an airless-spray two-part epoxy coating for protection against external corrosion. In October 2013, NACE International released an updated version of NACE SP0169, which addresses control of external corrosion on underground or submerged metallic piping systems. See the feature article beginning on page 24. Photo courtesy of Mears Group, Inc.

MATERIALS SELECTION & DESIGN

56An Analysis of the Updated Cost of Corrosion in IndiaR. Bhaskaran, Lalit Bhalla, Afzalur Rahman, Suruchi Juneja, Upma Sonik, Sukhpreet Kaur, Jasneet Kaur, and N.S. Rengaswamy

66Welding Consumable Issues on Corrosion of X65QT SteelBalraj Velu, Rajnish Garg, Mukesh Saxena, and Paul Rostron

72MSD Blog

CATHODIC PROTECTION

30CP Blog

SPECIAL FEATURES

24Updating NACE SP0169 for Controlling External Corrosion on Underground or Submerged Metallic Piping Systems Kathy Riggs Larsen

76Pipes and Pipelines Supplier Guide

COATINGS & LININGS

32Power Plant Condenser Tube Sheet Retroft with Epoxy Cladding and CP EvaluationZhiyuan Liu and John Yang

38CL Blog

CHEMICAL TREATMENT

46The Pursuit of a Green Carbon Steel Corrosion Inhibitor Part 1Matthew LaBrosse and Donovan Erickson

50CT Blog

About the Cover

2 AUGUST 2014 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 53, NO. 8NACE INTERNATIONAL: VOL. 53, NO. 8

24 66

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AUGUST 2014

VOL. 53, NO. 8IN THIS ISSUE

CORROSION PREVENTION AND CONTROL WORLDWIDE MATERIALS PERFORMANCE

DEPARTMENTS

6Up Front

8The MP Blog

14Material Matters 14. 3D scanning tool uses structured light to create images of pipe surface corrosion 18. Permanently installed guided wave testing tool facilitates frequent pipeline monitoring 21. Company News

22Product Showcase

96Spotlight on NACE International Corporate Members

98I AM NACE

111Building Business Connections 111. Corrosion Engineering Directory 115. Advertisers Index

116Corrosion Basics

116. Stress Corrosion Cracking

NACE NEWS

100NACE Area & Section News

103New and Revised Standards Announced

104NACE Foundation and Mears Group Team to Award Scholarship

105NACE Corporate Members

106Calendar of Events

107 NACE Course Schedule

109NACE Headquarters Directory

MP (Materials Performance) is published monthly by NACE International

(ISSN 0094-1492; USPS No. 333-860). Mailing address and Editorial

Offces: 1440 South Creek Drive, Houston, TX 77084-4906; phone: +1

281-228-6200. Internet address: www.nace.org. Preferred periodicals

nonproft postage paid at Houston, TX and additional mailing offces.

Canada Post: Publications Mail Agreement #40612608. Canada Returns

to be sent to Pitney Bowes, PO Box 25542, London, ON N6C 6B2. Copyright

2014 by NACE International. Reproduction of the contents, either as a whole

or in part, is forbidden unless permission has been obtained from the

publisher. Articles and editorials herein represent the opinions of the authors

and not necessarily those of NACE. Advertising is included as an educational

service, and products and/or services mentioned carry no implied or real

endorsement or recommendation from NACE. NACE reserves the right to

prohibit any advertisement that is not consistent with the objectives of

NACE.

POSTMASTER: Forwarding charges guaranteed. Send address changes to

NACE FirstService, 1440 South Creek Drive, Houston, TX 77084-4906.

SUBSCRIPTION RATES: To members as part of annual dues $12; U.S.

nonmembers $115; overseas nonmembers $130; libraries $205; overseas

libraries $220; single copy $20, availability permitting. Rates to nonmem-

bers subject to change. Subscriptions must be prepaid. Claims made within

6 months of issue date flled at no charge, availability permitting. Non-

airmail overseas subscribers must wait 60 days from issue date to claim

a replacement issue. Individual back issues may be available for up to 2

years. Requests for address changes should include previous address of

subscriber. Change of address should be provided 6 weeks prior to ensure

continued delivery (phone: 1 800-797-6223 U.S. and Canada or +1 281-

228-6223 worldwide or e-mail: [email protected]). Cancellation must

be made in writing. Refunds will be prorated less a $20 processing fee.

Information on becoming a NACE member can be obtained from the NACE

Membership Services Department at the above phone number and e-mail

address. PRINTED IN THE U.S.A.

4 AUGUST 2014 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 53, NO. 8

MP (Materials Performance) is published monthly by NACE International

(ISSN 0094-1492; USPS No. 333-860). Mailing address and Editorial

Offces: 15835 Park Ten Place, Houston, TX 77084; phone: +1 281-228-

6200. Internet address: www.nace.org. Preferred periodicals nonproft

postage paid at Houston, TX and additional mailing offces. Canada Post:

Publications Mail Agreement #40612608. Canada Returns to be sent to

Pitney Bowes, PO Box 25542, London, ON N6C 6B2. Copyright 2014 by

NACE International. Reproduction of the contents, either as a whole or in

part, is forbidden unless permission has been obtained from the publisher.

Articles and editorials herein represent the opinions of the authors and not

necessarily those of NACE. Advertising is included as an educational service,

and products and/or services mentioned carry no implied or real endorse-

ment or recommendation from NACE. NACE reserves the right to prohibit

any advertisement that is not consistent with the objectives of NACE.

POSTMASTER: Forwarding charges guaranteed. Send address changes to

NACE FirstService, 15835 Park Ten Place, Houston, TX 77084. SUB-

SCRIPTION RATES: To members as part of annual dues $12; U.S. nonmem-

bers $115; overseas nonmembers $130; libraries $205; overseas libraries

$220; single copy $20, availability permitting. Rates to nonmembers

subject to change. Subscriptions must be prepaid. Claims made within

6 months of issue date flled at no charge, availability permitting. Non-

airmail overseas subscribers must wait 60 days from issue date to claim

a replacement issue. Individual back issues may be available for up to

2 years. Requests for address changes should include previous address of

subscriber. Change of address should be provided 6 weeks prior to ensure

continued delivery (phone: 1 800-797-6223 U.S. and Canada or

+1 281-228-6223 worldwide or e-mail: [email protected]). Cancel-

lation must be made in writing. Refunds will be prorated less a $20 process-

ing fee. Information on becoming a NACE member can be obtained from

the NACE Membership Services Department at the above phone number

and e-mail address. PRINTED IN THE U.S.A.

14 18

104

HELP. NEED PHOTO

6

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Kathy Riggs Larsen


Pipeline Coating Assessment Facility Opens in Australia The National Facility for Pipelines Coat-

ing Assessment, an initiative of the Energy

Pipeline Co-operative Research Centre

(CRC), was recently launched at Deakin

Universitys Waurn Ponds campus in Vic-

toria, Australia and will be jointly man-

aged by the universitys School of Engi-

neering and Institute for Frontier

Materials. The independent facility will

perform coating testing for oil and gas

pipelines and provide research that sup-

ports pipeline coating selection and devel-

opment. The Energy Pipelines CRC is a

collaboration between Deakin, the Uni-

versity of Wollongong, Adelaide Univer-

sity, the Australian National University,

and the Australian Pipeline Industry As-

sociation. Source: Deakin University,

www.deakin.edu.au.

Spray-Applied Composite Protects Metals from Corrosion

Photo by Uwe Bellhuser.

An environmentally friendly spray-

applied composite material developed by

material researchers at the INMLeibniz

Institute for New Materials (Saarbrcken,

Germany) prevents corrosion of metals

exposed to aggressive aqueous solutions,

including salt solutions such as seawater

and salt spray on roads and aqueous acids

like acid rain. This is accomplished by the

protective layers structure, which is a few

micrometers thick. Several layers of pro-

tective particles are placed on top of each

other in an offset arrangement (similar to

roof shingles) to form a self-organized,

highly structured barrier. The composite,

which can be used to coat plates, pipes,

gear wheels, tools, machine parts, etc., ad-

heres to the metal substrate after thermal

curing at 150 to 200 C, and is suitable for

steels, aluminum, magnesium, copper,

and metal alloys. For more information,

visit www.inm-gmbh.de.

Monitoring Sewer Gases Can Determine Corrosion RiskResearchers with the University of Colo-

rado Boulder report that certain condi-

tions in wastewater pipes can help utili-

ties determine which ones need repairs.

Microbe communities have long been rec-

ognized as a factor in concrete pipe corro-

sion, but they have not been well studied.

To fill in the gaps, the research team mea-

sured bacterial diversity, gas concentra-

tions in the air above the waste water, and

other factors from 10 different sewer sys-

tems in major U.S. cities. In the most worn

pipes, they observed elevated levels of

both hydrogen sulfide (H2S) and carbon

dioxide (CO2) gases as well as low diversity

in the types of bacteria present. The re-

searchers concluded that wastewater util-

ities could economically monitor combi-

nations of these gases in sewage pipes to

determine which sites might be at higher

risk for corrosion. Source: American

Chemical Society, www.acs.org.

Self-Protecting Coatings Contain Inhibitors to Prevent Corrosion A team of researchers from Max Plank

Institute of Colloids and Interfaces (Pots-

dam, Germany) explored how self-protect-

ing anticorrosion coatings that contain

embedded spherical nanocontainers filled

with a corrosion inhibitor can be used to

autonomously protect expensive and

often difficult-to-reach metal parts and

infrastructure from surface corrosion.

Most conventional coatings are thinner

than 100 m, so nanocontainers should be

at least three times smaller in size to be

properly integrated into the coating. How-

ever, the total amount of a crack sealant

that can be loaded into these containers

isnt adequate to completely fill a typical

submillimeter-size scratch in the coating.

To overcome this problem, the researchers

extended the approach by using corrosion

inhibitors as the nanocontainers load. In

this situation, theres no need to cover the

scratch completelythe inhibitor ad-

sorbed onto the scratchs bare metal sur-

face can safely mitigate further corrosion

development. To read more, see the

Corrosion paper at http://dx.doi.org/

10.5006/0976.

Warning System Uses Coating to Detect Cracks in Concrete

Sensing skin report. Image by Aku

Seppnen.

A new sensing skin technology devel-

oped by researchers from North Carolina

State University (Raleigh, North Carolina)

and the University of Eastern Finland is

designed to serve as an early warning sys-

tem for concrete structures, allowing au-

thorities to respond quickly to damage in

critical infrastructure. The skin is an elec-

trically conductive coating that can be ap-

plied to new or existing structures. Elec-

trodes are applied around the perimeter of

a structure, and the sensing skin is

painted onto the structure and over the

electrodes. A computer program then runs

a small current between two of the elec-

trodes at a time, cycling through a number

of possible electrode combinations. Every

time the current runs between two elec-

trodes, a computer monitors and records

the electrical potential at all of the elec-

trodes on the structure. If the skins con-

ductivity decreases, that means the struc-

ture is cracked or damaged. A suite of

algorithms registers damage and deter-

mines where the damage has taken place.

To learn more, visit news.ncsu.edu.

UP FRONT

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mailto:[email protected]://www.elcometer.commailto:[email protected]://www.elcometer.com

Editor:In the May 2014 issue of MP there were

two excellent articles on corrosion and materials for carbon capture and seques-tration (CCS). Although corrosion is certainly a consideration when liquid water is present, it is not when water is soluble in supercritical CO

2 (SC-CO

2) and

no free water phase is present. However, for transport of SC-CO

2 to the location of

injection for CCS, the most common material for pipelines is carbon steel, which has been the mainstay of the oil and gas industry for over 30 years for enhanced oil recovery (EOR). Yet while corrosion is not an issue, the most impor-tant design consideration for transport of SC-CO

2 is the risk of a long-running

ductile fracture. This requires modeling of the decompression behavior of the CO

2

being transported coupled with the so-called Battelle two curve method. There are numerous references and sources on this design requirement; however, I felt the readers should be made aware, since this is Materials Performance, and not just a corrosion publication, that even after corrosion is considered for SC-CO

2 there are still

major materials properties that must also be evaluated for CCS.

Bruce Craig, Subject Matter Expert, Materials and Corrosion, Stress Engineering

Services, Inc., Houston, Texas, USA

The following are excerpts from the NACE

International Corrosion Network (NCN)

and NACE Coatings Network. These are

e-mail-based discussion groups for corro-

sion professionals, with more than 3,000

participants.

The excerpts are selected for their

potential interest to a large number

of NACE members. They are edited for

clarity and length. Authors are kept

anonymous for publication.

Please be advised that the items are

not peer-reviewed, and opinions and

suggestions are entirely those of the

inquirers and respondents. NACE does

not guarantee the accuracy of the techni-

cal solutions discussed. MP welcomes

additional responses to these items. They

may be edited for clarity.

For information on how to subscribe

to these free list servers, click on the

Corrosion Central link and then Online

Corrosion Community List Servers on the

NACE Web site: www.nace.org.

Weld degradation from muriatic acid

Q: Heavy-duty equipment, such as concrete skips and system

propping, is often returned to us heavily encrusted with dried concrete or cement, so they are regularly soaked/cleaned with a variety of powerful concrete removers/cleaners normally used for cleaning brickwork, tiles, etc.

On average, these cleaners contain between 12 and 18% muriatic (hydrochlo-ric) acid (HCl) and 1 to 6% sulfuric acid (H

2SO

4), both of which we know to be

highly corrosive to metals.The equipment in question is

commonly sprayed or brushed with copious amounts of these cleaners and often allowed to soak overnight (sometimes much longer) before being hosed or washed down.

A concrete skip can carry up to 5.5 metric tons of material, which is then hauled by crane to tremendous heights and may even be suspended for lengthy periods of time on a bridle supported only by two swivel pins.

Can the long-term, continuous use of these corrosive chemicals allow them to penetrate and damage the equipments structural or load-bearing welds?

Having seen numerous photos showing the corrosive effects of these chemicals on various types of metal plate, and knowing that the same acids are used to clean metal in the production of stain-less steel, you can understand my concern when considering that the weld is gener-ally the weakest point of any equipment. Many of these concrete skips are now several years old (some more than 10) and over this period, a variety of these chemi-cal cleaners have been used with much gusto.

Are my concerns warranted and am I worrying about nothing? Is there a research paper or any other reference or scientific document that I may obtain/purchase that covers the above issues?

THE BLOG

Continued on page 10

EDITORIAL

DIRECTOR, CONTENT DEVELOPMENT/ Gretchen A. Jacobson

MANAGING EDITOR

TECHNICAL EDITOR John H. Fitzgerald III, FNACE

ASSOCIATE EDITOR Kathy Riggs Larsen

EDITORIAL ASSISTANT Suzanne Moreno

CONTRIBUTOR Husna Miskinyar

GRAPHICS

ELECTRONIC PUBLISHING Teri J. Gilley

COORDINATOR

GRAPHICS DESIGNER Michele S. Jennings

ADMINISTRATION

CHIEF EXECUTIVE OFFICER Robert (Bob) H. Chalker

GROUP PUBLISHER William (Bill) Wageneck

ADVERTISING

SALES MANAGER Diane Gross

[email protected],

+1 281-228-6446

ASSISTANT SALES MANAGER Teresa Wright

[email protected],

+1 281-228-6472

ACCOUNT EXECUTIVES Erica R. Cortina

[email protected],

+1 281-228-6473

Brian Daley

[email protected],

+1 281-228-6455

Pam Golias

[email protected],

+1 281-228-6456

Jody Lovsness

[email protected],

+1 281-228-6257

Leslie Whiteman

[email protected],

+1 281-228-6248

ADVERTISING/BOOKS Brenda Nitz

COORDINATOR [email protected],

+1 281-228-6219

REGIONAL ADVERTISING SALES The Kingwill Co.

REPRESENTATIVES Chicago/Cleveland/

New York Area

[email protected],

+1 847-537-9196

NACE International Contact Information

Tel: +1 281-228-6200 Fax: +1 281-228-6300

E-mail: [email protected] Web site: www.nace.org

EDITORIAL ADVISORY BOARD

John P. Broomfield, FNACE Broomfield Consultants

Raul A. Castillo Consultant

Irvin Cotton Arthur Freedman Associates, Inc.

Arthur J. Freedman Arthur Freedman Associates, Inc.

David D. He PG&E

Orin Hollander Holland Technologies

W. Brian Holtsbaum Corsult Associates (1980), Ltd.

Russ Kane iCorrosion, LLC

Ernest Klechka CITGO Petroleum Corp.

Kurt Lawson Mears Group, Inc.

Lee Machemer Jonas, Inc.

Norman J. Moriber Mears Group, Inc.

John S. Smart III John Smart Consulting Engineer

L.D. Lou Vincent L.D. Lou Vincent PhD LLC


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A: Te short answer is yes, your concerns are warranted. Any

crevices will be subject to accelerated corrosion. I would be doubtful welds are perfect 100% of the time.

A: A more serious concern could be the evolution of nascent hydrogen

by acids, which could be absorbed by the steel or weld material and cause cracking. I have seen cracking on scafolding clips that we attributed to hydrogen absorp-

tion and cracking due to improper acid cleaning techniques.

Cracking of the base material would only be a problem for higher-strength steels, and skip base material would not, I would think, be at risk. However, depend-ing upon the welding procedure followed, the welds could be at risk. The swivel pins, if exposed to the acid, could be of particular concern.

I think it would be worthwhile having a few welds, pad eyes, and swivel pins destructively analyzed for cracking to see if there is a problem before you have a failure in the field.

A: We know from many sources that hydrogen generated from acid

attack will cause fracture of hardened steels. Te difcult part is to establish how severe the attack must be before the materials in your equipment are compro-mised. If they are all mild steel, the most you should expect is an occasional blister. On the other hand, if there are hardened components, there is a good probability of occasional failures. It sounds like you are firting with disaster and, in addition, it seems it would be very difcult to accurately duplicate the type of feld conditions you describe in a laboratory environment. On the other hand, there are probably thousands of similar cement truck applications around the world and we havent heard of many drums rolling loose.

Condenser materials

Q: I am looking at a steam surface condenser that may use circulat-

ing water with a chloride concentration of up to 7,000 mg/L. What materials can be used for the condenser tubes/tubesheets, etc.? I understand that most stainless steels (SS) cannot withstand this level of chlorides. Is there a way to predict the life of those tubes under those conditions?

A: Te best tube material is titanium. Several SS and copper

alloys are also okay. For utility applica-tions, however, copper may cause problems in the turbine.

A: We have titanium condenser tubes and a Muntz metal

tubesheet, and have had to coat the tubesheet to prevent leaks. Titanium does not easily roll in, and the tubesheet undergoes galvanic corrosion at the tube

BLOG

Continued from page 8


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interface. Use of dissimilar metals should be avoided!

A: I agree that titanium would be a good choice, but would the

copper-based alloys be the most suitable materials in terms of their performance and cost? Many of the steam surface condensers work well with 90-10 Ci-Ni or 70-30 Cu-Ni tubes where the cooling medium may be seawater.

A: In my country, we use copper-based alloys, especially 70-30

Cu-Ni, and we have had very good results. The chloride concentration of circulating water is nearly 19,000 mg/L. Titanium is a good choice, but is expensive and you have to consider the galvanic corrosion.

A: Copper-based alloys with due regard for water quality have

been successfully used for many years in seawater heat exchanger applications. They can offer benefits over SS in terms of crevice corrosion behavior and recovery from upset.

A: When using titanium materials, use caution if cathodic protection

is used to control galvanic corrosion. The very noble potential of titanium can only be brought to 0.650 off vs. a copper/copper sulfate (Cu/CuSO

4) reference

electrode without danger of hydrogen embrittlement. This danger would certainly eixist with magnesium and possibly even with zinc condenser anodes during times of no water f low. One should consider the old-school wisdom: Avoid use of dissimilar metals.

A: Te present slowing of deliveries of titanium are making people

reexamine alternative materials such as super ferritic and super-austenitic SS and Cu-Ni for seawater-cooled heat exchang-ers and condensers. Regarding Cu-Ni, 90-10 has been favored by the U.S. Navy since it was frst introduced in 1950, the main reason being that 90-10 has suf-cient fouling resistance in seawater to eliminate the need for chlorination. Unfortunately, 90-10 has to be periodi-cally replaced since it sufers from poor resistance to erosion-corrosion and very much accelerated corrosion in the presence of traces of hydrogen sulfde (H

2S) (e.g., 3 ppm), and gives rise to the

turbine problems in certain applications. As of a couple of years ago, the U.S. Navy


Copper-based alloys with due regard for water quality

have been successfully used for many years in seawater

heat exchanger applications.

11NACE INTERNATIONAL: VOL. 53, NO. 8 MATERIALS PERFORMANCE AUGUST 2014

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was focused on using titanium shipboard condensers together with specifc chlori-nation and dechlorination procedures. I would therefore examine and weigh the materials choices very carefully.

A: From my experience, people need to be extremely cautious about

mixing Cu-Ni and SS in seawater systems where Cu-Ni piping has failed locally in the vicinity of SS fttings, and also where Cu-Ni tubes have failed where attached to a SS tubesheet. It is not obvious from looking at a galvanic series in seawater that Cu-Ni and SS are incompatible. Use either all SS or all copper-based materi-als, and never mix the two!

Caustic embrittlement

in reinforced concrete

Q: Are there documented cases of caustic embrittlement of

reinforcing steel in concrete? When I look

at the Pourbaix diagram for water and Fe, I am tempted to say that under certain conditions of potential, although the pH is caustic, you will get embrittlement.

A: I have never heard of this occur-ring. Also, I have never heard of

caustic embrittlement of steel at normal ambient temperatures, where concrete is generally used. At elevated temperatures, the Pourbaix diagram is altered by expan-sion of the domain of stability for dissolved species. Te application of a cathodic current in an environment that contains calcium ions could lead to the formation of protective calcareous deposits.

A: Ive never heard of it in concrete. Tere can be hydrogen embrittle-

ment with excessive cathodic protection applied to high-strength steels used for prestressing. High alkali content in the cement can attack some siliceous aggre-

gate and rocks used in concrete through a process known as alkali silica reaction, but that is not a metal thing.

The alkalinity of concrete comes from the cement. When water is added to the mix, the cement rapidly produces a saturated lime (calcium hydroxide [Ca(OH)

2]) solution that has a nominal pH

of about 12.6. In the cement there are also alkali oxides present including sodium oxide (NaO) and potassium oxide (KO), which react with the mix water to produce sodium hydroxide (NaOH) and potassium hydroxide (KOH). These alkali hydroxides typically push the pH of concrete up to and past pH 13. In the ASM Handbook, Vol. 13C, Corrosion: Environments and Industries (2006), in the chapter on Corrosion in Bridges and Highways, the role of pore water pH and chloride-initiated corrosion is discussed. It reports that a concrete with a pH of 13.6

BLOG



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has a chloride content corrosion thresh-old about five times that of a lower alkali content concrete with a pH of 13.2.

The pH of cements used in Europe and concretes made in North America with pozzolans like f ly ash and silica fume is lower than standard mixes made with Type I/II cements. This is because slag cements are often used in Europe, and because pozzolans react with Ca(OH)

2

and the pH is reduced. Given the number of structures that have been built with non-pozzolan Type I/II cements, if caustic embrittlement were a problem, the cement alkali content would long ago have been restricted.

Use of silver

Q: How does silver perform in corrosive environments? In the

past it has been assumed that silver is very noble and therefore has been used for downhole and other hydrogen sulfide (H

2S) service conditions.

A: In addition to being very expen-sive in comparison with struc-

tural metallic materials, silver has a strong afnity for sulfur with which it forms a nonprotective surface compound. Te ASM Metals Handbook notes that even indoor atmospheres in large cities that contain traces of sulfur compounds cause sulfdation of silver at a rate in the order of 70 micrograms per dm2 per day. Te handbook also notes that surface plating of silver by rhodium over a nickel under-plate prevents tarnishing.

A: Principle applications of silver are in electronic contacts and

circuit boards. Such applications are discussed in the Instrument Society of America Standard ISA S71.04 published in 1985 (which sets limits for contami-nants found in the environment) and various other publications. See NACE International CORROSION 2007 paper no. 07400, for example, which principally concerns copper components but also references corrosion data for silver.

A: Tere are many old texts describ-ing the corrosion behavior of

silver, including the 8th edition of the ASM Metals Handbook, Vol. 1, pp. 1,181-1,185.

Editors Note: Additional MP Blog items appear in the individual technical sections:

cathodic & anodic protection (p. 30), coatings & linings

(p. 38), chemical treatment (p. 50), and materials selection & design (p. 72).


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http://www.corrpro.comhttp://www.corrpro.com

MATERIAL MATTERS

3D scanning tool uses structured light to create images of pipe surface corrosion

To successfully evaluate features

that may impact a pipeline or

other structures fitness for ser-

vice, field data are collected on

corrosion defects in hazardous liquid and

gas pipelines after inline inspection runs,

direct assessment, and other mainte-

nance activities. These data may need to

be further assessed using quantitative

also known as phase measurement pro-

filometry (PMP), to acquire 3D data. This

technique uses projected light patterns

and a camera to create a 3D image of the

surface under inspection, and an analyti-

cal software program that enables analy-

sis of the 3D data. The measurement

approach used by the tool falls into a

class of 3D measurements called triangu-

lation. Our eyes ability to assess three

dimensions is, for most people, based on

triangulation, says Matt Bellis, president

of Seikowave. A camera takes the place of

one eye and a projector is a substitute for

the other eye. Triangles are formed

between the camera sensor, the projector,

and the object under inspection.

To take a measurement of an object,

Bellis explains, specific patterns that

vary over time are projected onto the

object, and the camera captures images

of the object illuminated by the patterns

and computes the 3D pointscollecting

300,000 voxels (volumetric pixels or 3D

pixels) per scan. Based on the varying

projected patterns, a very precise triangle

is formed between the camera and the

object, which makes it possible to capture

the 3D features of the surface with a level

of precision within several thousandths of

an inch. Once the data are acquired, the

software generates a 3D image that repli-

cates the objects surface. With this tech-

nology, the features of a pipes surface

topography can be accurately measured

within 2 mils (51 m), says Joseph Pikas,

vice president of pipeline integrity with

Technical Toolboxes.

The 3D structured light tool is typi-

cally used when the results of an inline

inspection, such as an intelligent pig run,

indicate an anomaly on an area of the

tools to determine key parameters such

as the maximum allowable operating

pressure (MAOP) of the pipeline. Accu-

rately calculating the severity of defects

such as corrosion pitting, dents, and

gouges helps determine the remaining

strength of the structure and whether or

not repair or replacement is required.

Technical Toolboxes (Houston, Texas)

and Seikowave, Inc. (Lexington, Ken-

tucky) have developed and ruggedized a

field tool, the 3D Toolbox, that measures

the surface of any type of metallic pipe or

structure and creates a three-dimen-

sional (3D) model of the surface. The tool

comprises a 3D imaging system that uti-

lizes the 3D structured light technique,

A technician uses the 3D structured light scanning tool to take scans of external corrosion on a pipe

in the Algerian Desert. Photo courtesy of Joseph Pikas.


August 2014 MP.indd 14 7/21/14 7:42 AM

pipe and an additional inspection is nec-

essary to verify the severity of the anom-

aly. Most types of anomalies that can be

observed visually can be assessed with

the 3D structured light scanning tool.

These include corrosion, gouges, and

dents. Taking a 3D image is similar to

capturing an image with a two-dimen-

sional camera. The camera is aimed at the

anomaly to be inspected and the mea-

surement is captured and stored digitally

on the laptop computer that is part of the

system. It takes less than one second to

acquire a 3D image.

The procedure for examining the pipe

with the 3D structured light scanning

tool is similar to the procedure used when

examining a pipe manually with a con-

ventional pit gauge. Before taking a scan,


the pipe surface must be cleaned to

remove old coatings and debris, and pre-

pared to white metal1 or near white

metal2 by abrasive blasting or another

approved method to remove corrosion

products and scale. Drawing a grid on the

pipe to mark points for gauge readings is

not necessary.

In the case of a corrosion anomaly, the

software processes the 3D images and

creates a 3D model of the pipe surface

that is used to determine the maximum

pit depth of the corroded area. Once the

operator selects the grid size and interac-

tion rules for pitting, the software plots

the river bottom profile, which indicates

the deepest defects and their location in

the corroded area of the pipe surface. The

data can be used to calculate the MAOP

Currently the 3D scanning tool is being tested for submarine and offshore applications. Photo

courtesy of Seikowave.


Information on corrosion control and prevention

August 2014 MP.indd 15 7/21/14 7:42 AM

http://www.FarwestCorrosion.comhttp://www.FarwestCorrosion.com


Left: A 3D image generated from a scan of a segment of corroded pipe with an original wall thickness of 0.5 in (13 mm). Right: A corrosion analysis of

the corroded pipe. The 3D river bottom profle is shown in the upper right photo, and a graph of the corrosion profle is shown beneath it. Images

courtesy of Joseph Pikas.


MATERIAL MATTERS

August 2014 MP.indd 16 7/21/14 7:43 AM

http://www.elcometer.commailto:[email protected]://www.elcometer.commailto:[email protected]

and the predicted burst pressure using

RSTRENG (external pipeline corrosion

evaluation software), ASME B31G,3 or

Modified B31G. According to Bellis, the

RSTRENG effective area calculation,

which incorporates the river bottom pro-

file, provides the most repeatable MAOP

calculation.

The 3D structured light technology is

an easier and faster method to determine

the river bottom profile than any manual

assessment. In a manual assessment,

technicians draw a grid on the pipeline

and take depth measurements at inter-

secting points with a pit gauge; this is a

time-consuming process and is subject to

human error, Pikas says. A recent exam-

ple, he notes, was an 8-ft (2.4-m) length of

pipe with corrosion completely along the

bottom between the 4 oclock to 8 oclock

positions on the pipes circumference.

With a 0.5-in (13-mm) grid, it would

require over 10,000 manual readings to

determine the river bottom profile; this

could take as long as a day and a half.

With the 3D structured light scanning

tool, the 3D images could be acquired in

less than an hour. The software can ana-

lyze the data and provide a river bottom

profile, maximum safe operating pres-

sure, and predicted burst pressure within

a few minutes. Decisions can be made in

the field regarding the type of action to

take to address the anomalylower the

operating pressure, repair the pipe with a

composite sleeve, recoat the pipe, replace

a section of pipe, etc.

To ensure correct calculation of the

burst pressureor failure pressureand

safe pressure of the pipe, its very impor-

tant that the depths along the river bot-

tom are accurately measured, says Joe

Summa, president of Technical Tool-

boxes. Today were seeing river bottoms

run almost to the extent of the entire

length of the pipe joint: up to 40 ft (12 m).

Additionally, Summa notes, determining

the depth and location of the deepest

points manually when the corrosion is

complicated is challenging and it can be

difficult for a technician to accurately

gauge corrosion depths where a large por-

tion of the pipe surface is corroded. This

is especially true when there is a signifi-

cant amount of pitting and little or no

parent metal to which a manual pit gauge

can be anchored.

In a 3D analysis, the original condi-

tion of the pipe is used as a baseline,

Summa explains. Separate data are col-

lected for both damaged and undamaged

areas of the pipe. Once the undamaged

points are identified, they are used to

form surfaces that serve as a reference

against which damaged areas are mea-

sured. The extent of metal loss or defor-

mation can then be determined, he says.

Using the 3D structured light scan-

ning tool, even when considering opera-

tor and tool variability, the variation in

predicted burst pressure is

The GWT tools transducer array is attached with adhesive to the pipe surface at a particular axial

location, enclosed with a cover, and connected by cable to the pulser-receiver through a junction

box interface. Photo courtesy of Plant Integrity, Ltd.


MATERIAL MATTERS

Permanently installed guided wave testing tool facilitates frequent pipeline monitoring

To assist in detecting corrosion in oil and gas pipelines, Plant Integrity, Ltd. (Cambridge, United Kingdom), a subsid-

iary of TWI, Ltd., has designed an ultra-

sonic guided wave testing (GWT) tool for

permanent installation. The tool, Teletest

Permamount, uses low-frequency, long-

range guided waves to monitor pipe walls

for metal loss. The tool can identify

areas where changes in the pipe wall

cross-section thickness are occurring

along the entire length of pipeline being

monitored.

According to Paul Jackson, general

manager with Plant Integrity, this nonde-

structive testing (NDT) technology was

developed to cost-effectively enable

repeated GWT and monitoring of pipe-

lines that are difficult to access or in

areas where the environment is hostile or

safety may be an issue, such as buried or

elevated pipelines, offshore risers, jetty

lines, and pipelines that cross under

roads or rivers. The permanent tool is

intended to be used where traditional

GWT can be successfully implemented. In

many cases, Jackson says, the cost of

accessing a pipeline far exceeds the cost

of the NDT inspection. He uses a buried

pipe as an example, where the costs to

access a point on the pipe to conduct the

test include excavating, shoring the

trench, and backfilling the trench after-

ward. To help reduce the costs for pipe

access when the pipe needs to be tested

multiple times, the permanent GWT tool

is left in place on the pipe after it is

installed and the testing process is man-

aged from a more accessible location.

In addition to delivering a more con-

venient approach for repeatedly inspect-

ing pipelines with GWT, the permanent

tool also provides a means to increase

the sensitivity of the inspection data,

Jackson comments. The sensitivity of

GWT is stated in terms of the minimum

detectable percentage of change in a pipe

walls cross-sectional area, and typically

GWT inspections can identify cross-

section loss of ~5 to 9%. Because the per-

manently installed GWT tool facilitates

more frequent testing, a baseline can be

established. When current test data are

compared to previous data, much smaller

degrees of cross-section change within

the pipe wall can be determineddown

to 1%. The testing frequency, he adds, can

be established based on the risk associ-

ated with the pipe being monitored. Data

can be collected more frequently for

high-risk pipelines or for localized por-

tions of a pipeline with a known problem

area, and less frequently for low-risk

pipelines.

The tool is based on the GWT technol-

ogy first developed by TWI in the 1990s to

detect corrosion under insulation (CUI)

in oil and gas pipelines. It uses the same

basic components as traditional guided

wave NDTa transducer ring (an array

comprised of multiple transducers) that

fits around the circumference of the pipe-

line and generates low-frequency acoustic

waves (usually


The scan displays repeatable data from the tool. The responses in blue and green, grouped in

terms of temperature, were taken weeks apart but show minimal comparable error when overlaid.

The error can be quantifed by taking a residual between the two signals, which is displayed here as

the red trace. Image courtesy of Plant Integrity, Ltd.


insulation doesnt need to be completely

removed. The tool can be installed over

protective coatings such as fusion-

bonded epoxy and operate on pipes with

diameters ranging from 2 to 48 in (51 to

1,219 mm) and temperatures ranging

from 40 to 80 C.

The permanent transducer array will

sit dormant until it is connected to a

pulser-receiver, which directs the trans-

ducer array to generate low-frequency

acoustic waves that propagate in both

directions along the pipeline. According

to Jackson, the guided waves can propa-

gate ~100 ft (30 m) in both directions from

the transducer array and provide 100%

pipe wall coverage. Pipe conditions can

influence the wave range, he says. If the

surface of the pipe wall is coated or

degraded (e.g., with pitting corrosion) or

the pipe geometry is complex, the dis-

tance of the wave transmission may be

reduced. Additionally, the wave distance

is affected by the viscosity of the pipe con-

tents and can be reduced as the contents

viscosity increases. For a straight,

aboveground bare metal pipe conveying

gas, wave propagation distances of up to

590 ft (180 m) in both directions have

been achieved.

Two symmetric wave modes are trans-

mitted and received by the pulser-

receiverlongitudinal waves, which are

similar to compression waves, and tor-

sional waves, which have more of a twist-

ing motion. Jackson explains that where

there is a change in the cross-sectional

area of the pipe wall, such as a weld, bend,

or defect caused by corrosion, these

waves will convert into a f lexural wave.

This change in acoustic impedance is

ref lected back to the transducer array as

an echo. The distance of the detected fea-

ture from the transducer array can be

determined using the speed of the initial

wave and the receive time of the echo.

The test data collected by the pulser-

receiver can be probed in two ways. At the

junction box, an operator can either col-

lect and interpret the data in situ via a lap-

top computer and the accompanying soft-

ware program, or swap out the replaceable

data storage component on the pulser-

receiver unit and interpret the data at a

different location. In remote locations, a

battery-operated pulser-receiver can be

connected to the transducer array at the

junction box for several weeks to collect

data in bursts, then be removed and

Information on corrosion control and prevention

August 2014 MP.indd 19 7/21/14 7:43 AM

http://www.gmcelectrical.nethttp://www.gmcelectrical.net



MATERIAL MATTERS

reconnected at a later date to collect

another burst of data. The software pro-

gram interprets the data and presents

them as A-scans, which display the ampli-

tude of the reflected waves and their dis-

tance from the transducer array, and

C-scans, which plot the reflected ampli-

tude using a color scale and show the fea-

tures circumferential orientation as well

as distance from the transducer array.

Because welds are at known distances

from the transducer array and have a typ-

ical echo response, they are used to cali-

brate the tool so areas of cross-section

reduction can be located. To estimate the

degree of cross-sectional change, a sys-

tem of distance amplitude correction

(DAC) curves is used. GWT is considered

a screening method and currently there

are no means of determining the dimen-

sions of a detected f law. Typically, when

remaining wall thickness measurements

are required, a quantitative follow-up

technique is used where metal loss is

detected by GWT.

Longevity and repeatability of data

are critical for a permanently installed

GWT tool, which must remain stable over

long periods of time in harsh environ-

ments. So that test results are repeatable

and small changes in pipe condition can

be detected, the coupling force between

the transducers and the pipe is carefully

controlled so variability with tempera-

ture is minimal. This is done with a back-

ing mass on the transducer, a controlled

bond line between the transducer and the

pipe, and an individual transducer pres-

sure. During data collection, temperature

is also monitored at the tool.

So that components remain

unchanged during the tools service life,

which is designed to be five to 10 years, all

components are fabricated to meet IP691

ratings for protection against water

immersion and dust ingress for subsea

applications as well as pipelines that are

buried.

Contact Kamer Tuncbilek, Plant Integrity,

Ltd.e-mail: kamer.tuncbilek@plantinteg-

rity.co.uk.

Reference1 BS EN 60529:1992+A2:2013, Degrees of protec-

tion provided by enclosures (IP code) (Lon-

don, U.K.: BSI, 1992).

BibliographyJackson, P., Guided wave activity at TWI, http://

youtu.be/Jhf5e7P515M ( June 17, 2014).

K.R. Larsen

August 2014 MP.indd 20 7/21/14 7:43 AM

http://www.lidaproducts.comhttp://www.denora.comhttp://www.denora.commailto:[email protected]://www.lidaproducts.comhttp://www.denora.comhttp://www.denora.commailto:[email protected]:[email protected]:[email protected]://youtu.be/Jhf5e7P515Mhttp://youtu.be/Jhf5e7P515M

COMPANY NEWS

OEL Products Acquires Ammonite and Cormetrics

Jim ORourke, Presi-

dent of OEL Proj-

ects, Ltd., is pleased

to announce the

companys acquisi-

tion of Ammonite

Corrosion Engineer-

ing and Cormetrics,

Ltd. Founded by

incoming NACE

International Vice

President Sandy

Williamson and based in Calgary, Alberta,

Canada, Ammonite provides corrosion en-

gineering, materials selection advice, asset

integrity management programs, evalua-

tion of chemical treatment, and inspection

programs for the oil and gas industry.

Williamson will retain his current role as

President of Ammonite. Cormetrics, Ltd.,

managed by Frank Hornsby, provides fail-

ure analysis, corrosion inhibitor testing,

and crude corrosivity testing for the oil and

gas industry. OEL Projects, Ltd. is an engi-

neering, procurement, and project manage-

ment contracting company headquartered

in Calgary that serves the oil and gas indus-

try in Canada.

Sherwin-Williams Receives Military Coatings Project Award of Excellence The Sherwin-Williams Co. (Cleveland,

Ohio) was awarded the SSPC: The Society

measurement and/or control of hydro-

carbon fluids. For more than 70 years,

Francisco was an international leader in

the design, manufacture, and calibration

of turbine flow meters for rocket propul-

sion and industrial fluid flow measure-

ment applications. His engineering

accomplishments and inventions have

contributed significantly to the aerospace,

as well as the oil and gas industries.

Kapur Named President of Honeywell Process Solutions

Honeywell (Morris

Township, New Jer-

sey) announced

that Vimal Kapur

has been named

president of Hon-

eywell Process

Solutions (HPS), a

Honeywell busi-

ness that supplies automation control, in-

strumentation, and services to process

manufacturers in industries such as oil

and gas; refining; pulp and paper; petro-

chemicals; and metals, minerals, and min-

ing. A near-30-year veteran of the process

automation industry, Kapur has been with

Honeywell for more than 25 years. He has

held a number of key strategic business

positions within Honeywell, including vice

president of Global Marketing and Strat-

egy for HPS and managing director for

Honeywell Automation India, Ltd. (HAIL).

Prior to this appointment, he was vice

president/general manager of the Ad-

vanced Solutions line of business for HPS.

for Protective Coatings Military Coatings

Project Award of Excellence, along with

International Marine and Industrial Appli-

cators, LLC (IMIA), for its work on the U.S.

Navys USS Ronald Reagan (CVN-76). The

award recognizes exceptional coatings

work performed on U.S. military ships,

structures, or facilities. In the seven

months during the USS Ronald Reagans

dry docking at Puget Sound Naval Ship-

yard (Bremerton, Washington) in 2012 and

2013, more than 17 acres (68,799 m2) of

steel would need to be preserved on the

ships freeboard; underwater hull; sea

chests; cat walks; and various tanks, voids,

and vent plenums. This project was the

largest preservation project to have ever

been completed at the shipyard.

ISHM Announces 2014 Laurence S. Reid Award Recipient

The International

School of Hydro-

carbon Measure-

ment (ISHM)

(Norman, Okla-

homa) proudly an-

nounces that

Edward E. Fran-

cisco, Jr. is the re-

cipient of the 2014

Laurance S. Reid Award, which was pre-

sented posthumously. This award is

presented each year in recognition of out-

standing individual contributions to the

U.S. Water Expands into Mid-Atlantic Region U.S. Water Services (St. Michael, Minnesota

and Aberdeen, Maryland), a provider of

integrated water and process solutions for

industry, announces the acquisition of

Water Chemical Service, Inc. (Waterchem).

Waterchems Terry Bartley states, This acqui-

sition is a game changer for us in the market-

place. U.S. Water has a similar culture and

attitude to Waterchem, as well as expanded

service offerings and locations across the U.S. Well leverage and combine our strengths

with U.S. Water to target the immense growth opportunities presented to us in the area.

Were excited about what this acquisition will bring in terms of service and capabilities

to our existing and future customers.

MP welcomes submissions of

Company News. Please send photos and

information to Husna Miskinyar;

e-mail: [email protected].

NACE Incoming Vice

President Sandy

Williamson.


August 2014 MP.indd 21 7/21/14 12:50 PM

mailto:[email protected]

Fire Safe Flange Isolation Kits

PosiTector PC Powder Checker Now Available

DeFelsko

(Ogdensburg,

New York) is

pleased to

introduce the

next generation

of non-contact

powder thick-

ness gages. The

PosiTector PC

Powder

Checker

measures uncured powder coatings

using ultrasonic technology to auto-

matically calculate and display a

predicted cured thickness. The

PosiTector PC helps to control powder

consumption to ensure adequate cover-

age and reduce waste. The updated

PosiTector PC Powder Checker features

a color liquid-crystal display (LCD), an

expanded internal memory, and free

access to a full suite of PosiSoft

Solutions. The gage continually

displays/updates basic statistics and

automatically generates formatted

reports with measurement summaries

and charts. Notably, the PosiTector PC

applications, says Wisdom Dzotsi,

general manager, Quantum

Com posites. The hybrid carbon f iber

material, AMC-8590-12CFH, is an

advanced molding compound that

offers the performance benefits of

carbon f iber at a cost similar to high-

performance f iberglass. It is easily

moldable, delivering parts that are high

strength, low density, and resistant to

fatigue. Tel: +1 989-922-3863, Web site:

www.quantumcomposites.com.

Hybrid Performance Precision Grout for ConstructionBASF (Shakopee, Minnesota) introduces

a new product in North America de-

signed for precision grouting of critical

equipment. MasterFlow 4316 hybrid

performance grout combines the

strength of an epoxy grout with the ease

of applying cementitious grouting ma-

terials. MasterFlow 4316 grout is the

newest addition to the Master Builders

Solutions grout family, specified glob-

ally as premier products for demanding

applications such as compressors, gen-

erators, pump bases and drive motors,

tank bases, conveyors, and column sup-

ports. The one-component grout is easy

to mix, has low odor, and can be easily

cleaned up with water. Tel: 1 800-526-

1072, Web site: www.master-builders-

solutions.basf.us.

New 27MG Ultrasonic Thickness Gage

Olympus (Waltham, Massachusetts) is

pleased to announce the release of the

27MG Ultrasonic Thickness Gage that is

designed to make accurate measure-

ments from one side on internally

now accepts all PosiTector probes to

easily convert from measuring uncured

powder to cured dry film thickness,

surface profile, and more. Tel: 1 800-

448-3835, Web site: www.defelsko.com.

First Hybrid Carbon Fiber Material

Quantum Composites (Bay City,

Michigan), a business unit of The

Composites Group, introduces its f irst

hybrid carbon f iber material, a cost-

effective, lightweight, and high-

strength alternative for traditional

f iberglass and metal applications in the

automotive, heavy truck, medical,

sporting goods, and industrial markets.

This new materialwith its improved

f lexural and tensile moduli at a

sig nif icant cost reductionhas created

the opportunity for new thermoset

Lamons (Golden, Colorado), a manufac-

turer of fire safe f lange isolation kits for

critical offshore platform and refinery

applications, introduces the DEFENDER

FSTM sealing/isolating gasket. The product

is designed to withstand the rigorous API

standard 6FB (Third Edition) test and

therefore provides a solution for those who

want to electrically isolate their f lange,

provide a seal for media, and protect

against the introduction of fire in and

around the f lange. Available in ANSI, API,

and PN pressure classes with a nominal pipe size range of through 36 in (13

through 914 mm), the gasket utilizes a Kammprofile design with a standard Type 316

(UNS S31600) stainless steel core (Inconel and duplex available upon request). Isola-

tion materials are G10 or G11 and the Kamm profile seals are faced with Teflon and

Mica seal elements. Tel: +1 303-405-6812, Web site: www.lamons.com.


PRODUCT SHOWCASE

August 2014 MP.indd 22 7/21/14 7:43 AM

http://www.lamons.com/http://www.lamons.com/http://www.quantumcomposites.comhttp://solutions.basf.ushttp://www.defelsko.com

corroded or eroded metal pipes and

structures. It weighs only 12 oz (340 g)

and is ergonomically designed for easy,

one-hand operation. Despite its

compact size, the 27MG has many inno-

vative measurement features that

utilize the same technologies available

on more advanced thickness gages. The

durable, rugged 27MG is battery oper-

ated and features a large, backlit LCD

with easy-to-read numerals, and an

intuitive color-coded keypad with

direct access to many key features.

Tel: +1 781-419-3562, Web site: www.

olympus-ims.com.

New Metals from EOS

EOS (Krailling, Germany) metals port-

folio now includes new titanium and

stainless steel (SS) for end-use produc-

tion on its direct metal laser-sintering

(DMLS) systems. Lightweight EOS

Ti64ELI alloy has excellent corrosion

resistance and biocompatibility plus a

high grade of purity. It is extremely

well-suited for the additive manufac-

ture of medical implants for orthope-

dics. EOS Type 316L SS (UNS S31603)

combines corrosion resistance with

high ductility and is appropriate for

surgical instruments, endoscopic

surgery, orthopedics, and implants.

Parts built from the new steel have a

chemical composition corresponding to

that specified in ASTM F138 (a standard

for SS bar and wire for surgical

implants). The steel also has potential

applications in the watch and jewelry

industries, as well as in harsh and

demanding environments such as the

aerospace or marine industries. Tel: +1

248-306-0143, Web site: www.eos.info.

Intertherm 228HS for North American Market

International

Paint (Houston,

Texas) an-

nounces the in-

troduction of

Intertherm

228HS into

North Ameri-

cas offshore

and onshore in-

dustrial markets. This next-generation,

temperature-resistant epoxy phenolic

coating offers higher solids and lower

volatile organic compounds (VOCs) to

provide improved protection to insu-

lated steelwork. According to Chris Mc-

Millan, International Paints North

American marketing manager, One of

the many characteristics of Intertherm

228HS is its improved film build toler-

ance. While optimum performance can

be achieved in the typical 8 mil system

(2 by 100 m), the coating will perform

equally well at total f ilm builds of up to

12 mils (300 m). This dramatically re-

duces the risk of cracking from over ap-

plication when applied to weld areas

and equipment with complex geome-

tries. Tel: 1 800-525-6824, Web site:

www.international-pc.com.

PPG to Reintroduce DURANAR ADS Coatings for Architectural MetalsPPG Industries (Pittsburgh,

Pennsylvania) coil and building prod-

ucts coatings group announced that it

will reintroduce DURANAR ADS (air-

dried system) f luoropolymer coatings

this summer, three years after the prod-

ucts were withdrawn from the market.

This next-generation line of DUR ANAR

ADS coatings, based on a newly formu-

lated f luorinated copolymer resin

combined with PPG proprietary chem-

istry, is designed to repair f luoropoly-

mer coatings on architectural metals

damaged during production or after

f ield installation. In addition, these

high-performance coatings can provide

a wide range of color options for manu-

facturers and contractors in solid,

metallic, pearlescent, and infrared-

ref lective (IR-ref lective) pigment tech-

nologies. Tel: 1 888-774-4332, Web site:

www.ppgideascapes.com.

General Purpose Industrial Air Pressure Regulator Series

Marsh Bellofram Corp. (Newell, West

Virginia) announces the global market

launch of its Type T60 air pressure regu-

lators. The industrial air pressure regu-

lators are preset, f ixed units for instru-

mentation and general purpose use.

Through a combination of careful

design engineering and the incorpora-

tion of quality materials, Type T60

regulators offer trouble-free operation

over an extended useful service life,

even in the most difficult industrial

environments. A rubberized, soft-seat

valve stem provides positive shut-off

and forgives dirt or other foreign

matter. An aspirator maintains down-

stream pressure and compensates for

droop when high f low occurs. The inte-

gral gauge port is also convenient for

pressure gauge installation, and can be

used as an additional full f low outlet.

Tel: 1 800-727-5646, Web site: www.

marshbellofram.com.

MP welcomes submissions of product press releases and photos for Product Showcase. Please send them to the attention of Husna Miskinyar, NACE International; tel: +1 858-768-0829; e-mail: [email protected].


The Latest Tools forFighting Corrosion

August 2014 MP.indd 23 7/21/14 7:43 AM

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I

FEATURE ARTICLE

Updating NACE SP0169 for Controlling External Corrosion on Underground or Submerged Metallic Piping Systems

In October 2013, NACE International

released an updated version of SP0169,

Control of External Corrosion on

Underground or Submerged Metallic

Piping Systems, which presents methods

and practices for achieving effective

control of external corrosion on under-

ground or submerged metallic piping

systems. The revision was accomplished

by NACE Task Group (TG) 360, Piping

Systems: Review of NACE SP0169-2007.

This task group is administered by

Specific Technology Group (STG) 35,

Pipelines, Tanks, and Well Casings,

and is comprised of corrosion control

personnel from oil and gas transmission

companies, gas distribution companies,

water and wastewater utilities, power

companies, corrosion consultants, and

others concerned with external corrosion

control of underground or submerged

metallic piping systems. This is the fifth

revision of the standard, which was origi-

nally published in 1969. The previous

revision was performed in 1992 by NACE

TG T-10-1, and since then the standard

was reaffirmed (without revisions) in 1996,

2002, and 2007.

SP0169 describes the use of electrically

insulating coatings, electrical isolation, and

cathodic protection (CP) as they relate to

external corrosion control, and is intended

to be used by corrosion control personnel

responsible for pipelines that transport oil,

gas, water, and other fluids, although the

methods outlined in the standard are also

applicable to many other underground or

submerged metallic structures. Significant

changes and additions were made in the

2013 revision of SP0169, particularly in

Section 5, External Coatings, and Section

6, Criteria and Other Considerations for

Cathodic Protection. Additionally, a review

of potential criteria in national standards

from around the world was added as an

appendix.

Kathy Riggs Larsen, Associate Editor

Corrosion personnel perform nondestructive testing (magnetic-particle inspection) on an excavated portion of pipe. Photo courtesy of Drew Hevle.


Aug14_Feature.indd 24 7/21/14 1:01 PM


This is the standards fifth revision since its original publication in 1969.

A corrosion technician inspects an excavated portion of pipe for coating damage and external corrosion. Photo courtesy of Drew Hevle.

A pipe is recoated in the field with an airless-spray two-part epoxy coating, which protects it from external corrosion. Photo courtesy of Mears Group, Inc.

25MATERIALS PERFORMANCE AUGUST 2014 NACE INTERNATIONAL: VOL. 53, NO. 8


FEATURE ARTICLE

To learn more about the recent

revisions made to SP0169 and their impact

on industry, Materials Performance asked

several members of NACE TG 360 and

others interested in the standard revision

to comment on the updated portions of

the standard. Panelists are Jim Chmilar

with Chmilar & Associates Consulting

Ltd.; Drew Hevle with Kinder Morgan;

Mark Lauber with Laclede Gas Co.; and

Norm Moriber with Mears Group. (See

their biographies in the sidebar, Meet the

Panelists.)

MP: How does industry use NACE

Standard SP0169? Why is this standard

important?

Drew Hevle: NACE SP0169 is the

de facto standard for CP of pipelines in

the world, the first standard that NACE

published, and one of the most influential

standards issued by NACE. It contains

sections on coatings, CP criteria, and

the design, installation, operation, and

maintenance of CP systems. Many regula-

tory agencies reference this standard.

For example, the U.S. Department of

Transportation references the SP0169 CP

criteria for its hazardous liquid pipeline

safety regulations in the Code of Federal

Regulations (49 CFR 195 Subpart H).1

Mark Lauber: As an operations

manager responsible for pipeline safety

regulatory compliance for both steel

natural gas distribution and transmission

systems, I feel that SP0169 is a valuable

technical document because it is a

comprehensive resource for any pipeline

owner who wishes to identify the neces-

sary steps proven to adequately mitigate

corrosion of these valuable assets. The

standard is important for several reasons.

It provides specific criteria where corro-

sion control is expected to be achieved for

stated conditions, and it provides perfor-

mance language for pipeline operators

who have documented empirical evidence

indicating corrosion control effectiveness

using other criteria. The standard also

provides an enormous number of techni-

cal references for coatings applications,

Meet the Panelists

Jim Chmilar

Jim Chmilar gradu-

ated with an en-

gineering degree

from the University

of Calgary in 1972

and started as a

feld engineer do-

ing cathodic pro-

tection (CP) work with Associated Corro-

sion Consultants Ltd. in Calgary, Alberta,

Canada. He retired from that company

in 2003 after 30-plus years and formed a

one-man consulting company to enable his

continued involvement with NACE Interna-

tional. A NACE member since 1976, Chmi-

lar has been the chair of various commit-

tees, including Instructor and Peer Quality

Committee, Quality Committee, Technical

Practices Committee (TPC), Technical and

Research Activities Committee, the Policy

Committee, and Task Group (TG) 360.

Chmilar received a NACE Distinguished

Service Award in 1990 for section and area

conference work, and was the recipient of

the NACE R.A. Brannon Award in 2010.

Drew Hevle

D rew Hev le i s

manager of cor-

rosion control for

Kinder Morgans

natural gas pipe-

line group, based

in Houston, Texas.

He has a Bachelor

of Science degree in mechanical engi-

neering and holds several NACE certi-

fcations, including Corrosion Special-

ist, CP Specialist, and Level 3 Coating

Inspector. Hevle heads several NACE

technical committees, is vice chair of the

NACE Technical Coordination Commit-

tee (TCC), and is also a NACE instructor.

His hobbies are corrosion control and CP.

Mark Lauber

Mark Lauber is

the manager of

p ipel ine safety

compl iance for

the Laclede Gas

Co., which serves

eastern Missouri,

including St. Louis,

and western Missouri, including Kansas

City. A NACE-certifed CP Specialist since

1997, he is responsible for integrity man-

agement programs for the companys

gas transmission, gas distribution, and

hazardous liquid pipelines. This includes

corrosion control, main replacement,

and public awareness programs. In ad-

dition, Lauber has overall responsibility

for pipeline safety regulation compliance

for Laclede Gas. He holds a Bachelor of

Science degree in electrical engineering

from the University of Missouri-Rolla.

Lauber is a member of several NACE

technical committees, including TG 360.




CP criteria from other standards around

the world, and completed CP research.

Norm Moriber: RP0169 was the first

recommended practice developed by

the National Association of Corrosion

Engineers and was a critical document in

establishing NACE as the world leader in

corrosion prevention and control. This

standard has provided the framework

for pipeline integrity management plans

since before that terminology existed.

Engineers and operators have relied on

RP0169 (and now SP0169) as a refer-

ence for the industry consensus on best

practices for corrosion control on pipeline

systems.

Jim Chmilar: Industry primarily cites

the criteria in Section 6 for external corro-

sion control of underground or submerged

metallic piping systems. Some also find

the accepted methods and practices

covered in the other eight sections very

useful for design, installation, operation,

and maintenance of the corrosion control

system they establish.

MP: Why was it necessary to revise

SP0169?

Moriber: Technical Coordination

Committee (TCC) procedures require that

standards be reviewed every five years to

determine whether they should be

reaffirmed, revised, or withdrawn. This

standard was revised in 1972, 1976, 1983,

and 1992; and it was reaffirmed in 1996,

2002, and 2007, which means it had been

more than 20 years since it was updated.

A blue-ribbon ad hoc committee reported

in 2002 that revisions were required in

several key areas, including clarification of

CP criteria, better guidance regarding

microbiologically influenced corrosion

(MIC) and elevated-temperature corro-

sion, and upper limits of protection to

avoid cathodic disbondment of coatings

and damage to high-strength steels. It was

also recommended that information be

provided on CP criteria used outside of

North America in recognition of NACEs

commitment as an international

organization.

Lauber: I believe it was necessary to

revise SP0169 because pipeline opera-

tors like me found the 850 mV criterion

language to be confusing and unclear.

Furthermore, because SP0169 was

reaffirmed several times without updat-

ing technical references to the advances

in coatings and coatings standards that

had been made in the last several years,

the previous version of this standard was

seriously dated.

Chmilar: The previous revision of

this standard occurred in 1992, thanks to

Ted Kazmierczak and TG T-10-1. A STG

05, Cathodic/Anodic Protection, ad hoc

committee on Criteria Review in RP0169-

96 presented a report at CORROSION

2002 that stated: Section 6 could not be

reaffirmed as it exists; ambiguity exists

between the 0.850 vs. copper/copper

sulfate (Cu/CuSO4) electrode (CSE)

current-applied criterion and the 0.850

vs. CSE polarized criterion; there are

other international criteria that should

be considered; there is confusion regard-

ing 100 mV formation and decay; more

guidance is needed on CP criteria for

controlling MIC and corrosion at elevated

temperatures; and upper limits on CP

criteria for coating damage and/or high-

strength steels are needed.

STG 05 formed TG 285 in 2002 to

revise Section 6. That TG had numer-

ous meetings and conference calls and

gathered significant information, but did

not achieve its goal of getting out a ballot

to the group and was disbanded in 2006.

The task was turned over to TG 360 under

STG 35 to review the entire document,

including Section 6. Part of the NACE and

ANSI protocol requires all standards to be

revised or reaffirmed every five years.

Hevle: The goals included updating

the standard (last revised in 1992), clarify-

ing the CP criteria, and adding guidance

for special conditions such as alternating

current (AC) corrosion, MIC, dissimilar

metals, and high temperature. Other

sections needed updates, as technology

has changed in the last 20 years.

MP: What are the major changes made

during the latest revision?

Lauber: Without question, I believe

the criteria section has seen the most

significant changes. The definitions

section and coatings references have also

been expanded greatly. Additionally, infor-

mation on criteria and cautionary notes

was enhanced for special conditions such

as high-resistivity soils, MIC, high pH, and

high-temperature environments.

Chmilar: The major changes were in

Section 5 and Section 6 plus the addition

of abbreviations and acronyms to an

updated definitions section. In Section

5 on external coatings, there was signifi-

cant work done to upgrade and update

the standards lists with the addition of

numerous coating types and a table for

Norm Moriber

Norm Moriber is

chief engineer for

Mears Group, In-

tegrity Solutions

Division, in San

Ramon, California.

He is a graduate of

the Massachusetts

Institute of Technology and a Registered

Professional Corrosion Engineer in Califor-

nia with more than 40 years of experience

in the corrosion control industry. His areas

of specialization include CP design and

evaluation; external corrosion direct assess-

ment, focusing on cased piping; and stray

current evaluation and mitigation. He has

served on the NACE International Board

of Directors, as chair of the Public Affairs

Administrative Committee, has been a

member of the Materials Performance Edi-

torial Advisory Board since 2001, and is now

a technical editor for MP. He is a member

of TG 360 and has chaired Technology

Exchange Group (TEG) 179X, Cathodic

Protection, since 2004.

27MATERIALS PERFORMANCE AUGUST 2014 NACE INTERNATIONAL: VOL. 53, NO. 8


FEATURE ARTICLE

ductile iron, plus additional references

in Appendix A. In Section 6, there was a

restructuring of the stated criteria and the

addition of stainless steel (SS) pipe as a

pipe class. There are Special Conditions

and Relevant Considerations listed in

Section 6 that deal with issues such as

MIC; elevated temperatures; high-resis-

tivity electrolyte; mill scaled steel; mixed

metal piping; high-voltage AC (HVAC);

weak acid environments; stress corrosion

cracking (SCC); hydrogen embrittle-

ment (HE) and blistering; and electrical

shielding. There is now a figure showing

corrosion rates as a function of AC with

CP current densities and a figure on SCC

range. There is now a statement that

potential measurements related to criteria

are intended to be made at 25 C (77 F)

and a table for correction factors where

reference electrodes are not within 10 C of

25 C. There are eight pages of references

and a bibliography where more detailed

information can be located. There is now

an Appendix B, Review of International

Standards, which is a summary of inter-

national and country standards as they

relate to CP criteria.

Hevle: Many needed changes were

made, and all the sections were updated.

The most controversial change was made

to the CP potential criteria section on

how voltage drop errors are addressed.

Previous versions of this standard had

a number of variations to the wording

regarding how these errors are to be

addressed. This version uses the original

language, consideration of the signifi-

cance of voltage drops.

Moriber: There has been a major focus

on the CP criteria for steel piping systems,

and that is an important part of SP0169;

however, it is by no means the only section

where critical upgrades have been accom-

plished. CP criteria for steel and gray or

ductile cast iron have been clarified and

greater flexibility is now available for

operators to make choices that will meet

their corrosion control objectives. New

sections have been added to address CP

for copper, aluminum, and SS, along with

cautions about additional requirements to

address specific conditions. These include

MIC, high temperatures, SCC, overpro-

tection and hydrogen evolution effects,

dissimilar metal piping systems, acidic

and high-resistivity environments, electri-

cal shielding, and AC corrosion. Because

this standard addresses corrosion control

rather than CP alone, the section on

protective coatings was greatly expanded

and updated. This includes the removal of

references to numerous obsolete coating

standards and the addition of modern

coatings for steel and ductile iron. Other

sections address a variety of reference

electrodes and temperature correction for

potential measurements. New appendixes

describe CP criteria and other features

contained in ISO and European standards

in addition to those used in six other

countries.

MP: Why are these changes significant?

Chmilar: The changes to the 2013

version are really a change from the last

major revision completed in1992 by

Kazmierczak and TG T-10-1. The changes

outlined in my previous answer provide

additional resource information and

the coating information has also been

updated. One general criteria statement

was added, but the 2007 criteria were not

changed other than combining two 850

mV criteria into one stated criterion. The

standard does not contain actual test

methods as there is a specific test method

(TM) for that purpose [TM0497-20122].

This TM was first issued in 1997 and

revised in 2012.

Hevle: The changes reflect the consen-

sus standard practices of the industry. In

many ways the standard has changed to

recognize new technologies. The provi-

sions of any standard must be applied by

competent persons, and it is impossible

to write a standard so inflexible that it

cannot be misapplied without compromis-

A CP technician checks the rectifier outputs for a cathodically protected pipeline. Photo courtesy of Mears Group, Inc.




ing technically sound applications.

Moriber: These additions and

updates restore one of NACEs signature

standards to the level of quality that the

world has come to expect of the leading

corrosion control organization. SP0169

now includes a wealth of new informa-

tion and references to related documents

that provide valuable guidance for those

responsible for pipeline integrity. This

standard will also be linked with the next

revision of TM0497, the TM standard that

will complement the clarifications to the

CP criteria. These documents, together

with the summaries of other internation-

ally recognized standards, will provide

options and flexibility that will allow

operators to customize the procedures for

achieving their corrosion control

objectives.

Lauber: I believe that the ambigu-

ity surrounding the 850 mV criteria in

the previous standard version has been

eliminated. The listed criteria calling for

a structure-to-electrolyte potential of

850 mV or more negative gives opera-

tors a roadmap that includes clear steps

that must be taken for interpretation if a

current-applied measurement is used.

MP: How will these changes impact

industry? How will they impact your

organization?

Hevle: Presently my organization

(Kinder Morgan Natural Gas Pipelines)

is not directly affected, because the U.S.

natural gas pipeline safety regulations do

not reference this standard, but indus-

try consensus standards are extremely

valuable. Standards codify and improve

industry practices and allow a common

language. They make pipelines safer and

more reliable by incorporating expertise

and experience from across the industry.

Standards reduce costs by

Documents

354215-AUG 2014