Title: Atmospheric Corrosion
1Atmospheric Corrosion
- NiSource
- Exposed pipelines
2Team Objectives
- Create a standardize process for identifying and
repairing atmospheric corrosion in the NiSource
system. - Standardize on the documentation
- Standardize on the repair methodology
- Standardize on the timeframe of execution
- Standardize on the data storage and collection
3Codes and Compliance of Atmospheric Corrosion
- DOT subpart I 192
- Revised on Atmospheric corrosion codes
- December 15, 2003
4Codes and Compliance of Atmospheric Corrosion
- DOT definition
- 192.461 External corrosion control Protective
coating - (a) Each external protective coating, whether
conductive or insulating, applied for the purpose
of external corrosion control must
5Codes and Compliance of Atmospheric Corrosion
- DOT definition (a) continue
- (1) Be applied on a properly prepared surface
- (2) Have sufficient adhesion to the metal surface
to effectively resist underfilm migration of
moisture - (3) Be sufficiently ductile to resist cracking
6Codes and Compliance of Atmospheric Corrosion
- DOT definition (a) continue
- (4) Have sufficient strength to resist damage
due to handling and soil stress - (5) Have properties compatible with any
supplemental cathodic protection. - (b) Each external protective coating which is an
electrically insulating type must also have low
moisture absorption and high electrical
resistance.
7Codes and Compliance of Atmospheric Corrosion
- DOT definition
- 192.479 Atmospheric Corrosion Control General
(Revised)
8Codes and Compliance of Atmospheric Corrosion
- DOT definition
- (a) Each operator must clean and coat each
pipeline or portion of pipeline that is exposed
to the atmosphere, except pipelines under
paragraph (c) of this section. - (b) Coating material must be suitable for the
prevention of atmospheric corrosion.
9Codes and Compliance of Atmospheric Corrosion
- (c) Except portions of pipelines in offshore
splash zones or soil to-air interfaces, the
operator need not protect from atmospheric
corrosion any pipeline for which the operator
demonstrates by test, investigation, or
experience appropriate to the environment of the
pipeline that corrosion will-- - (1) Only be a light surface oxide or
- (2) Not affect the safe operation of the pipeline
before the next scheduled inspection.
10- Metal loss Atmospheric Corrosion
- Rust(oxidation) non-Atmospheric Corrosion
11Codes and Compliance of Atmospheric Corrosion
- DOT definition
- 192.481 Atmospheric Corrosion Control
Monitoring. Revised
12Codes and Compliance of Atmospheric Corrosion
- DOT definition
- (a) Each operator must inspect each pipeline or
portion of pipeline that is exposed to the
atmosphere for evidence of atmospheric corrosion,
as follows each operator shall, - at intervals not exceeding 3 years for onshore
pipelines not to exceed 39 months, - at least once each calendar year, but with
intervals not exceeding 15 months, for offshore
pipelines,
13Codes and Compliance of Atmospheric Corrosion
- DOT definition
- (b) During inspections the operator must give
particular attention to pipe at soil-to-air
interfaces, under thermal insulation, under
disbonded coatings, at pipe supports, in splash
zones, at deck penetrations, and in spans over
water.
14Codes and Compliance of Atmospheric Corrosion
- DOT definition
- (c) If atmospheric corrosion is found during an
inspection, the operator must provide protection
against the corrosion as required by Sec.
192.479.
15Phases
- Phase One
- Corrosion personnel communicates with Leakage
Inspector in order to Document all Exposed
Pipelines - Exposed Pipelines Evaluation sheet Used
- Corrosion Personnel visits sites of exposed
pipelines to confirm condition for proper
documentation - Corrosion Personnel hands off to Appointed
Clerical personnel for Database entry (Vicki
Tehan). - Corrosion Personnel will be required to Check off
on Exposed Pipelines Inspection Sheet once every
three years.
16Phases
- Phase Two
- All Information Collected entered on Data Base
System (Common MRC Drive) - Information Entered by Location Number or by
State/City - Excel Spread Sheet Used Exposed Pipeline
Evaluation - Corrosion Personnel Identifies Areas of
Atmospheric Corrosion Based on Data Collected - Target Set for Remedial Action to be Taken
- 33 each year
- 100 Completed within a Three Year Timeframe
- Communication to Operational Center of Status and
Goal
17Phases
- Phase Three
- Corrosion Personnel works with the operational
center as an adviser to assure quality of work in
the remedial process - May require for the Corrosion Personnel to fill
in as Contract Inspector - Corrosion personnel will specify the material to
be used on the pipeline for proper repair
methodology - Corrosion Personnel Updates on Standard form
Evaluation of Exposed Pipelines updated on
Network Common Drive (MRC) - Corrosion FLL evaluates data base system for
status on target goals, once a year
18Process Map of Exposed Pipelines Atmospheric
Corrosion
19Process Map cont.
- A developed program
- Standardize
- DOT compliance
- PUC compliance
- Policy and Procedure compliance
- Best Practice
- Cost Effective
What is the Atmospheric Corrosion Program ????
20Process Map cont.
- Create Exposed Pipeline Evaluation
- Communicate with Leakage for Data input
- Create book or binder for data information
- Create RTs
- Make copies of inventory maps, store maps into
binder (highlight areas of exposure)
What is the Atmospheric Corrosion Program ????
21Process Map cont.
- Inspection performed by Leakage program
- Normal Program Timeframes
- Check for Status Change on Pipeline in
comparison to last inspection by use of Exposed
Pipeline Evaluation sheet
22Process Map cont.
- Inspection performed by Corrosion personnel
every three years not to exceed 39 months - RT Created for sections or segment of pipeline
(33 of total area per RT) - Job Type 2312 Maintenance of Mains
- 33 goal set up per year, 3 RTs per Area
- Update Exposed Pipeline Evaluation Sheet (per
RT)
23Process Map cont.
- Visual Inspection Performed
- Coating Damage
- Pipe Support Damage
- Corrosion/Pitting
24Process Map cont.
- Corrosion/Leakage Inspector Documents on
Standard Form of Visual Inspection - Exposed Pipelines Evaluation Form Used
- Identifies Specific Areas of Atmospheric
Corrosion - Identifies Inspector
- Meets the DOT Compliance for 3 yr Interval
survey
25Process Map cont.
- Leakage inspector hands off to Corrosion
personnel of any updated status of exposed
pipeline - Corrosion Personnel will hand off to appointed
clerical for data base entry (Vicki Tehan)
26Process Map cont.
- Common MRC Drive used
- Installed by Location number or state/city
- Entered by Clerical help
- Accessible by MRC staff
- FLL checks Status annually
27Process Map cont.
- If Further Action is Required
- Corrosion Personnel will need to create a
further action job order (2312 job type) for
remedial action to be taken - Job order needs to be updated with commit date
and with specific target dates
28Process Map cont.
- Corrosion Personnel recommends Corrosion
materials to be used - Corrosion Personnel to assist Operations
centers in coordinating repairs - Contacting OCMs, Corrosion FLLs, FOLs
RPs - Communicates status of Exposed pipelines
needing remedial action for budgeting - Setting up timeframes for work completion
- May need to follow up for QA
29Process Map cont.
- After Completion of Work on Exposed Pipeline -
Repeat Process - Corrosion Personnel Performs a Final
evaluation of Pipeline - Positive Documentation on Exposed Pipeline
Evaluation form to be entered on Common MRC drive
30Generalized Corrosion
- If any pipeline identified with atmospheric
corrosion will need to be evaluated for the
severity of the corrosion. (Generalized or
Localized) - If Corrosion Personnel determines pipeline as
Generalized Corrosion, the section will need to
be replaced or repaired before any coating
application. - Snap Wraps or Clock Springs could be
considered as a repair method.
31Generalized Corrosion - Definition
- Generalized Corrosion
- Pipe wall less than 30
- Place a clamp onto the pipe, it will crush the
pipe - Wall thickness less than required for the Maximum
Allowable Operating Pressure
32Repairing Generalized Corrosion
- Best practice
- Snap Wrap application
- Max 20 SYMS
- Max 500lbs pressure
- Minimum Wall thickness no less than 10
- Cost about 300.00 to 400.00 per kit
- Shelve life, normally a year
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39Snap Wrap Application
- Give 12 hours for setting up
- Manufacture recommends 4 hours
- Remove the metal bands
- Coat with epoxy paint to prevent damage from the
UV rays - Applicable for underground use
40Coating Application
- For Bridge crossings (Recommendation)
- For New or Replacement applications
- Pipeline - use Power Crete coated pipe for extra
UV protection, Option - Fusion Bonded Epoxy
min.40 mil thickness - Joints Use Protal 7200 on replacements, Protal
ST for repairs - Supports - insulated and coated with the Protal
7200 - Urethane coating shall be applied for extra UV
protection for all application (can be requested
at the pipe coating mill)
41Coating Application
- For Bridge crossings
- (Recommendation)
- For Repair Application
- Cold Applied Tapes Used
- Wax Tapes
- Petrolatum Tapes with the PVC outer wrap
- Two part liquid epoxy used -
- Protal ST
- Do not use polyethylene (extruded) coating -
normally a yellow jacketed coating. Not approved
for above ground use.
42Exposed Pipeline Evaluation Sheet
43Information Required
- RT Number
- RT number created, three total for each area, 33
of workload per RT. - Location area, city, map , and town
- Street Location Needed or Intersecting Streets,
add specific additional information for location
of pipeline.
44Exposed Pipeline Evaluation Sheet
45Information Required
- Pipe Diameter
- Measured in Inches
- Length
- Total length of exposure measured in feet
- Hangers, Rollers and Shields
- Total number of each if applicable
- Comments of pipeline surface and coating
- Over the entire exposure with particular
attention to the soil to air interfaces, deck
penetrations, and supports -
46Exposed Pipeline Evaluation Sheet cont.
47Information Required
- Atmospheric Corrosion (Y or N)
- We want to identify if metal loss has taken
place. - Remedial Job Orders
- Remedial job order Job order number.
- Target Date Date set to make repairs.
- Corrosion Technician initials and date
- Corrosion technician initials and documents the
date of the inspection