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Atmospheric Corrosion

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Atmospheric Corrosion NiSource Exposed pipelines Team Objectives Create a standardize process for identifying and repairing atmospheric corrosion in the NiSource system. – PowerPoint PPT presentation

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Title: Atmospheric Corrosion


1
Atmospheric Corrosion
  • NiSource
  • Exposed pipelines

2
Team 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

3
Codes and Compliance of Atmospheric Corrosion
  • DOT subpart I 192
  • Revised on Atmospheric corrosion codes
  • December 15, 2003

4
Codes 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

5
Codes 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

6
Codes 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.

7
Codes and Compliance of Atmospheric Corrosion
  • DOT definition
  • 192.479 Atmospheric Corrosion Control General
    (Revised)

8
Codes 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.

9
Codes 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

11
Codes and Compliance of Atmospheric Corrosion
  • DOT definition
  • 192.481 Atmospheric Corrosion Control
    Monitoring. Revised

12
Codes 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,

13
Codes 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.

14
Codes 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.

15
Phases
  • 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.

16
Phases
  • 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

17
Phases
  • 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

18
Process Map of Exposed Pipelines Atmospheric
Corrosion
19
Process Map cont.
  • A developed program
  • Standardize
  • DOT compliance
  • PUC compliance
  • Policy and Procedure compliance
  • Best Practice
  • Cost Effective

What is the Atmospheric Corrosion Program ????
20
Process 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 ????
21
Process 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

22
Process 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)

23
Process Map cont.
  • Visual Inspection Performed
  • Coating Damage
  • Pipe Support Damage
  • Corrosion/Pitting

24
Process 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

25
Process 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)

26
Process 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

27
Process 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

28
Process 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

29
Process 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

30
Generalized 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.

31
Generalized 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

32
Repairing 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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39
Snap 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

40
Coating 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)

41
Coating 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.

42
Exposed Pipeline Evaluation Sheet
43
Information 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.

44
Exposed Pipeline Evaluation Sheet
45
Information 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

46
Exposed Pipeline Evaluation Sheet cont.
47
Information 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
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