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Atmospheric Corrosion

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  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 RT’s • 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 RT’s 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 OCM’s, Corrosion FLL’s, FOL’s & RP’s • 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

  33. 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

  34. 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)

  35. 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 epoxyused - • Protal ST • Do not use polyethylene (extruded) coating - normally a yellow jacketed coating. Not approved for above ground use.

  36. Exposed Pipeline Evaluation Sheet

  37. 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.

  38. Exposed Pipeline Evaluation Sheet

  39. 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

  40. Exposed Pipeline Evaluation Sheet – cont.

  41. 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