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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
6 AUGUST 2014 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 53, NO. 8
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
August 2014 MP.indd 6 7/21/14 7:40 AM
http://www.deakin.edu.auhttp://www.inm-gmbh.dehttp://www.acs.orghttp://news.ncsu.eduhttp://dx.doi.org/10.5006/0976http://dx.doi.org/10.5006/0976
August 2014 MP.indd 7 7/21/14 7:42 AM
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
+1 281-228-6446
ASSISTANT SALES MANAGER Teresa Wright
+1 281-228-6472
ACCOUNT EXECUTIVES Erica R. Cortina
+1 281-228-6473
Brian Daley
+1 281-228-6455
Pam Golias
+1 281-228-6456
Jody Lovsness
+1 281-228-6257
Leslie Whiteman
+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
+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
8 AUGUST 2014 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 53, NO. 8
August 2014 MP.indd 8 7/21/14 7:42 AM
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August 2014 MP.indd 9 7/21/14 7:42 AM
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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
Continued on page 12
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
Continued from page 11
12 AUGUST 2014 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 53, NO. 8
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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).
13NACE INTERNATIONAL: VOL. 53, NO. 8 MATERIALS PERFORMANCE AUGUST 2014
August 2014 MP.indd 13 7/21/14 7:42 AM
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.
14 AUGUST 2014 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 53, NO. 8
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,
Continued on page 16
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.
15NACE INTERNATIONAL: VOL. 53, NO. 8 MATERIALS PERFORMANCE AUGUST 2014
Information on corrosion control and prevention
August 2014 MP.indd 15 7/21/14 7:42 AM
http://www.FarwestCorrosion.comhttp://www.FarwestCorrosion.com
Continued from page 15
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.
16 AUGUST 2014 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 53, NO. 8
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.
18 AUGUST 2014 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 53, NO. 8
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
Continued on page 20
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.
19NACE INTERNATIONAL: VOL. 53, NO. 8 MATERIALS PERFORMANCE AUGUST 2014
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
Continued from page 19
20 AUGUST 2014 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 53, NO. 8
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.
21NACE INTERNATIONAL: VOL. 53, NO. 8 MATERIALS PERFORMANCE AUGUST 2014
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.
22 AUGUST 2014 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 53, NO. 8
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].
23NACE INTERNATIONAL: VOL. 53, NO. 8 MATERIALS PERFORMANCE AUGUST 2014
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.
24 AUGUST 2014 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 53, NO. 8
Aug14_Feature.indd 24 7/21/14 1:01 PM
Updating NACE SP0169 for Controlling External Corrosion on Underground or Submerged Metallic Piping Systems
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
Aug14_Feature.indd 25 7/21/14 1:02 PM
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.
26 AUGUST 2014 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 53, NO. 8
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Updating NACE SP0169 for Controlling External Corrosion on Underground or Submerged Metallic Piping Systems
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
Aug14_Feature.indd 27 7/21/14 1:02 PM
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.
28 AUGUST 2014 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 53, NO. 8
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Updating NACE SP0169 for Controlling External Corrosion on Underground or Submerged Metallic Piping Systems
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