11 Corrosion Prevention of Steel Pipes 2012
Transcript of 11 Corrosion Prevention of Steel Pipes 2012
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Northwest Pipe CompanyNorthwest Pipe CompanyPresenter: Ronald S. BrownPresenter: Ronald S. Brown
Corrosion PreventionCorrosion Preventionfor Steel Water Pipefor Steel Water Pipe
Presented to: Presented to:
Water Wastewater SectionWater Wastewater SectionAUCSCAUCSC
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Steel Water PipeSteel Water PipeCorrosion PreventionCorrosion Prevention
Presentation OverviewPresentation Overview
History
Applications Steel Pipe Manufacturing
Pipe Coatings-Importance Corrosion Prevention, Asset Mgt.
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History and OverviewHistory and Overview
ApplicationsApplications
Water TransmissionWater Transmission
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Spiral welded pipeSpiral welded pipe–– 1717”” to 156to 156”” diameterdiameter
–– Lengths up to 60Lengths up to 60’’–– 0.1050.105”” to .875to .875”” wall thicknesswall thickness
Rolled & welded pipeRolled & welded pipe–– ≥≥4242”” X 2.0X 2.0””
Linings and coatingsLinings and coatings–– CML, epoxy, polyurethane, & paint systemsCML, epoxy, polyurethane, & paint systems–– CMC, CTE, tape, PritecCMC, CTE, tape, Pritec®®, epoxy, polyurethane, & paint, epoxy, polyurethane, & paint
End treatmentsEnd treatments–– Welded & nonWelded & non--welded gasket joints
History and OverviewHistory and Overview--
Manufacturing CapabilitiesManufacturing Capabilities
welded gasket joints
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History and OverviewHistory and Overview
ApplicationsApplications
GasketedGasketed jointjointWater transmission pipeWater transmission pipe
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History and OverviewHistory and Overview
ApplicationsApplications
Long SpansLong SpansPower PlantPower Plant
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History and OverviewHistory and Overview
ApplicationsApplications
Horizontal Directional DrillingHorizontal Directional Drilling
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Engineered SystemsEngineered Systems
Field fitField fit--upsups
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History and OverviewHistory and Overview
Secaucus NJ 72Secaucus NJ 72”” LockLock--Bar Pipe Bar Pipe –– 1919. (Riveted Pipe 1904)1919. (Riveted Pipe 1904)
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History and OverviewHistory and Overview
ApplicationsApplications
Sanitary Force mains with pushSanitary Force mains with push--on, on, restrained or flanged jointsrestrained or flanged joints
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Corrosion ProtectionCorrosion Protection
Polyurethane LiningPolyurethane Lining
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Steel BasicsSteel Basics
AWWA Standards ConformanceAWWA Standards Conformance
Steel water pipe per MSteel water pipe per M--11 Design Guide11 Design Guide–– C200C200----Manufacturing StandardManufacturing StandardFabrication/fittings Fabrication/fittings –– C208C208FlangesFlanges–– C207C207Linings & coatings :Linings & coatings : C205, C209, C210, C205, C209, C210, C214, C216, C218, C222C214, C216, C218, C222
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Design Design CriteriaCriteria
Welded Steel Pipe - AWWA C-200
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Northwest Pipe CompanyNorthwest Pipe Company
Pressure Class Pressure Class Design Design AWWA DESIGN GUIDEAWWA DESIGN GUIDE----MM--1111
1. Internal pressure1. Internal pressure2. Handling2. Handling3. External load3. External load4. Joints both push4. Joints both push--on and restrainedon and restrained5. Corrosion protection5. Corrosion protection
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SteelSteelNorthwest Pipe CompanyNorthwest Pipe Company
C200 Steel C200 Steel GradesGrades
Yield PointYield Pointpsipsi
30,000-70,00030,000-70,00035,000-52,00033,000-50,00036,000
ASTM A1011 GR 30-70ASTM A1018 GR 30-70ASTM A139 GR B,C,D,EASTM A570 GR 33-50ASTM A36
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Back to Basics of Design...Back to Basics of Design...
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Spiral Welded Pipe Spiral Welded Pipe PhotosPhotos
Rolled & Welded Pipe Rolled & Welded Pipe PhotoPhoto
Return to Engineered SystemsReturn to Engineered Systems
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Additional ServicesAdditional Services
Hydro TestingHydro TestingAWWA & ASTM AWWA & ASTM StandardsStandards–– 75% of yield of steel75% of yield of steel
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Engineered SystemsEngineered Systems
Joint SystemsJoint Systems
Typical Pipeline Joints
O-ring Joint Lap Joint
Butt Strap Joint Butt Weld Joint
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Engineered SystemsEngineered Systems
Joint SystemsJoint Systems
Bell and Spigot Lap WeldBell and Spigot Lap Weld
Used for higher pressures or other critical Used for higher pressures or other critical locationslocationsBell can be mitered for greater angular Bell can be mitered for greater angular deflectiondeflectionRestrained, providing economical thrust Restrained, providing economical thrust resistanceresistanceCan be welded ID or ODCan be welded ID or OD
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Engineered SystemsEngineered Systems
Joint SystemsJoint Systems
Bell and Spigot OBell and Spigot O--ringring
Economical pushEconomical push--together assemblytogether assemblySuitable for typical operating pressuresSuitable for typical operating pressuresCan accommodate some angular deflectionCan accommodate some angular deflectionNonNon--restrainedrestrainedRolled groove provides economyRolled groove provides economy
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Basic ConsiderationsBasic ConsiderationsCorrosion Control--Slow down rate--defined
service/design lifeCorrosion Protection /Prevention
Pipelines will operate indefinitely without failures from natural or manmade corrosive environments.
Protection of taxpayer and/or owner investment –ASSET MANAGEMENTThe pipeline will operate continuously for as long as needed with the lowest full life-cycle cost.
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Design CriteriaDesign Criteria
HowHow cancan wewe protectprotect ourour pipelinepipelineinfrastructureinfrastructure forfor 100100 plusplus yearyeardesigndesign lifelife? ?
HighHigh--quality coatingsquality coatingsElectrical continuityElectrical continuity——for gasket jointsfor gasket jointsTest stationsTest stationsCathodicCathodic protectionprotection-- Use an independent Use an independent NACE corrosion specialist who will follow NACE NACE corrosion specialist who will follow NACE SP0169 standardsSP0169 standardsISOLATIONISOLATION of dissimilar pipe systems if neededof dissimilar pipe systems if needed
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““Control of External Corrosion Control of External Corrosion on Underground oron Underground orSubmerged Metallic Piping Submerged Metallic Piping SystemsSystems””NACE Standard SP0169NACE Standard SP0169--20022002“This standard presents acknowledged practices for the control of external corrosion on buried or submerged steel, cast iron, ductile iron, copper, and aluminum piping systems.”
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Cathodic Protection Definition ( NACE
International )
“ A technique to reduce the corrosion of a metal surface by making that surface the cathode of an electrochemical cell ”
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Types of CathodicProtection
– Galvanic• Current supplied by metal more
anodic than the structure (pipe)
• Naturally occurring current flow– Impressed Current
• Current supplied by electrical device to convert AC to DC current
• Forced current flow--through rectifiers and groundbeds
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EXTERIOR COATINGSEXTERIOR COATINGS
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Expectations of a coatingExpectations of a coatingLong term protection from Corrosion, MIC, stray currentsTight bond to surface (adhesion)Ease of Installation/Maintenance or RepairCompatible with Cathodic ProtectionCost effective
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Design CriteriaDesign Criteria
Corrosion ProtectionCorrosion ProtectionCementitiousCementitious----CoatingsCoatings–– Raises pHRaises pHBonded Dielectric CoatingBonded Dielectric Coating–– Eliminates all corrosion including Stray Current Eliminates all corrosion including Stray Current
MigrationMigration–– Eliminates Oxygen & Water Eliminates Oxygen & Water
migration,eliminates corrosionmigration,eliminates corrosion
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Common Coatings Common Coatings seen in U.S.seen in U.S.
Dielectrics– PE Tape (80 mils)30”
up– Spray-applied Systems
• Polyurethane (25 mils)• Epoxies (16 mils)• Zinc (4 mils)
– Wax Tapes– Fusion Bond Epoxy (12
mils) API pipe—not avail for spiral weld pipe
– Coal Tar Enamel (3/32”)
Cement Mortar or grout (¾” thick)
Steel Water PipeSteel Water Pipe
Exterior CoatingsExterior Coatings
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Steel Water PipeSteel Water Pipe
Common AWWA StandardsCommon AWWA StandardsPipe CylinderPipe Cylinder••AWWA C200 AWWA C200 -- ManufactureManufacture••AWWA M11 AWWA M11 -- DesignDesignFlangesFlanges••AWWA C207AWWA C207WeldingWelding••AWWA C206AWWA C206FittingsFittings•AWWA C208
LiningsLinings••AWWA C205 AWWA C205 -- Cement MortarCement Mortar••AWWA C210 AWWA C210 -- EpoxyEpoxy••AWWA C602 AWWA C602 -- Field Applied MortarField Applied Mortar••AWWA C222 AWWA C222 -- PolyurethanePolyurethaneCoatingsCoatings••AWWA C203 AWWA C203 -- Coal Tar EnamelCoal Tar Enamel••AWWA C205 AWWA C205 -- Cement MortarCement Mortar••AWWA C209 AWWA C209 -- Joint Tape Joint Tape ••AWWA C210 AWWA C210 -- EpoxyEpoxy••AWWA C214 AWWA C214 –– TapeTape••AWWA C215 AWWA C215 -- PritecPritec••AWWA C216 AWWA C216 -- Heat Shrink SleevesHeat Shrink Sleeves••AWWA C218 AWWA C218 -- Exposed Paint SystemsExposed Paint Systems••AWWA C222 AWWA C222 -- PolyurethanePolyurethane
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Corrosion ProtectionCorrosion Protection
CoatingsCoatings----per AWWA Criteriaper AWWA Criteria
CementCement----C205C205
DielectricDielectric–– Bonded PE TapesBonded PE Tapes----
C214C214
–– Paint systemsPaint systems•• EpoxiesEpoxies--C210C210•• PolyurethanePolyurethane--C222C222
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C-210 16 mil 400 lb/sq in Vapor Trans RPO 188 1978C-213 12 mil Knife test NA RPO 490 1979C-214 50-80 mil 200 oz/in width 0.20% 6000 V min 1983C-215 49-69 mil NA 0.20% RPO 274 1988C-216 40-60 mil 8 lbs/lin in Vapor Trans Required 1989C-217 wax 40 mil NA Vapor Trans NA 1990C-218 3.5 -14 mil V cut NA NA 1991C-222 20-25 mil 750-2000 psi 3.00% RPO 188 1999C-224 nylon 24-40 mil 2000 psi 2.70% RPO 188 2001C-225 50-75 mil 32 ft lb/ in width0.20% RPO 188 2003
Diversity of Materials RequirementsDiversity of Materials Requirements
All above standards require a min SSPC SP 6 /NACE 3 blast All above standards require a min SSPC SP 6 /NACE 3 blast cleaningcleaning
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Familiar Knowledge ?Familiar Knowledge ?
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Field Joint Coating per Field Joint Coating per AWWA CAWWA C--205205
Assemble joint and pour soupy cement mixture from one side of diaper
Place diaper around pipe
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Expectations of a liningExpectations of a lining
Good Flow CharacteristicsProtects Pipe from Corrosion and AbrasionEase of Installation/MaintenanceCost effective
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Corrosion ProtectionCorrosion Protection
LiningsLinings
CementCementPaint systemsPaint systems–– EpoxiesEpoxies–– PolyurethanePolyurethane
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Steel Water PipeSteel Water Pipe
Interior LiningsInterior Linings
Cement Mortar LiningCement Mortar LiningStullsStulls used for used for shipping and handlingshipping and handlingJoint recess usually Joint recess usually pointedpointedEasily repaired and Easily repaired and modified in the Fieldmodified in the FieldLow CostLow Cost
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Interior Joint GroutingInterior Joint GroutingPack joint with
grout Remove excess grout
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Polyurethane coatingsPolyurethane coatings
AWWA C-22225 mils ThicknessExtremely abrasion resistantsensitive to blast and temperatureGood dielectric strengthMore costly
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Corrosion ProtectionCorrosion ProtectionPOLYURETHANE COATINGPOLYURETHANE COATING----AWWA C222AWWA C222
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Polyurethane Coating Polyurethane Coating RepairRepairAWWA CAWWA C--222 222
Repair coating if necessary
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PAINTED COATINGSPAINTED COATINGS
EpoxiesEpoxiesZinc Rich PaintsZinc Rich Paints
PrimersPrimers
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AWWA C214AWWA C214--Machine Applied Polyethylene Machine Applied Polyethylene TapeTape
PRIMERPRIMER
989 INNER LAYER
956 UVI OUTER LAYER956 UVI OUTER LAYER955 MIDDLE LAYER955 MIDDLE LAYER
YGIII® System ComponentsYGIIIYGIII® ® System ComponentsSystem Components
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Linings and CoatingsLinings and Coatings
Tape CoatingTape Coating
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Steel Water PipeSteel Water Pipe
Exterior CoatingsExterior Coatings
AWWA C214 TapeAWWA C214 Tape8080--mil, threemil, three--layer factory layer factory applied systemapplied systemEffective as dielectric Effective as dielectric coatingcoatingEase of field useEase of field use25+ year history in water 25+ year history in water industry ( 50 oil & gas) industry ( 50 oil & gas) Low CostLow Cost
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Advantages of Shop Applied Advantages of Shop Applied MultiMulti--Layered Coatings ,per Layered Coatings ,per AWWA C214AWWA C214
Proven long-term PerformanceHighest Dielectric StrengthWorld Class Coating SystemUtilized on High-Pressure Oil & Gas TMImpermeable to Oxygen & WaterLow Cathodic Protection Current RequirementsAdhesion to primed steel--exceeds 300 oz/inCathodic Disbondment Results G8--.25 in radiusEasily Repaired on the jobsite--with field tapePE backings--identical to landfill liners--
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Water AbsorptionASTM G-62
Water AbsorptionASTM G-62
0
0.5
1
1.5
2
2.5
3
% W
ater
Abs
orbe
d
Coal Tar Fused Epoxy YG-III0
0.5
1
1.5
2
2.5
3
% W
ater
Abs
orbe
d
Coal Tar Fused Epoxy YG-III
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Method of Delivery Method of Delivery Flat Bed TruckVans RailBarge
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Stringing/Storing PipeStringing/Storing Pipe
String pipe in accordance with the supplied lay diagram/schedulePlace pipe on dirt berms, padded boards, or sand bags
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PrePre--Installation Prep WorkInstallation Prep WorkInspect factory applied coating– Visual – Mechanically with Holiday testing
equipment– Repair all damage to coatings
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Polyethylene Coating RepairPolyethylene Coating RepairAWWA CAWWA C--209209
Repair coating if necessary
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Engineered SystemsEngineered Systems
Joint CompletionJoint Completion
Joint bonding– Gasketed joints– Electrical continuity– Allows monitoring– Provides for future CP
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Engineered SystemsEngineered Systems
Joint CompletionJoint Completion
HandHand--applied tapeapplied tapeHeatHeat--shrink sleeveshrink sleeve
Return to Engineered SystemsReturn to Engineered Systems
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Field Joint CoatingField Joint CoatingShrink Sleeves per AWWA Shrink Sleeves per AWWA CC--216216
Shrink Sleeves applied with propane torch
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Corrosion Protection Methods Corrosion Protection Methods in Any Soil Environmentin Any Soil Environment
GRADE
TEST BOX
ANODESPIPELINE
WELDED TO PIPETEST LEADS THERMITE
REFERENCE ELECTRODE
TERMINAL BOARD
CABLE SPLICEANODE HEADER
ANODE HEADERCABLE
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In-Ground PerformanceInIn--Ground PerformanceGround Performance
Bell hole examinationsBell hole examinationsno coating degradation no coating degradation
CP surveyCP survey2 to 6 2 to 6 µµA per ftA per ft22
> 99.95% coating efficiency> 99.95% coating efficiency
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Discussion PointsDiscussion Points
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Discussion PointsDiscussion Points
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Discussion PointsDiscussion Points
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Discussion PointsDiscussion Points
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Cost - to - Benefit Ratio
7 - to - 1
Save $7 for every $1spent
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PolywrapPolywrap not recommendednot recommended
••Not tightly BONDED to pipe Not tightly BONDED to pipe ••Easily damaged during installation Easily damaged during installation –– 8 mils8 mils••Does not prevent moisture (perforations and Does not prevent moisture (perforations and joint leakage) from forming corrosion cell.joint leakage) from forming corrosion cell.••CathodicCathodic ShieldingShielding••Encasement not a coatingEncasement not a coating••DOES NOT COMPLY WITH NACE SP01DOES NOT COMPLY WITH NACE SP01--6969--0202
Steel Water PipeSteel Water Pipe
Exterior CoatingsExterior Coatings
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Steel Water PipeSteel Water Pipe
Corrosion EngineeringCorrosion Engineering
Common Corrosion ProtectionCommon Corrosion ProtectionPractices for Buried PipePractices for Buried Pipe
Use highUse high--quality proven bonded coatingsquality proven bonded coatingsAssure electrical continuity with bonded joints or Assure electrical continuity with bonded joints or welding.welding.Install test stations for periodic monitoringInstall test stations for periodic monitoringUseUse cathodiccathodic protection as specified byprotection as specified by corrcorr. report. reportIsolate Pipelines as necessaryIsolate Pipelines as necessary
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Corrosion Prevention for Corrosion Prevention for Steel Water PipeSteel Water Pipe
Questions?Questions?