Atmospheric Corrosion NiSource Exposed pipelines.

Atmospheric Corrosion

NiSourceExposed pipelines

Team Objectives Create a standardize process for

identifying and repairing atmospheric corrosion in the NiSource system. Standardize on the documentation Standardize on the repair methodology Standardize on the timeframe of

execution Standardize on the data storage and

collection

DOT subpart I 192DOT subpart I 192 Revised on Atmospheric corrosion

codes December 15, 2003

Codes and Compliance of Atmospheric Corrosion


DOT definitionDOT definition – – 192.461 External corrosion control:

Protective coating (a) Each external protective coating,

whether conductive or insulating, applied for the purpose of external corrosion control must–


DOT definition –DOT definition – (a) continue (1) Be applied on a properly prepared

surface; (2) Have sufficient adhesion to the

metal surface to effectively resist underfilm migration of moisture;

(3) Be sufficiently ductile to resist cracking;


DOT definitionDOT definition – (a) continue (4) Have sufficient strength to resist

damage due to handling and soil stress; &

(5) Have properties compatible with any supplemental cathodic protection.

(b) Each external protective coating which is an electrically insulating type must also have low moisture absorption and high electrical resistance.


DOT definition –DOT definition – 192.479 Atmospheric Corrosion

Control: General (Revised)


DOT definitionDOT definition – – (a) Each operator must clean and coat each pipeline or portion of pipeline that is exposed to the atmosphere, except pipelines under paragraph (c) of this section.

(b) Coating material must be suitable for the prevention of atmospheric corrosion.

(c) Except portions of pipelines in offshore splash zones or soil to-air interfaces, the operator need not protect from atmospheric corrosion any pipeline for which the operator demonstrates by test, investigation, or experience appropriate to the environment of the pipeline that corrosion will--

(1) Only be a light surface oxide; or (2) Not affect the safe operation of the pipeline before the next scheduled inspection.


Metal loss – Metal loss – Atmospheric Atmospheric CorrosionCorrosion

Rust(oxidation) – Rust(oxidation) – non-Atmospheric non-Atmospheric CorrosionCorrosion


DOT definition –DOT definition – 192.481 Atmospheric Corrosion

Control : Monitoring. Revised


DOT definitionDOT definition – – (a) Each operator must inspect each pipeline

or portion of pipeline that is exposed to the atmosphere for evidence of atmospheric corrosion, as follows: each operator shall,

at intervals not exceeding 3 years for onshore pipelines not to exceed 39 months,

at least once each calendar year, but with intervals not exceeding 15 months, for offshore pipelines,

DOT definition –DOT definition – (b) During inspections the operator must

give particular attention to pipe at soil-to-air interfaces, under thermal insulation, under disbonded coatings, at pipe supports, in splash zones, at deck penetrations, and in spans over water.


DOT definition –DOT definition – (c) If atmospheric corrosion is found during

an inspection, the operator must provide protection against the corrosion as required by Sec. 192.479.


Phases Phase One –

Corrosion personnel communicates with Leakage Inspector in order to Document all Exposed Pipelines

Exposed Pipelines Evaluation sheet Used Corrosion Personnel visits sites of exposed pipelines

to confirm condition for proper documentation Corrosion Personnel hands off to Appointed Clerical

personnel for Database entry (Vicki Tehan). Corrosion Personnel will be required to Check off on

Exposed Pipelines Inspection Sheet once every three years.

Phase Two – All Information Collected entered on Data Base

System (Common MRC Drive) Information Entered by Location Number or by

State/City Excel Spread Sheet Used – Exposed Pipeline

Evaluation Corrosion Personnel Identifies Areas of Atmospheric

Corrosion Based on Data Collected Target Set for Remedial Action to be Taken

33% each year 100% Completed within a Three Year Timeframe Communication to Operational Center of Status and Goal

Phases

Phase Three Corrosion Personnel works with the operational

center as an adviser to assure quality of work in the remedial process

May require for the Corrosion Personnel to fill in as Contract Inspector

Corrosion personnel will specify the material to be used on the pipeline for proper repair methodology

Corrosion Personnel Updates on Standard form Evaluation of Exposed Pipelines updated on Network Common Drive (MRC)

Corrosion FLL evaluates data base system for status on target goals, once a year

Phases

Process Map of Exposed Pipelines – Atmospheric Corrosion

A tm o s ph e ric C o rro s io nPro g ra m

I n s pe ct io n Po s it iv eD o cu m e n ta t io n

Rep

ortin

g

D a ta ba s e /I n fo rm a t io nco lle ct io n

R e m e dia l A ct io nTa k e n

A tm o s ph e ricco rro s io nPre s e n t

Y ES

FU

RT

HE

R A

CT

ION

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?

Process Map – cont.


• A developed programA developed program

• Standardize Standardize

• DOT complianceDOT compliance

• PUC compliancePUC compliance

• Policy and Procedure Policy and Procedure compliancecompliance

• Best PracticeBest Practice

• Cost EffectiveCost Effective

What is the Atmospheric Corrosion Program ????



• Create Exposed Pipeline Create Exposed Pipeline EvaluationEvaluation

• Communicate with Leakage Communicate with Leakage for Data input for Data input

• Create book or binder for Create book or binder for data informationdata information

• Create RT’sCreate RT’s

• Make copies of inventory Make copies of inventory maps, store maps into binder maps, store maps into binder (highlight areas of exposure)(highlight areas of exposure)

What is the Atmospheric Corrosion Program ????

I n s pe ct io n• Inspection performed Inspection performed by by Leakage programLeakage program

Normal Program Normal Program TimeframesTimeframes

Check for Status Check for Status Change on Pipeline in Change on Pipeline in comparison to last comparison to last inspection by use of inspection by use of Exposed Pipeline Exposed Pipeline Evaluation sheetEvaluation sheet


I n s pe ct io n

• Inspection performed by Inspection performed by Corrosion personnelCorrosion personnel every three every three years not to exceed 39 monthsyears not to exceed 39 months

RT Created for sections or RT Created for sections or segment of pipeline (33% of segment of pipeline (33% of total area per RT)total area per RT)

Job Type 2312 Maintenance of Job Type 2312 Maintenance of MainsMains

33% goal set up per year, 33% goal set up per year, 3 3 RT’s per AreaRT’s per Area

Update Exposed Pipeline Update Exposed Pipeline Evaluation Sheet (per RT)Evaluation Sheet (per RT)


I n s pe ct io n• Visual Inspection Visual Inspection PerformedPerformed

Coating DamageCoating Damage

Pipe Support Damage Pipe Support Damage

Corrosion/PittingCorrosion/Pitting



Po s it iv eD o cu m e n ta t io n

• Corrosion/Leakage Corrosion/Leakage InspectorInspector Documents on Documents on Standard Form of Visual Standard Form of Visual Inspection Inspection

• Exposed Pipelines Evaluation Exposed Pipelines Evaluation Form UsedForm Used

Identifies Specific Areas Identifies Specific Areas of Atmospheric Corrosionof Atmospheric Corrosion

Identifies InspectorIdentifies Inspector

Meets the DOT Meets the DOT Compliance for 3 yr Interval Compliance for 3 yr Interval surveysurvey


Rep

orting

• Leakage inspectorLeakage inspector hands off to Corrosion hands off to Corrosion personnel of any updated personnel of any updated status of exposed pipelinestatus of exposed pipeline

• Corrosion PersonnelCorrosion Personnel will hand off to appointed will hand off to appointed clerical for data base entry clerical for data base entry (Vicki Tehan)(Vicki Tehan)


D a ta ba s e /I n fo rm a t io nco lle ct io n

• Common MRC Drive Common MRC Drive usedused

Installed by Installed by Location number or Location number or state/citystate/city

• Entered by Clerical Entered by Clerical helphelp

• Accessible by MRC Accessible by MRC staffstaff

• FLL checks Status FLL checks Status annually annually


FU

RT

HE

R A

CT

ION

??

?

• If Further Action is RequiredIf Further Action is Required

Corrosion Personnel will Corrosion Personnel will need to create a further need to create a further action job order (2312 job action job order (2312 job type) for remedial action to type) for remedial action to be takenbe taken

Job order needs to be Job order needs to be updated with commit date updated with commit date and with specific target and with specific target datesdates

A tm o s ph e ricco rro s io nPre s e n t


R e m e dia l A ct io nTa k e n

• Corrosion Corrosion Personnel recommends recommends Corrosion materials to be usedCorrosion materials to be used

• Corrosion Personnel to assist Corrosion Personnel to assist Operations centers in coordinating Operations centers in coordinating repairs repairs

Contacting OCM’s, Corrosion Contacting OCM’s, Corrosion FLL’s, FOL’s & RP’sFLL’s, FOL’s & RP’s

Communicates status of Communicates status of Exposed pipelines needing Exposed pipelines needing remedial action for budgetingremedial action for budgeting

Setting up timeframes for work Setting up timeframes for work completion completion

May need to follow up for QAMay need to follow up for QA


R E P E A T P R O C E S S

A F TE R C O M P L E T IO N O F

W ORK

• After Completion of Work After Completion of Work on Exposed Pipeline - Repeat on Exposed Pipeline - Repeat ProcessProcess

Corrosion Personnel Corrosion Personnel Performs a Final evaluation Performs a Final evaluation of Pipelineof Pipeline

Positive Documentation Positive Documentation on Exposed Pipeline on Exposed Pipeline Evaluation form to be Evaluation form to be entered on Common MRC entered on Common MRC drivedrive

Generalized Corrosion

If any pipeline identified with atmospheric If any pipeline identified with atmospheric corrosion will need to be evaluated for the corrosion will need to be evaluated for the severity of the corrosion. (Generalized or severity of the corrosion. (Generalized or Localized)Localized)

If Corrosion Personnel determines If Corrosion Personnel determines pipeline as Generalized Corrosion, the pipeline as Generalized Corrosion, the section will need to be replaced or section will need to be replaced or repaired before any coating application.repaired before any coating application.

Snap Wraps or Clock Springs could Snap Wraps or Clock Springs could be considered as a repair method. be considered as a repair method.

Generalized Corrosion - Definition Generalized Corrosion –

Pipe wall less than 30% Place a clamp onto the pipe, it will

crush the pipe Wall thickness less than required for

the Maximum Allowable Operating Pressure

Repairing Generalized Corrosion Best practice

Snap Wrap application Max – 20% SYMS Max – 500lbs pressure Minimum – Wall thickness – no less than

10% Cost about $300.00 to $400.00 per kit Shelve life, normally a year

Snap Wrap Application Give 12 hours for setting up

Manufacture recommends 4 hours Remove the metal bands Coat with epoxy paint to prevent

damage from the UV rays Applicable for underground use

Coating Application For Bridge crossings

(Recommendation) For New or Replacement applications –

Pipeline - use Power Crete coated pipe for extra UV protection, Option - Fusion Bonded Epoxy min.40 mil thickness

Joints – Use Protal 7200 on replacements, Protal ST for repairs

Supports - insulated and coated with the Protal 7200

Urethane coating shall be applied for extra UV protection for all application (can be requested at the pipe coating mill)

Coating Application For Bridge crossings (Recommendation)

For Repair Application Cold Applied Tapes Used –

o Wax Tapes o Petrolatum Tapes with the PVC outer wrap

Two part liquid epoxy used - Protal ST

Do not use polyethylene (extruded) coating - normally a yellow jacketed coating. Not approved for above ground use.

Exposed Pipeline Evaluation Sheet

RT#

Area

City

Specific Location of Exposure

Pipe Exposure Sheet

Map#

Town

Information Required RT Number

RT number created, three total for each area, 33% of workload per RT.

Location – area, city, map #, and town Street Location Needed or Intersecting Streets, add

specific additional information for location of pipeline.

Exposed Pipeline Evaluation Sheet

Pipe Diameter Length Hangers RollersInches FT No. No.

Shields

Comments on Pipline Surface & Coating- Soil Air Interface, Deck Penetrations and at Pipe Supports

No.

Pipe Diameter Measured in Inches

Length Total length of exposure measured in feet

Hangers, Rollers and Shields Total number of each if applicable

Comments of pipeline surface and coating Over the entire exposure with particular attention to

the soil to air interfaces, deck penetrations, and supports

Information Required

Exposed Pipeline Evaluation Sheet – cont.Atm. Corro

Yor N

Additional Comments

Corr. Tech.

InitialsDateRemedial Job Orders

Target Dates

Atmospheric Corrosion (Y or N) We want to identify if metal loss has taken place.

Remedial Job Orders Remedial job order – Job order number. Target Date – Date set to make repairs.

Corrosion Technician initials and date Corrosion technician initials and documents the date

of the inspection

Information Required

Atmospheric Corrosion NiSource Exposed pipelines.

Documents

Transcript of Atmospheric Corrosion NiSource Exposed pipelines.