/ Hart Energy Publishing, LP Official Show Daily Publisher of the NACE CORROSION 2008 Conference & Expo

New OrleansNew OrleansNew OrleansNACE International - Leaders in Corrosion Technology Preview

By Monique A. Hitchings, Editor-in-Chief, FUEL

NACE is an organization particularly near and dearto outgoing President Lou Vincent, who feels

global issues are of particular importance to thisyear’s show.

The NACE CORROSION 2008 programs at the topof his list as far as importance, are the MarineCoatings Forum, a joint meeting with the AustralasianCorrosion Association (ACA) and the WorldCorrosion Organization (WCO) meeting.

“The top program item would be the MarineCoatings Forum, since it brings together expertsfrom around the world to discuss the impact of theIMO [International Maritime Organization] BallastTank Regulations and how to best meet those chal-lenges for shipyards and coatings manufacturers.

“Another important session will be a joint meet-ing between the ACA and NACE as they worktogether to bring forward a state-of-the-art concretemaintenance course.

“The WCO meeting is very important as we workjointly with other societies to spread the knowl-edge of means to combat corrosion of our struc-tures, both industrial and marine.”

And keeping with the global theme of his toppicks for this year’s convention, Vincent hopes ifthere is one lesson attendees walk away with it’s“that corrosion is a global issue and must be dealtwith from a global perspective, rather than a

parochial perspective,” hesaid. “The work of the WCO isa pivotal point in achievingthe recognition of the perva-sive nature of corrosion.”

NACE is an organizationthat thrives on educationand awareness – bringingopportunities and informa-tion to people, companies

and organizat ions around the world to helpbecome better informed about corrosion, its causesand ways to stop it.

So when asked what the one area he’s seen growthe most during the past year and why, here’s whatVincent had to say.

“That one is easy. It is our education courses. Thereason is quite simple; industry throughout the world

‘Corrosion is a Global Issue’2007-2008 NACE President Lou Vincent may be leaving his post at midnight Thursday, but he’s got a couple of things on his mind and plate to sharebefore he does.

See GLOBAL continued on page 10 >>

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Plenary Lecture toDiscuss LessonsLearned withGlobalization ofStandardsSpeaker James Skogsberg will describe thenumerous years of effort that have gone intobringing cooperative international guidelines topublications and the lessons learned that can beapplied to future efforts.

Now-retired, James Skogsberg, who will speakduring Monday’s 8 a.m. Plenary Lecture, began

his 31-year career of materials engineering forupstream and downstream operations withinChevron in the corporate materials and corrosiongroup in 1975.

“I was pursuing a Masters degree of MaterialsScience at The Ohio State University,” Skogsbergsaid. “My thesis advisor, Dr. Roger Staehle, wouldhold regular seminars at his home, which involved

By Monique A. Hitchings, Editor-in-Chief, FUEL

See PLENARY continued on page 7 >>

Lou Vincent

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CORROSION 2008 Conference & Expo. The

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NACE SHOW DAILY ★ Preview • March 16-17

Sunday, March 167:30 a.m. to 6:30 p.m. Registration

Lobby B

8 a.m. to 5:30 p.m. NACE Bookstore

B2-1

8 a.m. 13th Annual NACE Race

Audubon Park

9:45 a.m. to 5 p.m. International Marine Coatings Forum

Room 220

5 to 6 p.m. The Technically “Cool” Event

Hilton New Orleans Riverside

Third Level, Napoleon Ballroom

5:30 to 7 p.m. Welcome Reception

Hilton New Orleans Riverside

First Level, Grand Ballroom

Monday, March 177:30 a.m. to 7 p.m. Registration

Lobby B

7 to 8 a.m. Women in Corrosion Breakfast

Room 211

8 a.m. – 5:30 p.m. NACE Bookstore

B2-1

8 to 8:45 a.m. Corrosion & Punishment Forum: Can you

be Held Legally Responsible?

La Louisiane Ballroom A

9 to 11:30 a.m. Nuclear Coating Inspector Forum

Room 210

9:30 to 11:30 a.m. NACE Jeopardy

Room 219

1 to 3:30 p.m. Bridge Painting:

The Usual to the Unusual

Room 210

1 to 4 p.m. Career & Employment Fair

Lobby A

4 to 5:30 p.m. NACE Student Meeting

Generation Y: A Younger Perspective on

the Corrosion Industry

Room 219

5:30 to 7 p.m. Expo Grand Opening

Exhibit Halls A/B

8 to 11 p.m. Generation Next: Movers and Shakers

Mix ‘n’ Mingle Party

Lucy’s Retired Surfers Bar and

Restaurant (I.D. Required)

701 Tchoupitoulas St. (walking distance

from the convention center)

Tuesday, March 187:30 a.m. to 5:30 p.m. Registration

Lobby B8 a.m. to 5:30 p.m. NACE Bookstore

B2-1 8 to 9 a.m. And They All Come Tumbling Down:

Anatomy of Bridge FailureRoom R04

8 to 10:30 a.m. Front Page IssuesR09Session 1—HR 1770 Corrosion Prevention Act of 2007Session 2—Fueling the Future

8:30 to 10:30 a.m CIP Open Forum—Technology Update:Surface Preparation for ProtectiveCoatingsRoom 213

10 a.m. to 5 p.m. Exhibit10:30 to 11:15 a.m. CORROSION 2008 Keynote Speaker:

Buzz AldrinAchieving the Impossible: Yesterday,Today, and TomorrowB2-2

11:30 a.m. Whitney Award LectureCorrosion from the Nanoscale to the PlantRoom 220

1:30 to 3:30 p.m. Pipeline and Hazardous Material SafetyAdministration ForumRoom R04

7 p.m. Cocktails— One Groovy Night, Part Deux8 p.m. Show Hilton New Orleans Riverside, First Level,

Grand Ballroom

Wednesday, March 197:30 a.m. – 5:30 p.m. Registration

Lobby B10 a.m. to 5 p.m. Exhibit8 a.m. to 5:30 p.m. NACE Bookstore

B2-1 11:15 a.m. Speller Award Lecture

Practical Corrosion Prediction—Developing and Applying TechnologiesRoom 220

7:30 p.m., 6:30 Reception Annual Awards DinnerHilton New Orleans Riverside, First Level,Grand Ballroom

Thursday, March 207:30 a.m. to 2 p.m. Registration

Lobby B8 a.m. to Noon NACE Bookstore9 a.m. to Noon Exhibit Hall

March 16-20, 2008NACE CORROSION 2008

Conference & ExpoNew Orleans, LA

SCHEDULE OF EVENTS2008 CO N F E R E N C E & EX P O

NACE CORROSION 2008Ernest N. Morial Convention Center

New Orleans, March 16-20All events to be held in the Convention Center unless otherwise noted

Bidding in the Big EasyMonday to Wednesday

Halls A/B, Center Lounge

Support the NACE Foundation at the 4th Annual Silent Auction, newly expanded toinclude signed sports and celebrity memorabilia. Items will be on display in the exhibithall and bidding will be open during Expo hours until Wednesday at 1 p.m. Check outfor successful bidders will be between 2 and 4 p.m. on Wednesday.

4 March 16-17 • Preview ★ NACE SHOW DAILY

By Bruce Beaubouef, PH.D., Editor, PipeLine Gas and Technology

Corrosion-related pipeline failures have been innews headlines in recent years, and now the

U.S. government is holding individual personnel,including management, non-management and tech-nical personnel, criminally responsible for notensuring safe operation of pipelines. These issuescontinue to be of interest to the industry, regulatorsand the public at large.

To provide an update on integrity managementand regulatory matters, NACE CORROSION 2008will again host a forum on Corrosion & Punishment:Can you be Held Legally Responsible? from 8 to8:45 a.m. Monday.

Following the success of last year’s forum, NACEfelt it was imperative to bring back John Clayton ofJackson & Walker and Kevin Garrity of CCTechnologies to discuss the legal issues surroundingpipeline failures.

A key portion of the discussion will focus on theimpact of the PIPES Act, where responsibility isclearly placed on the senior leadership within opera-tor companies. The panel will discuss the role of thecorrosion professional in ensuring pipeline integrityand the potential liability.

Key points of discussion will include: • How does the PIPES Act affect operator responsi-

bility, legal and otherwise?• How do these regulations impact day-to-day oper-

ations? • How do these regulations impact regulatory

reporting? How do they impact or change theconsequences of an incident?

How will the government view your role if a corro-sion failure occurs on one of your pipelines?

The panel will discuss possible consequences in

this new climate of enforce-ment, and this is sure to beanother high-interest andhigh-attendance forum.

Following the Corrosion &Punishment Forum i s theNuclear Coating InspectorForum from 9 to 11:30 a.m.This forum wil l cover anumber of critical issues sur-rounding nuclear coatings,such as plant life extension,the effects of an aging work force on qualifiednuclear coat ings personnel , new test ingapproaches for nuclear power plant (NPP) coatingsand changes in containment coatings for the newgeneration of NPP designs. Jon Cavallo, vice presi-dent of Corrosion Control Consultants & Lab Inc.will moderate the forum. He also will give his ownpresentation on plant life extension. NPPs in theUnited States were originally licensed for 40 years,but many will be suitable for operation for another20 years, Cavallo said. The U.S. Nuclear RegulatoryCommission (NRC) has specific regulatory require-ments for operating license extension, includingcoatings within the reactor containment. This ses-sion will outline the regulatory and technicalrequirements for plant coatings life extension, andidentify available guidance on the subject.

Garth Dolderer of Florida Light and Power willprovide a presentation about the nuclear powerindustry’s aging work force. With the retirement ofmany nuclear coatings personnel, younger workersmust be trained to serve in the nuclear industry forexisting and proposed new NPPs. This session willdefine a training syllabus for new nuclear workers,both craft and non-manual.

This will be followed by a presentation on new test-ing approaches for NPP coatings,to be given by John Debarba,PPG, testing; John Kloeopper,Carboline, testing; and TimEckert, EPRI, research. This ses-sion will define new questionsthat have arisen concerning NPPcoatings, and new testing proto-cols and research projects thathave been developed or are indevelopment.

In addition, Heidi Dergel,AREVA NP, Tim Andreychek,Westinghouse, and Lee Chul-Woo, KOPEC/KHNP, will addressthe issue of changes in contain-ment coatings for the new genera-tion of NPP designs. This sessionwill focus on describing the coat-ing systems and coating systemphilosophies involved in the newgeneration of NPPs, foreign anddomestic.

Dean Reynolds and BobWalcheski of UnderwaterEngineering Inc. will addressunderwater applied immersioncoatings in boiling water reactortori/suppression pools. DBA-qualified underwater appliedimmersion coatings have beensuccessful ly used in boil ingwater reactor tori/suppressionpools since the 1980s to mitigatecorrosion and facilitate decon-tamination. This presentationwill acquaint the attendees withproven underwater coatingstechnologies and the elementsof a successful coatings project.Underwater desludging andinspection methodologies willalso be discussed.

John Burke of NRC will provide

his perspective on safety and regulatory perspectiveson protective coatings used in nuclear power facili-ties. Burke will discuss lessons learned from GenericSafety Issue (GSI) 191, “Assessment of DebrisAccumulation on PWR Sump Performance.” Thispresentation will include discussion of the potentialimpact of protective coatings on reactor safety aswell as regulatory perspectives for coatings used innuclear power facilities.

Concurrent with the Nuclear Coating InspectorForum sessions, there will be a tutorial on How toAvoid Premature Coating Failures, from 9 a.m. tonoon. It will be led by presenter Mike O’Brien,Pres ident of MARK 10 Resource Group Inc.Premature paint failures continue to cost speci-fiers, plant owners, contractors and paint manufac-turers significant amounts of time and money, andcause irreparable damage to customer relation-ships. This tutorial will provide participants withpractical knowledge to examine and reduce coat-ing failures.

Later in the day, from 1 to 3:30 p.m., the confer-ence will host the forum Bridge Painting: The Usualto the Unusual. This forum will take the attendeesthrough the entire bridge coating evaluation pro-cess, allowing them to see how decisions are madeabout such issues as whether to consider a bridgefor coating repair or full re-coat. In addition, atten-dees will learn about standard bridge painting programs and some unique and interesting bridgepainting projects.

Bridge painting sessions will include: • Louisiana Bridge Paint Evaluation Studies, pre-

sented by Frank Rea, director of coatings andchief chemist, Greenman Pedersen Inc.; andSteven Sibley, Bridge Inspection quality assur-ance/quality control engineer, LouisianaDepartment of Transportation. This presentationwill not focus on any bridge painting inspectiontopics; however, it will detail the methodologyused to evaluate the coatings condition on abridge. This will ultimately tell an owner whethera bridge will need to be painted and prioritize itagainst other structures.

• Woodrow Wilson Bridge Painting, An Overview,presented by Bruce Nelson, coatings team leader,Maryland State Highway Department. This is amajor new movable bridge crossing the PotomacRiver to replace an aging structure, along withinterchange upgrades and improvements in thisheavily traveled corridor. This presentation willcover the bridge painting aspects of this impor-tant project.

• From the Chemistry in the Can., to theChemistry on the Project, presented by RonRauch, interim director/bridge painting, NewYork City Department of Transportation. This willbe an unusual and dynamic bridge painting topic.This presentation does not focus on bridge paint-ing techniques, but investigates the varied and dif-ferent relationships that are present on such aproject. The speaker will address what consti-tutes a well-run project and discusses where someprojects go wrong.

• The Pros and Cons of Chloride Removal fromSteel Structures, presented by Dan Castrigano,chief engineer, Ohio Turnpike Commission; andDouglas Hedrick, construction manager, OhioTurnpike Commission. Some agencies have specsthat address chloride contamination during thesurface preparation process, while others do not.Is it important? What are the costs? Do pitted sur-faces need different treatment? These are justsome of the questions that will be posed in thispresentation.

• FHWA’s High Performance Steel Program AsIt Relates to Bridge Coatings, presented byLouis N. Triandafilou, materials specialist,FHWA Resource Center. This presentationdeals with the coatings that are applied tohigh-performance steel used to constructtoday’s modern bridges. ■

Monday Discussions Touch on Key Industry ElementsForums discuss legal, safety issues for oil and gas, nuclear power and infrastructure industries.

John Clayton

By Gretchen Jacobson, Publications Director,NACE International

With more than 10,000 individuals completingthe NACE Coating Inspector Program (CIP),

CIP professionals are using their expertise in 100countries to ensure assets and infrastructure are prop-erly protected and maintained in industries thatinclude oil and gas, marine, ship building, bridges,and other elements of the infrastructure in all envi-ronments and conditions.

Established by a core of dedicated NACE membersin the protective coatings industry and NACEEducation Division staff, the CIP has steadily grownand evolved to meet industry needs and regulatoryrequirements. Today, NACE CIP courses are offered in30 countries, in languages that include Chinese,Japanese, English and Spanish.

“When we look at the greatest strengths of the CIPover the years, we can immediately highlight the factthat we not only offer courses all over the world, butour instructors, peers and students living andworking worldwide provide a constant flow ofinformation and updates,” said Ray Stone, pastchair of the NACE CIP subcommittee, chair ofthe Education Committee and a CIP instructor forthe past 20 years. “This helps us keep the coursesup-to-date, and the sharing of experiences is ben-eficial to all involved.”

The CIP training curriculum consists of threecourse levels, ranging from basic to advanced coat-ing inspection knowledge. The program teachesinspectors, applicators, blasters, manufacturers,specifiers, engineers, owner’s representatives andtechnical salespeople the concepts of corrosion,coating application techniques, and proper meth-ods for paint inspection and project management.

“CIP brings together all the disciplines of theprotective coatings industry into a two-week for-mat,” said CIP Instructor Phil Fouche, NACE trea-surer and chair of the CIP subcommittee. “Moreimportantly, it brings the people involved in thisindustry together to learn and share with eachother: instructor to student, student to instructorand student to student.”

Enriching careers of students“Since going through CIP, I’ve pretty much had a20-year run of success,” said Steve Davis, whopassed Peer Review in 1987. “Before I started theprogram, I was considering giving up my 10-yearcareer as a painter, foreman and general foremanafter leaving a bad situation at my company. Myconfidence was at its lowest ever. But as it turnedout, I made at least a 90 in each of my CIP classesand passed my peer on the first shot. The drivehome to Corpus Christi from Houston was theshortest 200 miles ever, I was so happy!

“The results were twofold and almost immedi-ate. First, as a result of doing well in the classesand Peer Review, I regained my confidence in myability. I had rubbed elbows with a state senator,paint representatives, business owners, Navypaint personnel and other professionals in myindustry. Second, I went to work as an inspectoralmost immediately. So many of the good thingsin my life started with going through the CIP.”

“I have taken many different courses through-out my Naval career; however, none were asintense and well-formatted as my CIP Level 1Course, which I took in Halifax, Nova Scotia,”said Hugh Lankester, a CIP instructor based inCanada. “The course was further condensed by aday because of a snowstorm that shut the citydown and an afternoon when the power wentout. The instructors were extremely professionaland covered all the topics in depth in the short-ened time frame.”

Fouche has seen and heard many times overhow the CIP has altered the careers and lives of

his students, leading to newopportunities, better jobprospects and higher incomes.But none touched him as muchas two students he taught in hisfirst class.

“There were two students inthe first course I ever taughtwho did an outstanding job onthe practical exam (use of instru-ments), but failed the writtenexam,” he recalled. “I hadgraded their quizzes and quicklyrealized that they had readingdifficulties. I praised their useand knowledge of the instru-ments but told them they hadfailed the written exam. My

NACE International’s Coating Inspector Program Celebrates 25 Years of ExcellenceThe NACE International Coating Inspector Program – the first and leading coating inspector program in the world – celebrates its 25th anniversary this year.

5NACE SHOW DAILY ★ Preview • March 16-17

Students in the NACE CIP learn the concepts of corrosion, coating applicationtechniques, and proper methods for inspection and project managementthrough a combination of classroom and hands-on training.(Photo courtesy of NACE)

See PROGRAM continuedon page 11 >>

By Richard Norsworthy, Polyguard Products Inc.,Lancaster, Texas

After 40 years of use, many end users do not recog-nize one important benefit of fusion-bonded epoxy

(FBE) pipeline coatings – they are “fail safe.” As with allpipeline coatings, FBE coatings have failed while in ser-vice, but rarely is there corrosion on the pipe underthe failed coating.

When adequate cathodic protection (CP) is avail-able, FBE is fail-safe because it does not shield CP cur-rent when disbondment occurs. Those responsiblefor selecting pipeline coatings should consider theuse of FBE or other proven fail-safe coating, so whenthe coating fails, the CP will protect the pipe.

This is not a 100% claim, but this phenomenon hasbeen witnessed and documented on many in-servicepipelines coated with FBE. When FBE fails, corrosionis rarely present under the failed FBE when adequateCP is available (Figure 1).

There are many parameters that must be consideredwhen selecting pipeline-coating systems. One of theparameters many engineers fail to include in the coat-ing selection criteria, is “What will happen if and whenthe coating fails?” A key consideration should be “Willthe coating shield CP if the bond fails?” However, allcoatings experience some disbondment and, therefore,the behavior of a disbonded coating is important in theoverall performance of a coating system. Even withadequate CP, corrosion can occur under most dis-bonded coatings. With adequate CP, FBEs do not com-pletely shield CP currents; therefore corrosion is not amajor problem.

Another important factor about FBE pipeline coat-ings is that stress corrosion cracking (SCC) hasnever been found under disbonded FBE coatings. Itis believed the high permeability of FBE coating towater is the reason for the apparently “transparent”

nature of FBE coating to the CP. So allowing CP cur-rent and creating a high pH also help prevent SCCon pipelines coated with FBE.

Coatings failure modesImproper surface preparation is the reason for most

coating failures. Contaminants,such as ionic salts, will mix withwater to cause disbondment andblistering. Hydrocarbons willnot allow proper adhesion. FBErequires a well-prepared andclean surface (near white) witha profile of 1.5 to 3.0 mils ofanchor pattern.

Application techniquesApplication processes can be acritical problem for all pipelinecoatings. Application temperatureis the most critical for the properapplication of FBE.

Soil stressSoil stress can damage many typesof coating systems. When the coat-ing strength is less than the stressesintroduced by the soil, the coatingwill fail. FBE is rarely affected bysoil stress, but it can damage mostother coating systems.

Selection criterionMany t imes, coatings areselected for reasons that do nottake into account all the possi-ble failure modes, and the result-ing consequences when they dofail. All coatings will and do fail.All coatings have openings, pin-holes, micro-fissures and othermethods of allowing water, oxy-gen and other corrosion-causingcompounds to migrate throughat different rates. FBE, for exam-ple, allows some water to pene-trate. It does, however, maintainits insulating properties in thepresences of moisture and CPcurrent.

Operating temperatureOperating temperature is always a critical factor inchoosing a proper coating system. The pipeline operat-ing temperature affects many coatings, including FBE.Higher or lower than specified temperatures can causecoatings to deteriorate, crack, lose adhesion or gravityflow of the coating on the pipe. Higher and lower-tem-perature FBE coatings have been developed. Thehigher the operating temperature, the more rapidlywater will penetrate.

There are many other parameters that affect the per-formance of a pipeline coating, but these are some ofthe more critical ones. One must consider all the fac-tors for each particular exposure and service whenchoosing a coating type.

Typical FBE failure modesFBE can fail like any other coating. In most cases, thefailure is not the fault of the coating or its formulation,but of the application techniques, selection criteria orsurface preparation.

Cathodic disbondmentCathodic protection can affect all coatings. The alka-line conditions that develop at the cathode will deteri-orate some types of coatings and cause others to dis-bond. Formation of hydrogen and hydrogen evolutionhas been debated and studied as another possiblecause of coating disbondment. Laboratory tests indi-cate the presence of hydrogen bubbles plays little orno role in the rate of disbondment.

Different companies have used various “on” or“polarized” potentials through the years in an effort toestablish a potential at which to operate their CP sys-tem when using FBE. This author has been involved inFBE systems that operate at “on” potentials more nega-tive than -6 v for several years, with no detrimentaleffects to the FBE. Other systems have blisteringor failed at “on” potentials of –1 v or less negative.This seems to point to the fact that many of theFBE failures are related to causes other than overvoltage. Cathotic protection will cause the waterto penetrate more rapidly. The water that pene-trates is relatively pure, but will mix with surfacesalts to cause blistering if the areas of contamina-tion are small. Larger areas of contamination maycause the FBE to fail in large, disbonded sheets. Pinholesor holidays may be present, but are not necessary for

Reviewing Coating EffectivenessAfter 40 years of service, fusion-bonded epoxy has been shown to have “fail safe” characteristics.

6 March 16-17 • Preview ★ NACE SHOW DAILY

See COATING continued on page 11 >>

Figure 1. Lack of adhesion and blistering with water under blisters on FBE coated pipeline. No corrosion and a pH of12 proved its “fail safe” properties.

7NACE SHOW DAILY ★ Preview • March 16-17

NACE International, which began in1943, is an organization designed to

protect people, assets and the environmentfrom the effects of corrosion.

The group has grown from an initial 11engineers to more than 18,000 members inmore than 100 countries.

Contributed by Champion Technologies

Researchers studied the effect on corrosion ratesof carbon steel exposed to a brine solution super-

saturated with iron, with and without quaternaryamine, and under stagnant conditions and with shear.The ionic composition of the brine and the pH valuesused were applicable to the southern Alberta regionof Canada.

Researchers first measured changes in potential ofthe current created by the electrochemical reactionon the surface of a carbon steel coupon submerged ina brine solution purged with carbon dioxide. Relativelevels of corrosion resistance were inferred fromchanges in surface potential during the process ofiron carbonate (FeCO3) formation, expressed as lin-ear polarization resistance (LPR) and measured byelectrochemical impedance spectroscopy (EIS). Thestructure of FeCO3 crystals formed was verified byobtaining post-test surface and cross-sectional images– generated by a scanning electron microscope withenergy-dispersive x-ray spectroscopy (SEM/EDS) – of

the surfaces of carbon-steel coupons used in tests.The composition of crystals formed in experimentswas confirmed by analyzing the spectra of corrosionscale using a new on-surface x-ray diffraction (XRD)method researchers developed.

LPR and EIS data showed resistance of electro-chemical reactions was higher in the presence of aquat amine inhibitor than when the inhibitor waswithheld, indicating FeCO3 scale was growing atfaster rates and less corrosion was occurring.SEM/EDS images revealed the reaction with quater-nized amine present also produced thinner scale and

smaller FeCO3 crystals vs. non-treated conditions.Researchers found quaternized amine inhibitor in

concentrations of 50 ppm did not completely preventiron carbonate growth, and they observed corrosionrates decreased most when concentrations ofinhibitor were 50 ppm and concentrations of Fe2+

were 100 ppm or greater.Results showed that applying shear to the surface

increased the threshold concentration at which acontinuous FeCO3 scale was formed. Also, increasingthe ionic concentration of the brine decreased therate of precipitation of FeCO3. Corrosion-scale spec-tra obtained using the new on-surface XRD analyticmethod confirmed the composition of crystalsformed in experiments as FeCO3.

A technical paper summarizing test results, Effectof Corrosion Inhibitor Active Components on theGrowth of Iron Carbonate Scale under CO2Conditions (NACE CORROSION 2008 paper No.08345), is being presented at NACE International’sCORROSION 2008 technical conference in NewOrleans this week. ■

Working Synergistically to Prevent CorrosionA recent study conducted at the Calgary laboratory of Champion Technologies notes corrosion inhibitors and iron carbonate interact to work in partnershipto prevent corrosion.

The ionic composition of thebrine and the pH values used

were applicable to the southernAlberta region of Canada.

discussions and debates between studentsand visiting scientists. At one of these semi-nars, I met the senior corrosion engineerfrom Chevron, John Coombs, who convincedme to visit San Francisco and learn about theoil industry.

“I interviewed and was impressed, notjust with the technical challenges for mate-rials and corrosion, but also with the caliberand integrity of the people that I wouldwork with.”

When asked why he felt the topic he willdiscuss Monday was an important one, hesaid corrosion is a challenge that involvesglobal participation.

“NACE International has long recognizedthat corrosion is a challenge that involvesthe partnering of oil and gas companies withequipment manufacturers, universities, inde-pendent labs, technical societies and stan-dards writing organizations. This is a world-wide partnership that can only be effectiveif information is shared and transferredthrough international guidelines and stan-dards,” he said.

“The NACE MR0175/ISO 15156 documentwas the first joint effort between NACEInternational and ISO to draft a guideline ofwide ranging application. That is the use ofmetal alloys in sour service production anddrilling operations,” he said.

This standard, according to NACE, tookyears to develop with efforts from industry,academia, and NACE and ISO volunteers.

“A unique structure of task groups and vot-ing procedures was adopted to bring forwarda consensus for standard,” according to thePlenary Lecture abstract. “The lessons learnedfrom this international partnership can serveas a guideline for choosing which NACE stan-dards should be considered for transition toISO standards, how communication andcooperation between ISO and NACE may beenhanced, and the pitfalls that should beavoided while drafting the final standards.” ■

PLENARY continued from page 1 >>

8 March 16-17 • Preview ★ NACE SHOW DAILY

By Kathy Riggs Larsen, Staff Writer,Materials Performance

Studies of the Gupta period Delhi Iron Pillar, a monu-ment in the Qutub Minar complex in New Delhi,

India, that has resisted corrosion for the past 1,600years, determined that relatively high phosphorus con-tent (0.25 wt%) in the forge-welded structure assistedthe formation of a protective passive film on the struc-ture’s surface that contributed to its remarkableendurance. But in the modern steel-making process,

phosphorus content is controlledto less than 0.05 wt% becausephosphorus segregation to grainboundaries reduces steel ductilityand makes it brittle.

With a goal of applying theknowledge gained from the IronPillar to contemporary metallur-gical applications, graduate stu-dent Gadadhar Sahoo, now withthe Research and DevelopmentCentre for Iron and Steel, SteelAuthority of India (Ranchi,India), along with RamamurthyBalasubramaniam, professorwith the Institute’s Materialsand Metallurgical EngineeringDepartment, launched a detailedstudy to determine how to ren-der modern phosphoric ironsductile as well as identify poten-tial applications for these corro-sion-resistant materials. Theirresearch was inspired by Balasubramaniam’s earlierstudies of the Delhi Iron Pillar and its remarkableresistance to atmospheric corrosion. (See “1,600Years Young” by Matthew V. Veazey, MaterialsPerformance, July 2005.)

The researchers realized carbon could replacephosphorus from the grain boundaries by the sitecompetition effect when the iron-phosphorus alloyscontain a low amount of carbon. Phosphorus wouldnot be present in regions where carbon is in the ironmatrix, Balasubramaniam said, because phosphorus isa substitutional solute element and carbon is an inter-stitial solute element.

“The challenge was to locate these carbon atomsalong the grain boundaries,thereby keeping the phosphorusatoms away from these loca-tions,” Balasubramaniam said.

To do this, researchers soakedthree phosphoric iron ingots withvarying levels of phosphorus –0.11 wt%, 0.32 wt%, and 0.49wt% – at temperatures between1,831°F (1,000°C) and 2,011°F(1,100°C). After soaking, the sam-ples were air-cooled. Tensile test-ing of the samples indicated goodductility for phosphoric iron,especially the samples with 0.11wt% P and 0.32 wt% P, whencompared with a commercialreinforcement bar used for con-crete reinforcement.

“We made use of heat treat-ment in the dual-phase (ferrite +austenite) region of the iron-phos-phorus phase diagram to locateaustenite along grain boundariesof ferrite. Austenite (a face-cen-tered cubic solid solution of ironand an alloying element at tem-peratures above 910°C) has ahigher solubility for carbon thanphosphorus, while ferrite (a body-centered cubic solid solution ofiron and an alloying element) hashigher solubility for phosphorusthan carbon,” Balasubramaniamsaid. “Therefore, during soaking,carbon is pushed to the grainboundary region while the phos-phorus is removed from the grainboundary region. The benefit ofthis treatment is that phospho-rus removed from the grainboundary regions during soakingdoes not return to these regionsduring air cooling because phos-

phorus requires time to diffuse to the grain bound-ary regions.”

In the test samples, microscopy analysis confirmedlow phosphorus content at the grain boundaries.

Researchers concluded that, unless exposed to atemperature range of 391°F (200°C) to 1,111°F(600°C) for extended periods of time, phosphoriciron will retain its ductility. Exposure to these tem-peratures could lead to temper embrittlement, wherethe phosphorus diffuses and segregates to the grainboundaries.

“However, there would be no problem in applyingphosphoric irons at ambient temperatures,”Balasubramaniam said.

Phosphoric irons can also be strengthened using athermo-mechanical treatment similar to what is usedto strengthen commercial concrete reinforcementbars, he said. Several aspects of the process, includ-ing ingot soaking, bar quenching and cooling, couldbe fine-tuned to produce phosphoric iron with atough surface and a strong interior.

When evaluated in a variety of environments, thephosphoric iron demonstrated corrosion resistance innear neutral and alkaline conditions and exhibitedgood passivity in concrete environments, making it agood candidate for concrete reinforcement, theresearchers said. The team tested the material exten-sively in simulated concrete environments and com-pared it with commercially available reinforcing steel.Results of the detailed study verify the superior corro-sion resistance of phosphoric irons in concrete, andshow the corrosion rate of other reinforcing steels tobe higher when compared to phosphoric irons.

Another plus, the team noted, is that phosphoricirons show excellent corrosion resistance in the pres-ence of chloride ions, which generally tend to destabi-lize surface films on steel surfaces. This significant resultindicates phosphoric irons will provide good service inareas prone to chloride exposure, such as marine envi-ronments and locations where deicing salts are used. ■

Source: Materials Performance, January 2008

New Corrosion-resistant Iron Links to the PastInspired by technology used by ancient Indian iron metallurgists, researchers with the Indian Institute of Technology Kanpur (Kanpur, India) have formulated a modern iron material that exhibits corrosion resistance as well as good ductility.

Ramamurthy Balasubramaniam and his students in frontof the Delhi Iron Pillar.(Photos courtesy of R. Balasubramaniam)

Phosphoric iron samples (in the center three flasks) are relatively unaffectedafter 90 days of immersion in a saturated calcium hydroxide solution containing5% sodium chloride while two commercial concrete reinforcement materialson the two ends are severely corroded.

The challenge was to locate these carbon atoms alongthe grain boundaries, therebykeeping the phosphorus atoms

away from these locations.–Ramamurthy Balasubramaniam

Professor, Research and Development Centre

for Iron and Steel, Steel Authority of India

By LaVonne Carlson, Marketing Manager,NACE International

In October 2007 at the International MarineCoatings Summit in Shanghai organized by NACE

International, prominent leaders in the shipbuildingand marine coatings industries came together toaddress issues coming out of the InternationalMaritime Organization (IMO) recommendation forperformance standards for protective coatings (PSPC).

The performance standard regulations specify thatthe coating inspector involved in the process must bequalified as NACE Coating Inspector Level 2-Certifiedor equivalent.

At the summit, Andy Alderson, chairman of theInternational Association of Classification Societies(IACS) EG/Coatings, director of the RINA TechnicalExcellence Centre and NACE member, addressed thecommercial issues involved in coatings inspection.Portions of his presentations are shared here.

The role of vetting and inspectionFor the oil company-vetting manager, every vessel heor she approves is a career decision. Many vetting man-agers make decisions using reports and evidence thatarrived at their desks from inspections. It is not in theirinterest to turn down vessels. If they do not grant vet-ting approval, then there is no future work for anyone.

Vetting serves two purposes. One is to identify ves-sels and owners that are an acceptable risk to themarine transportation of crude oil and its productsand use them. The other is to identify vessels andowners that are an unacceptable risk – and excludethem from maritime activities.

Balancing commercial pressures while ensuringship safety creates a challenge. First, a ship mustbe inspected to comply with the necessary vettingrequirements. Yet an inspection is not generallypossible while the ship is in service because ofport restrictions, safety or other practical con-cerns. This requires time off hire to be inspectedfor chartering. And owners are seeking ways tobalance the two needs.

Maintenance and repair: to be or not…?IACS Recommendation 87 was developed in con-junction with the industry in efforts to provideguidance on repairs to coatings. The IMO Guideline

for Maintenance Coating & Repair used IACSRecommendation 87 as a basis for its development.This guideline is under development by IMO’sDesign & Equipment Subcommittee, and is almostcomplete with the only outstanding areas being thedevelopment of “areas under consideration for allship types” – a task being undertaken at IMO’srequest by IACS.

The ideas of Maintenance & Repair have been sepa-rated in the draft IMO document with maintenancebeing considered as an onboard in-service activity,which maintains the coating condition as it is usingtools and equipment normally available on board.Repair being reserved for work is generally conductedwith a vessel out of service and at a repair facilityusing specialized tools and equipment.

Performance standards for protective coatingsare essential to successful use of coatings to ensurea ship’s safety and prolong its life. The ability of aship’s coating system to reach its targeted useful

life depends on the type of coating system, steelpreparation and application as well as coating inspec-tion and maintenance. IMO PSPC requires that in-ser-vice maintenance, repair and partial re-coating activi-ties should be recorded in the coating technical file inaccordance with the relevant section of the guidelinesfor coating maintenance and repair.

The IMO clearly refers to a requirement for mainte-nance and repair, but is maintenance on board reallypossible? And is the concept of “maintenance free”really viable? As simple as that sounds, the reality isthat some level of watchfulness is needed to deter-mine when and how much maintenance is required.

The key to monitoring and measuring the need formaintenance is ongoing and consistent inspection.Knowing the true condition of the ship enables effec-tive planning and successful implementation of repair,if required, at appropriate facilities.

Commercial Pressures on Ballast Tank Coating Assessments In December 2006, the International Maritime Organization adopted legislation requiring a performance standard for ballast tank coatings.

9NACE SHOW DAILY ★ Preview • March 16-17

By Bruce Beaubouef, Ph.D., Editor, PipeLine Gas and Technology

The second day of NACE CORROSION 2008 willaddress coating technology, a topic of key interest

for all segments of the oil and gas industry. This symposium will contain technical papers about

accelerated lab coating testing methods, residualstresses in coatings, cathodic disbondment testing,new developments in pipeline coatings, new develop-ments in ballast water tank coatings, and evaluation ofTSA and other coatings under wet insulation.

Correlation of Accelerated Corrosion Testing withNatural Exposure After 6+ Years in a CoastalEnvironment is scheduled to be presented by DarrenWard of International Paint Ltd. In the coatings indus-try, new technologies often are necessary to producehigh solids materials required to meet current andfuture VOC legislation. Because of the lack of trackrecord with some of these technologies, it is essentialto use accelerated test methods to evaluate perfor-mance. There are a number of internationally recog-nized accelerated corrosion tests that can be used,including NACE TM0304, ASTM B117, ASTM D5894and ISO 20340. Ward will discuss each of these testmethods and will correlate data produced from the

accelerated testing of various high-performance coat-ing systems with performance in real life exposure ata coastal environment. The major findings are thatcyclic corrosion testing produces a higher degree ofcorrelation with natural weathering, and thereforeprovides a more reliable method of predicting coatingperformance.

Technical Aspects of Soluble Salt ContaminationAnalysis in New Shipbuilding Yards is scheduled tobe presented by C. H. Lee, S. M. Son, C. S. Shin, Y. H.Baek and K. K. Baek of the Protective Coatings &Corrosion Research Department of Hyundai HeavyIndustries Co. Recently, the International MaritimeOrganization (IMO) adopted Performance Standardfor Protective Coatings (PSPC) regulation for shipwater ballast tanks, which will be effective for shipscontracted after August 2008. This regulation speci-fies the allowable sodium chloride (NaCl) limit to be50 mg/m2 or less for primary and secondary surfacepreparation, which will be obtained by conductivitymeasurement in accordance with ISO 8502-6 and ISO8502-9. However, the specified method provides thelevel of total soluble salt, which is different from theamount of NaCl or chloride ion. Still, it has been spec-ified to measure the amount of NaCl on a steel surfacein IMO’s PSPC, which might be a source of dispute in

worldwide implementation of the PSPC for new ship-building. The authors will discuss the effects of thesenew regulations.

Optimization of Application Procedure for Non-Skid Coating Materials in Offshore Structure isscheduled for presentation by Chung Seo Park,Mong Kyu Chung, Eun Ha Song, Kwang Ki Baekand Eul Soo Chung of Hyundai Industrial ResearchInstitute’s Offshore Painting Department. Theupper decks of offshore platforms require theapplication of heavy-duty, non-skid coating sys-tems, of which durability and resistance are a majorconcern for the offshore structure to reduce main-tenance and repair. Through proper application ofthese non-skid coatings, long-term performancewithout premature crack and/or delamination willbe achieved. To optimize the field applicationmethod of these coatings, the authors review theapplication method and its inherent problems, andthen evaluate four different types of coating appli-cation method systems. These are compared interms of surface friction coefficient and crack resis-tance as well as work eff iciency. From theseresults, a new coating application method wasselected that can be used for escape route and heli-decks of ships and offshore structures. ■

Coating Technology Sessions Session One of the Oil/Gas Coating Technology Symposium will run from 1 to 5 p.m. Monday, with Session Two taking place Tuesday.

See PRESSURES continued on page 10 >>

Booth #1113

10 March 16-17 • Preview ★ NACE SHOW DAILY

By Stephanie Garner, Marketing Specialist,NACE International

The National Center for Construction Educationand Research (NCCER)/NACE Industrial

Coatings Applicator Training and CertificationProgram is the first and most in-depth certificationprogram offered for industrial paint applicators. Itsupports the joint standard NACE No. 13/SSPC-ACS-1, Industrial Coating and Lining ApplicationSpecialist Qualification and Certification, by pro-viding the 450 required hours of training for Levels 1and 2 qualification.

The program is designed especially for companiesthat wish to do their own training, though NACEInternational also is prepared to provide the trainingprogram in public offerings. The training materialscover criteria for the knowledge, skills and experi-ence required of an application specialist for prepar-ing surfaces and applying protective coatings tosteel and concrete surfaces of complex industrialstructures. This unique training and certification pro-gram promotes a career path for the industrialpainter industry that can easily be implemented ininternational markets.

“NACE training programs have grown substan-tially in recent years, and we are consistently askedfor an applicator training program that can be deliv-ered outside the traditional classroom setting,” saidTony Keane, NACE executive director.

“NACE sought a training partner with credentialsin craft training to meet the special hands-onrequirements of this workforce, and it was apparent

that NCCER is the organization with the most expe-rience and success,” Keane said.

The program includes material from NCCER’sCore Curriculum for construction-related training.Subject-matter experts develop the curriculum,ensuring exceptional training that meets or exceedsindustry standards.

Training topics stem from NACE No. 13/SSPC-ACS-1 and cover industrial coating safety, corro-sion protection, containment and ventilation, sur-face preparation, industrial coating application,work planning and quality control, and projectmanagement.

The National Center for Construction Education

and Research and NACE designed this program tomeet the U.S. Department of Labor’s Office ofApprenticeship requirements for time-based train-ing. It consists of three levels of training withthree tiers of assessment; each level the studentpasses is equivalent to a year’s worth of training.Once applicators complete their training, theymust test through an NCCER AccreditedAssessment Center to receive Level 1, Level 2 andLevel 3 Industrial Coating and Lining ApplicatorSpecialist certified status.

Deidre Dunkin, president of Dunkin and Bush, anindustrial coating applications company, enthusiasti-cally endorsed the partnership and training program.

“Coating application personnel are often the firstline of defense in protecting structures from theeffects of corrosion; therefore, quality training ofapplicators is key to our company and the industryas a whole,” Dunkin said.

The first level of the coating applicator trainingprogram is scheduled to begin in summer 2008, fol-lowed immediately by Levels 2 and 3.

“The key to combating the diminishing workforceis to build skilled craft professionals and ensure theportability of their skills across the industry,” saidNCCER President Don Whyte. “This program willbring us one step closer to accomplishing that goal.”

For more information, please visit www.nace.org.Instructor resources include PowerPoint slides,transparency masters and computerized testing soft-ware. The instructor also receives a guide for eachlevel of training that contains end-of-chapter writtenand performance tests. ■

NACE/NCCER Join Forces for Industrial Paint Applicator ProgramNACE International and the National Center for Construction Education and Research, two leading providers of industry education, training and certification,are joining forces to launch a comprehensive industrial coating applicator training and certification program this summer.

has recognized the true value of our courses. It is a valuable resource for owners andcontractors alike to facilitate continuing education for their employees on an afford-able basis with course locations in many countries.”

And while there are lessons to be learned and notes to be taken at CORROSION2008, at the end of the day, Vincent said, it’s all about networking.

“To me the conference has always been a forum for networking with one’s peers.The relationships and bonds that form at a conference last a lifetime,” he said.

More than 5,000 people are expected to attend NACE CORROSION 2008 with morethan 500 exhibit booths, according to the organization.

“This year’s theme, ‘Revive...Jive...Thrive!’ says a lot about what’s happening in NewOrleans these days. All of the areas that conventioneers and NACE staff would visit arein great shape. As a matter of fact the French Quarter is cleaner than most people haveever seen,” according to NACE’s internal newsletter NACE ZONE.

“I would particularly like the attendees to see and feel the re-birth of New Orleans,”Vincent said. ■

GLOBAL continued from page 1 >>

PRESSURES continued from page 9 >>

Potential impact of IMO guideline for Maintenance & Repair If everyone can agree that, at the minimum, some level of inspection is necessary,then owners and industry leaders can focus on addressing its impact. Key questionspertaining to impact are:

• Can owners carry out inspections while ships are in service?• How often should inspections be carried out – every 6 months, every 3 months…?• What should be the total number of inspections (is once every month acceptable)?• What are the vetting requirements? • What extent of repairs or maintenance is allowable?• What level of training is required?• What level of knowledge is expected from the ship’s staff? • How far can performance standards for protective coatings extend?• How much attention should be paid to void spaces?• What is the greater implication for cargo tanks?These questions come into play when people attempt to define and develop standards.

To enable those affected by the outcome of these impacts to offer input, everyone affectedshould begin to consider these questions and define the parameters of what they consideracceptable. If each person comes to discussions with suggestions for what’s acceptableand a willingness to consider all the viewpoints, much progress can be attained. ■

"The key to combating the diminishing workforce

is to build skilled craftprofessionals and ensure the

portability of their skills acrossthe industry. This program will

bring us one step closer toaccomplishing that goal.”

–DonWhyte

NCCER President

11NACE SHOW DAILY ★ Preview • March 16-17

advice to them was to consider enrolling in a programto strengthen their reading and writing skills.

“Five years later, I was teaching a course at the samelocation and standing at the doorway were those sametwo students. I went over to see them, and with tearsflowing down their cheeks, they explained that theyhad enrolled in a night school and had gotten theirGEDs (their wives did so as well). That same day, theyinformed me that they had passed their Peer Reviews.

“When you see a person able to achieve a careerstep and their lives change for the better, it makesthose long days away from home all worth it!”

Instructors learn tooDannie Vickers, a CIP instructor since 1984, said hiscareer has directly benefited from his experienceteaching courses.

“Teaching in different global climates has helpedme learn first-hand about corrosion-inducing condi-tions elsewhere,” he said. “My career has been incoating manufacturing, so by taking (and later teach-

ing) the courses, I’ve been able to improve the prod-ucts my company manufactures by creating coatingsthat sustain a longer life, even in extreme conditions.”

“CIP has allowed me to be with the most knowl-edgeable people in this industry as well as increaseexponentially my knowledge in the coatings field,”Fouche added. “Becoming an instructor enables me todo what I enjoy most – teach others. In so doing, Ihave been blessed to travel to other countries andhave come to appreciate and learn from the manydiverse cultures of this world.”

A universal programAlthough there can be significant differences in environ-ments, infrastructure, products and cultures from coun-try to country, coating inspectors encounter circum-stances and challenges that are universal worldwide.

“From my experience, surface preparation, applica-tion, and inspection of protective coatings are verysimilar around the world,” said Rob Freedman, a CIPinstructor based in Merewether, Australia.“Sometimes there are minor variations in the type ofequipment or abrasives used; however, all owners of

plants and equipment are trying to achieve the samelevel of quality when protecting their assets.”

Demand for CIP continues to grow“The development of CIP into a world-renowned cer-tification program is a reflection of the many CIP-certi-fied professionals whose work has impacted a widevariety of global industries,” said Tony Keane, execu-tive director of NACE. “As the market demand for CIPcontinues to grow, NACE continually updates the CIPcourses to meet those demands and provide the besttraining available.”

“Over the 25 years of the CIP’s existence, the courseshave been constantly updated and revised,” Stone said.“CIP subcommittee members, volunteering their owntime, work with NACE International’s Education Divisionstaff to provide the superior training the CIP is knownfor. As our international membership and marketinvolvement continue to grow, CIP will remain the ‘go-to program’ in coating inspector training worldwide.”

To learn more about the CIP, please visit the NACEWeb site: www.nace.org/cip or contact NACE at +1281-228-6223 or first.service@nace.org ■

PROGRAM continued from page 5 >>

this disbondment to occur because the water pene-trates through the coating.

Blistering of FBE will occur when water penetrates andcombines with the surface salts to cause the disbond-ment and the subsequent blistering. Blistering from CP isthe result of the alkaline environment that develops at thecathode. Areas where the wetting out of the surface bythe coating was not sufficient or contaminants were pre-sent leave small areas of little or no adhesion. Thesebecome areas where water can be reduced. As watermigrates to these areas, electron transfer takes place, cre-ating hydroxyl ions, starting the blistering process.

Loss of adhesionFBE has the best overall adhesion of any pipeline coat-ing system when properly applied. If large areas ofadhesion failure occur, the cause may be an inadequateprofile, large areas of surface contamination or applica-tion temperature problems.

Excessive holidaysExcessive holidays are commonly caused from over-heating during the application process, slivers in thepipe steel, contaminants on the pipe or in the coatingmaterial, or mishandling during the coating process orconstruction. The coating applicator has the responsi-bility of checking for and repairing holidays during thecoating inspection process at the plant. The contractorhas the responsibility of inspecting for and repairingholidays during construction.

If holidays are found during dig inspections, theircause will typically be backfill-related. If these were notproperly inspected or repaired, they could be from theproblems mentioned earlier. The holiday was not nec-essarily present before the blistering occurred.

Operating temperatureIf the FBE operating temperature is exceeded, then thecoating can deteriorate. The FBE may become soft orgrainy, and can be easily removed with a knife. FBEcoatings can absorb more water than normal at highertemperatures, but do not flow or move on the structure.Glass transition temperatures can be exceeded, butchanges in physical properties should be expected insuch a case. This may not affect long-term performance.

Chalking and disbondmentPolymer degradation (chalking) from ultra-violet expo-sure will cause FBE to be grainy in appearance, and sur-face chalking of 2 to 3 mils can be easily removed. Thereis a discoloration and change in appearance. This damagewill typically be a few mils of thickness. If FBE-coatedpipe is stored where sunlight and air-borne elementssuch as dust, rain and snow contact the coated pipe, FBEcan be damaged, leading to failure of the coating. For thisreason, if FBE is stored, it should be protected from theelements as much as possible. Tarps, covered sheds, and

other techniques can be used to shield it from ultra-violetrays and other environmental damage.

Fail-safe characteristics of FBEFBE coatings have effective electrical insulation whenoriginally installed and continue to provide effectiveinsulation even as the coating begins to absorb water.FBE continues to have low CP current requirementsyears after installation if it remains well bonded. Even ifblistering and small areas of disbondment occur, thecurrent requirement increases are minimal. However,the electrical resistance is low enough to allow CP toprevent corrosion on the pipe with disbonded or blis-tering coating – FBE is non-shielding.

The amount of oxygen available at the cathode willcontrol the rate of the corrosion process under dis-bonded coatings. FBE has an advantage over manyother coatings because it is a good barrier to oxygen.All (organic) coatings are permeable and have micro-pores and fissures that eventually allow water vapor toreach the substrate. The rate and type of water allowedto permeate are important to coating failures.

With FBE, the rate may be somewhat faster than forsome other coatings, but the water that does penetrateis relatively pure, therefore it has a minimal effect onthe corrosion rate. If the water mixes with ionic saltson the pipe surface, the blistering or disbondment pro-cess begins. Cathodic protection accelerates the rate atwhich water penetrates all coatings. The cathodic pro-cess (reduction) creates H2O, OH- and H at the cathodesurface; therefore water is available for transport to thesubstrate. Electron transfer takes place at the metalelectrolyte interface.

This concept becomes important when evaluatingany coating failures. Taking the pH reading of anywater under a blister or disbondment will validate theeffectiveness of the FBE to allow CP currents to protectthe substrate. OH- ions are being created at the pipesurface; therefore the pH becomes alkaline indicatingthe CP is providing protection to the steel. The corro-sion rate for steel is reduced or non-existent in alkalinepH environments (typically from 9 to 13). If the pH is 8or less, the CP may not be adequate, or may beshielded by the coating or some other material. Thepipe surface may have some discoloration under thefailed FBE, but the important issue is that there is usu-ally no corrosion under the coating.

There has to be adequate CP for this phenomenon totake place. Compared with other pipeline coating sys-tems, less or no corrosion is found on FBE-coatedpipelines when using internal inspection tools. FBEmay not be 100% fail safe, but experience has shownthat if adequate CP is available and no shielding is pre-sent, there is no corrosion.

Another advantage of FBE is that when FBE fails,these areas can be found more easily with direct cur-rent voltage gradient surveys. Since more current isallowed through FBE at these areas of failure, they canbe detected and may show up as small holidays. The

owner has theoption of repair-ing the damagedcoating or wait-ing, and the pipewill not likelyhave corrosionproblems if CP isadequate.

Remediationalternatives If corrosion isfound on pipelinescoated with FBE, acareful evaluationmust be made todetermine whenand how it devel-oped. Do notassume if corro-sion is present thatFBE disbondedand shielded thepipe from CP.

Remember totake the pH underany failed coating. This will tell you if the pipe is receiv-ing adequate CP at that time.

Girthweld and repair coatings One issue operators confront is which coating toselect for the girthwelds and related repairs. Mostcorrosion on FBE-coated pipelines occurs at thegirthwelds coated with materials that are not failsafe. FBE can be applied to the girthwelds by usingheat induction coils and flocking equipment. TheFBE on the girthweld provides the end user with acoating system equivalent to the main line pipewhen properly applied.

The second choice would be to use other provenfail-safe coating systems, such as the Polyguard RD-6geo-textile mesh-backed tape system (Figure 2). Two-part epoxies are also a choice that will provide a coat-ing that is similar to FBE, but may not always be failsafe. However, if not applied too thick, the two-partsystem seems to provide this characteristic. Theseepoxies bond well to FBE coatings when the surfacepreparation and application are performed properly.For these reasons, two-part epoxies are good repairmaterials for FBE coated pipelines. ■

Acknowledgment Based on a paper presented at the CORROSION 2006,San Diego, Calif., March 12-16.

Editor’s Note: This is a modified version of an articlethat originally appeared in the March 2007 issue ofHart’s PipeLine and Gas Technology.

COATING continued from page 6 >>

Figure 2. Application of PolyguardRD-6 coating system. After threeyears of service when applied overa sweating natural gas pipeline,the system had poor adhesion, butthe water pH was 11, proving the“fail safe” properties of RD-6.