Peabody's control of pipeline corrosion PDF
Preview Peabody's control of pipeline corrosion
P1:FCE/FEP P2:FCE CE003-FM CE003-Peabody November16,2000 13:35 CharCount=0 PEABODY’S CONTROL OF PIPELINE CORROSION SECOND EDITION A.W. PEABODY Editedby RONALD L. BIANCHETTI NACEInternational TheCorrosionSociety 1440SouthCreekDrive Houston,Texas77084 i P1:FCE/FEP P2:FCE CE003-FM CE003-Peabody November16,2000 13:35 CharCount=0 NACEInternational TheCorrosionSociety (cid:176) C 1967,2001byNACEInternational SecondEdition2001. Allrightsreserved. LibraryofCongressCatalogNumber99-80032 ISBN1-57590-092-0 PrintedintheUnitedStatesofAmerica. Allrightsreserved. Thisbook,orpartsthereof, maynotbereproducedinanyformwithoutpermissionofthecopyrightowners. Neither NACE International, its officers, directors, or members thereof accept any re- sponsibilityfortheuseofthemethodsandmaterialsdiscussedherein. Theinformation isadvisoryonlyandtheuseofthematerialsandmethodsissolelyattheriskoftheuser. CoverillustrationbyMarkLewis,courtesyoftheEastBayMunicipalUtilityDistrict. NACEPress: DirectorofPublications:JeffLittleton ManagerofNACEPress:NeilVaughan NACEInternational 1440SouthCreekDrive Houston,Texas77084 http:==www.nace.org ii P1:FCE/FEP P2:FCE CE003-FM CE003-Peabody November16,2000 13:35 CharCount=0 Table of Contents Preface v AbouttheAuthor vii Contributors ix Chapter1 IntroductiontoCorrosion JohnA.Beavers 1 Chapter2 PipelineCoatings RichardN.Sloan 7 Chapter3 CathodicProtection—HowItWorks JohnA.Beavers 21 Chapter4 CriteriaforCathodicProtection JohnA.BeaversandKevinC.Garrity 49 Chapter5 SurveyMethodsandEvaluationTechniques RonaldL.Bianchetti 65 Chapter6 Instrumentation MarkLewis 101 Chapter7 GroundBedDesign RonaldL.Bianchetti 131 Chapter8 ImpressedCurrentCathodicProtection RonaldL.Bianchetti 157 iii P1:FCE/FEP P2:FCE CE003-FM CE003-Peabody November16,2000 13:35 CharCount=0 iv TableofContents Chapter9 CathodicProtectionwithGalvanicAnodes RonaldL.Bianchetti 177 Chapter10 CathodicProtectionwithOtherPowerSources JohnA.Beavers 201 Chapter11 StrayCurrentCorrosion MichaelJ.Szeliga 211 Chapter12 ConstructionPractices RonaldL.Bianchetti 237 Chapter13 MaintenanceProcedures RonaldL.Bianchetti 261 Chapter14 MicrobiologicallyInfluencedCorrosion BrendaJ.LittleandPatriciaWagner 273 Chapter15 Economics RonaldL.Bianchetti 285 Chapter16 FundamentalsofCorrosion JohnA.Beavers 297 AppendixA NACEGlossaryofCorrosion-RelatedTerms 319 AppendixB AdditionalImportantInformationonUndergroundCorrosionControl 339 Index 341 P1:FCE/FEP P2:FCE CE003-FM CE003-Peabody November16,2000 13:35 CharCount=0 Preface Thisbookwasoriginallypublishedin1967bySamPeabodyandisthemostquotedand useddocumentinthecorrosionindustryforpipelinecorrosioncontrolandtesting. When theoriginalbookwaspublished,specificcriteriaforcathodicprotectionforunderground pipelines were still under evaluation and consideration. Not until 1969 was the first documentedstandardapprovedbyNACEInternationaloncriteriaRP0169. Thedepth andvisionthatPeabodyincorporatedinthefirstversionofthebookhasstoodthetest oftime. Thisrevisedversionofthe1967bookisnotanattempttomakeradicalchangestothe originaldocument. Muchoftheoriginaltextandconceptsremainintact. Weattempted, however, to incorporate original traditional elements of the book with updates and expanded discussions on equipment, testing techniques and criteria, coatings, survey methods,anddataanalysis. AnintegralpartofthisrevisionisaCD-ROMthatcontainsformulasofkeydesign calculations, case examples of corrosion control designs which provide a set-by-step overviewofhowtodesignvariouscomponentsofcathodicprotectionsystems,andan electroniccopyoftherevisedbookedition. AsdescribedinthePrefaceoftheoriginal1967edition,everyattempthasbeenmade to check the accuracy of all statements and other data. However, it is unreasonable to assume that everything in this book is accurate and exact. Any suggestions will be consideredwhenfutureeditionsofthisbookareprepared. v P1:FCE/FEP P2:FCE CE003-FM CE003-Peabody November16,2000 13:35 CharCount=0 About the Author 1915–1998 ThisupdatedversionofNACEInternational’sbooktitledControlofPipelineCorrosionis dedicatedtothememoryofitsoriginalauthor,A.W.(Sam)Peabody. Sinceitspublication in 1967, the book has been translated into at least seven different languages and is consideredbymostasthedefinitiveworkonpipelinecorrosion. Samreceivedhisbachelor’sdegreefromtheUniversityofMaineandpursuedgrad- uatestudiesattheBrooklynPolytechnicInstituteinNewYork. HeworkedforEbasco Services Inc. (no longer in existence) for over 40 years until his retirement in 1980 as DirectorofCorrosionEngineering. HewasanactivememberofNACEsince1947. His accomplishments,awards,andrecognitionsaretoomanytolisthere. Hisbiggestlegacy, especiallytothoseofuswhohadtheprivilegeofworkingforandwithhim,isthathe was the perfect example of “a gentleman and a scholar.” He was an excellent teacher whoalwaysemphasizedprofessionalintegrity,aqualityheinstilledinsomany. vii P1:FCE/FEP P2:FCE CE003-FM CE003-Peabody November29,2000 10:8 CharCount=0 Contributors JohnA.Beavers John A. Beavers is Vice President of Research at CC Technologies, a corrosion engineering andresearchcompany. HereceivedB.S.andPh.D.degreesinmetallurgicalengineeringfrom theUniversityofIllinoisatUrbana-Champaignin1973and1977, respectively. Dr. Beavers has directed and contributed to numerous research programs on corrosion performance of structuralmaterials.Theseprogramsincludedfailureanalyses,criticalliteraturereviews,and laboratoryandfieldevaluationsofmetallicandnon-metallicmaterial.Dr.Beavershasutilized state-of-the-artelectrochemical,surfaceanalytical,andmechanicaltechniquesfortheevalua- tionofmaterialsperformance.Amajoremphasisofhisresearchhasbeenthemechanisticand practicalaspectsofcorrosionandstresscorrosioncracking(SCC)onundergroundpipelines. Dr.BeaversworkedatBattelleMemorialInstitutefrom1977to1987,wherehewasaSenior ResearchLeaderintheCorrosionSection. HejoinedCCTechnologiesin1987. Dr. Beavers has authored over 80 papers in the field of corrosion and has received two U.S. Patents. An active member of NACE, he was Chairman of the Research in Progress Symposiumin1994andofthePublicationsCommitteein1991and1992. Editor’s Note: Sincere appreciation to John Beavers for investing a lot of time on a detailed and productivereviewofthefinaldraftontheevebeforeprinting. RonaldL.Bianchetti Ronald L. Bianchetti is currently a Senior Engineer at East Bay Municipal Utility District (EBMUD) in Oakland, California. He received a B.S. in engineering in 1975 from the University of California, Davis and an MBA in 1981 from St. Mary’s College of California. HeisaRegisteredProfessionalEngineerandhasover25yearsofexperience. Priortoholding his current position, Mr. Bianchetti worked in the private sector as a consultant in the cor- rosion industry from 1975 to 1992. His work includes planning, designing, testing, and the construction management of cathodic protection systems for underground pipelines, tanks, refineries,powerplants,andmarinestructures. HehasservedinNACEInternationalasPast ix P1:FCE/FEP P2:FCE CE003-FM CE003-Peabody November29,2000 10:8 CharCount=0 x Contributors Chairman of the Publications Committee, ad-hoc member to the Board of Directors, Past WesternRegionChairmanandPastSectionChairoftheSanFranciscoSection. Mr. Bianchettihaspublishedover30papersinthefieldofcorrosionandhasgivenhun- dredsofpresentationsoncorrosionandcorrosioncontrol. KevinC.Garrity,P.E. Kevin C. Garrity, P.E., is currently Vice President of Engineering at CC Technologies, a cor- rosion engineering and research company. He received a B.S. in electrical engineering in 1974fromthePolytechnicInstituteofBrooklyn. HeisaNACECertifiedCathodicProtection Specialist and a Registered Professional Engineer in seven states. Mr. Garrity has 26 years of experience in the design, installation, monitoring, and assessment of cathodic protection systems for buried pipelines, underground storage tanks, concrete structures, and marine structures. Mr. GarrityworkedatEbascoServicesfrom1974to1982,wherehewasaSenior CorrosionEngineer,andatHarcoCorporationfrom1982to1989,wherehewasVicePresident ofEngineering. HejoinedCCTechnologiesin1989. In1996,Mr. GarrityreceivedtheColonelGeorgeW.CoxAwardforoutstandingcontribu- tionstothefieldofundergroundcorrosioncontrol. Hehaspublishedmorethan20papersin thefieldofcorrosioncontrol. Mr. GarritydeliveredtheplenarylectureatCorrosion’98. MarkLewis Mark Lewis is Assistant Corrosion Engineer at the East Bay Municipal Utility District (EBMUD) in Oakland, California. He is a graduate of Kent State University and attended Bethany College in West Virginia. He has worked in the cathodic protection and corrosion engineeringfieldsince1980, bothwithintheUnitedStatesandinternationally. HeisaPast ChairmanoftheSanFranciscoBayAreaSectionofNACEInternational. Heistheauthorofseveraltechnicalandhistoricalarticlesoncathodicprotectionandhas madenumerouspresentationsonthesubject.Mr.Lewishasapatentpendingforadistribution systemrectifierdesign. BrendaJ.Little BrendaJ.Little,SeniorScientistforMarineMolecularProcessesattheNavalResearchLabora- tory,hasaPh.D.inchemistryfromTulaneUniversityandaB.S.inbiologyandchemistryfrom BaylorUniversity. SheisamemberoftheAmericanChemicalSocietyandtheNationalAs- sociationofCorrosionEngineers(NACEInternational). SheisaNACEInternationalFellow andtherecipientofa1999NACEInternationalTechnicalAchievementAward. Dr. Little serves on the editorial board for Biofouling and is the author of one book, 20 bookchapters,andover80peer-reviewedjournalarticles. P1:FCE/FEP P2:FCE CE003-FM CE003-Peabody November29,2000 10:8 CharCount=0 Contributors xi SteveMcKim Since 1989, Steve McKim has been Vice President of American Construction & Supply, Inc. Basedin Mill Valley, California, his company specializesincathodicprotectionconstruction services.Mr. McKimpreviouslyworkedwithHarcoCorporationandChevronUSA.Hehas beeninthecorrosionindustrysincehegraduatedfromtheUniversityofIllinoiswithaB.S.in mechanicalengineeringin1983. HeisaPastChairmanoftheNACESanFranciscoBayArea Section. RichardN.Sloan ThelateRichardSloan,wasanauthorityinthefieldofpipelinecoatings. Heworkedforover 45yearswithacompanythatwasfirstknownasHCPrice. (Thecompanychangeditsname several times: HC Price, Ameron Price, Bredero Price, and Energy Coatings.) He attended DrexelUniversityandgraduatedwithabachelor’sdegreeinIndustrialAdministration. During his professional career, Richard Sloan taught various short courses in pipeline coatings,andwasaspeakeratnumerousseminarsonthesubject. ThelateMr.Sloanwasan activeandlong-standingmemberofNACE,AWWA,andWesternPipeliners. MichaelJ.Szeliga MichaelJ.Szeliga,P.E.,istheChiefEngineerforRussellCorrosionConsultants,Inc. Hehas more than 23 years of experience in corrosion control engineering. Much of his work has involved the analysis and control of stray current from DC-powered transit systems and from impressed current cathodic protection systems. A Licensed Professional Engineer in severalstatesandcertifiedbyNACEInternationalasaCorrosionSpecialistandaCathodic Protection Specialist, Mr. Szeliga has been and is the principal corrosion consultant for the design, construction, and maintenance of many light and heavy rail transit systems. He is presently chairman of the NACE (05)024X Committee on Interference Problems Associated withRailTransit. Mr. SzeligaisalsochairmanoftheASTMsubcommitteeonstraycurrent. HehaseditedabookforNACEInternationaltitledStrayCurrentCorrosionandhaspub- lishedseveralarticlesonthesubject. PatriciaWagner PatriciaWagnerretiredfromtheNavalResearchLaboratoryin1998after14yearsofextensive experienceinmicrobiologicallyinfluencedcorrosion. Sheisthecoauthorofonebookandthe authorofnumerousarticlesoncorrosion. P1:GKW/SPH P2:GKW/UKS P3:GKW/UKS QC:GKW/UKS T1:GKW CE003-01 CE003-Peabody November15,2000 10:33 CharCount=0 1 Chapter Introduction to Corrosion John A. Beavers WHAT IS CORROSION? One general definition of corrosion is the degradation of a material through environ- mentalinteraction.Thisdefinitionencompassesallmaterials,bothnaturallyoccurring and man-made and includes plastics, ceramics, and metals. This book focuses on the corrosion of metals, with emphasis on corrosion of carbon and low-alloy steels used inundergroundpipelines.Thisdefinitionofcorrosionbegsthequestion;whydomet- als corrode? The answer lies in the field of thermodynamics, which tells whether a process such as corrosion will occur. A second logical question is what is the rate of corrosion or how long will a pipeline last? Corrosion kinetics can help provide an answertothisquestion.BothtopicsarediscussedingreaterdetailinChapter16.Chap- ter 1 contains an introduction to the subject of underground corrosion. A glossary of terms is included in Appendix A of this book to help with the sometimes confusing terminology. A significant amount of energy is put into a metal when it is extracted from its ores,placingitinahigh-energystate.Theseoresaretypicallyoxidesofthemetalsuch as hematite (Fe O ) for steel or bauxite (Al O ¢H O) for aluminum. One principle of 2 3 2 3 2 thermodynamicsisthatamaterialalwaysseeksthelowestenergystate.Inotherwords, mostmetalsarethermodynamicallyunstableandwilltendtoseekalowerenergystate, whichisanoxideorsomeothercompound.Theprocessbywhichmetalsconverttothe lower-energyoxidesiscalledcorrosion. Corrosionofmostcommonengineeringmaterialsatnear-ambienttemperaturesoc- cursinaqueous(water-containing)environmentsandiselectrochemicalinnature.The aqueous environment is also referred to as the electrolyte and, in the case of under- ground corrosion, is moist soil. The corrosion process involves the removal of elec- trons(oxidation)ofthemetal[Equation(1)]andtheconsumptionofthoseelectronsby someotherreductionreaction,suchasoxygenorwaterreduction[Equations(2)and(3), 1
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