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Corrosion Control Project

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Corrosion Control Project

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  2. 2. PROJECT TITTLE Corrosion Control/ Cathodic Protection, and Field Surveys of underground pipeline network DAWOOD UNIVERSITY OF ENGINEERING & TECHNOLOGY KARACHI 2
  3. 3. Group Members Dilnawaz D-12-MME-373 Shahnawaz D-12-MME-394 Waqas Junaid D-12-MME-375 Abdul Baseer D-12-MME-379 Israr Ahmed D-12-MME-363 Internal Supervisor METALLURGY & MATERIALS ENGINEERING DEPARTMENT Dr Khursheed Mehmood 3
  4. 4. CONTENTS  Objective  Introduction To Corrosion  Corrosion Control Techniques  Coatings  Cathodic Protection  Chemical Inhibitors  Field Surveys  Experimental Work And Results 4
  5. 5. OBJECTIVE To minimize the corrosion rate in oil & gas sectors To save worlds metal Avoiding hazardous conditions (hydrogen embritlement , blasting of pipes) For increasing life of oil/Gas pipeline To provide high quality of product To run plants good and safe manner 5
  6. 6. INTRODUCTION TO CORROSION 6
  7. 7. CORROSION . Material (Pipeline) Soil Water Oxygen CO2H2O H2SO4 Corrosion E N V I R O N M E N T E N V I R O N M E N T 7
  8. 8. S:No Environment Corrosivity 01 Sea water High 02 Fresh water Low 03 H2SO4 Very high 04 Petroleum & gasses High ENVIRONMENTS AND CORROSIVITY 8
  9. 9. CORROSION CYCLE 9
  10. 10. FORMS OF CORROSION Uniform corrosion Crevice corrosion Galvanic corrosion attack Pitting corrosion 10
  11. 11. Intergranular corrosion attack Stress corrosion cracking Erosion corrosion 11
  12. 12. CORROSION CONTOL TECHNIQUES 12
  13. 13. CORROSION CONTROLLING METHODS 1. Coating 2. Cathodic Protection • Cathodic Protection with Galvanic Anodes • Impressed Current Cathodic Protection 3. Chemical Corrosion Inhibitors 13
  14. 14. COATING FOR PIPELINE Coating is used to protect the pipeline structure and acts as insulated barrier between the environments and the pipelin. Coating is also known as first line of action. It is the best way to protect the metal pipeline from corrosion.  It prevents the metal pipeline in direct contact with the electrolyte (soil & water). Coating can also be used for any environment. 14
  15. 15. TYPES OF COATING 1. ENAMEL COATING 2. TAPE COATING 3. POLYETHYLENE C OATING 4. COLD APPLIED LIQUID COATING 15
  16. 16. ENAMEL COATING TAPE COATING 16
  17. 17. POLYETHYLENE COATING 17
  18. 18. COLD APPLIED LIQUID COATING 18
  19. 19. CATHODIC PROTECTION CHEMICAL INHIBITORS 19
  20. 20. CATHODIC PROTECTION FOR PIPELINE Cathodic protection is an electrochemical process of controlling corrosion activities of underground or submerged metallic structures. The concept of cathodic protection involves reducing the potential differences between the local anodic and cathodic sites. Rate of corrosion could be reduced if every bit of exposed metal on the surface of a pipeline could be made to collect current 20
  21. 21. TYPES OF CATHODIC PROTECTION 1. CATHODIC PROTECTION WITH GALVANICANODES 2. IMPRESSED CURRENT CATHODIC PROTECTION 21
  22. 22. CATHODIC PROTECTION WITH GALVANIC ANODES 22
  23. 23. IMPRESSED CURRENT CATHODIC PROTECTION 23
  24. 24. NACE CRITERI FOR CATHODIC PROTECTION NACE standard RP0169 “control of external corrosion on underground or submerged metallic piping system.” There are three criteria defined in the NACE RP0169 for steel and cast iron including ductile iron are: •A negative (cathodic) potential of at least 850 Mv •A negative polarized potential of at least 850 mV •A minimum of 100 mV of cathodic polarization 24
  25. 25. CHEMICAL INHIBITORS 25
  26. 26. SURVEYS ON PIPELINE 26
  27. 27. PIPE TO SOIL POTENTIAL (PSP) DIRECT CURRENT VOLTAGE GRADIENT (DCVG) CLOSE INTERVAL POTENTIAL SURVEY(CIPS) PIPELINE CURRENT MAPPER (PCM) FIELD SURVEYS 27
  28. 28. PIPE-TO-SOIL POTENTIALS 28
  29. 29. DIRECT CURRENT VOLTAGE GRADIENT (DCVG) 29
  30. 30. CLOSE INTERVAL POTENTIAL SURVEY(CIPS) 30
  31. 31. EXPERIMENTAL WORK & RESULTS 31
  32. 32. Our project experimental work totally based on the field surveys and collecting result of different pipeline structures. We spent 15 days and did some survey at MPL-325, MPL-316, MPL-330, and FOJI FERTILIZER BIN QASIM LIMITED post line. We had two days on coating of indus left bank pipeline 16” dia. We did following surveys and test there: •Pipe-to-soil potential •Close interval potential Survey •Holiday inspection of new coated pipeline EXPERIMENTAL WORK 32
  33. 33. Check Test point Locations Reading Current drain MPL-325 1.28 No current drain MPL-316 1.45 No current drain MPL-330 0.87 Current drain found FFBQL 1.25 No current drain PIPE-TO-SOIL POTENTIAL 33
  34. 34. KMP-341 U/S graph CLOSE INTERVAL POTENTIAL SURVEY 34
  35. 35. KMP-341.5 U/S 35
  36. 36. HOLIDAY INSPECTION Holiday inspection is used to detect coating defect and holidays on new coated pipeline before it buried and old pipeline that has some coating damages. We inspected this method on indus left bank pipeline 16” dia, that was dug for new coating about 1Km. Coal-tar coating was applied on pipeline. We inspected that coated pipeline with holiday detector, and three section were not properly coated. All the damaged sections recoated again and inspected to witness that no holidays on pipeline. 36
  37. 37. CONCLUSION Corrosion is most common problem for any metallic structure that are used in different operating conditions and environments. It is very critical for oil and gas sector pipeline and underground storage tanks.  Cathodic protection has variety of application over this underground pipeline and storage tanks.  The cathodic protection designed and installed according to the NACE standards. NACE standards for external metallic cathodic protection is RPO 169 that is the potentials must be maintained - 850 mV 37
  38. 38. •https://www.corrosionpedia.com/definition/1470/corrosion-cell •https://www.scribd.com/search- documents?query=corrosion+in+oil+industris •http://brage.bibsys.no/xmlui/bitstream/handle/11250/182434/Kote eswaran,%20Mythili.pdf?sequence=1 •http://www.corrosion-doctors.org/Pipeline/Internal-corrosion.htm •http://primis.phmsa.dot.gov/comm/FactSheets/FSInternalCorrosio n.htm?nocache=5208 •http://www.ieaghg.org/docs/General_Docs/Reports/2010-03.pdf •http://precisiondipcoating.com/bed-powder- coating/materialsspecscolors/polyethylene 38
  39. 39. •http://www.corrpro.co.uk/pdf/Anodes/Magnesium/Magnesiu m-Anodes.pdf •http://www.bushman.cc/pdf/impressed_current_system_desig n.pdf •http://cdn.intechopen.com/pdfs-wm/46243.pdf •https://www.wattpad.com/10079155-uses-of-corrosion- inhibitors •http://www.schneider- electric.com/solutions/sa/en/med/691367129/application/pdf/2 393_pipeline-integrity- 39
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