This document discusses corrosion mechanisms and corrosion control for water and wastewater systems. It begins by defining corrosion and describing the 4 components of an electrochemical corrosion cell: the anode, cathode, electrolyte, and metallic path. It then discusses various corrosion mechanisms for water pipes, including internal corrosion in wastewater systems driven by sulfuric acid formation. The document outlines the 4 main methods for corrosion control: material selection, inhibitors, coatings, and cathodic protection. It emphasizes that corrosion control is a long-term process rather than a single project. Condition assessment techniques for various pipe materials are also summarized.
As the oil and gas market moves towards new corrosion-resistant materials and alloys, specifying products has become increasingly complex.
When no single material performs well in every application, how can specifiers determine the best fit for a project? And what can be done to predict the expected service life of a component?
This technical seminar, run by Parker on its stand at the major oil and gas event Offshore Europe 2017, looks at:
• Common types of corrosion and their triggers
• Key factors to consider when selecting materials for a project
• Different manufacturer perspectives and the science behind their arguments
• Risks associated with mixing dissimilar materials.
About Clara Moyanno: As an innovation engineer and expert metallurgist working across the globe, Ms. Moyanno, innovation engineer with Parker Hannifin, deals with all sorts of challenges. She is often involved in discussions on materials selection, including advice to oil and gas producers working on new platforms around the world.
Clara specializes in areas such as tackling corrosion, and materials selection for design specifications. She also advises on quality certifications and regulations around the manufacturing of metals.
Learn more http://parker.com/ipd
Corrosion represents one of the most serious noticed in the industrial world especially in petrochemical, petroleum, power plants, etc.
Billions of Dollars are lost yearly due to the affect of corrosion in the world.
General Corrosion
Galvanic Corrosion
Concentration-Cell Corrosion
Intergranular Corrosion
Stress Corrosion Cracking
Pitting
As the oil and gas market moves towards new corrosion-resistant materials and alloys, specifying products has become increasingly complex.
When no single material performs well in every application, how can specifiers determine the best fit for a project? And what can be done to predict the expected service life of a component?
This technical seminar, run by Parker on its stand at the major oil and gas event Offshore Europe 2017, looks at:
• Common types of corrosion and their triggers
• Key factors to consider when selecting materials for a project
• Different manufacturer perspectives and the science behind their arguments
• Risks associated with mixing dissimilar materials.
About Clara Moyanno: As an innovation engineer and expert metallurgist working across the globe, Ms. Moyanno, innovation engineer with Parker Hannifin, deals with all sorts of challenges. She is often involved in discussions on materials selection, including advice to oil and gas producers working on new platforms around the world.
Clara specializes in areas such as tackling corrosion, and materials selection for design specifications. She also advises on quality certifications and regulations around the manufacturing of metals.
Learn more http://parker.com/ipd
Corrosion represents one of the most serious noticed in the industrial world especially in petrochemical, petroleum, power plants, etc.
Billions of Dollars are lost yearly due to the affect of corrosion in the world.
General Corrosion
Galvanic Corrosion
Concentration-Cell Corrosion
Intergranular Corrosion
Stress Corrosion Cracking
Pitting
Customer Bulletin 0611 Insulant Impact on Corrosion in Steel Piping Applicati...Dyplast Products
Corrosion is defined by the National Association of Corrosion Engineers as “the deterioration of a material, usually a metal, by reaction with its environment.” Corrosion under insulation (CUI) is not a distinct form of corrosion; rather it refers to the location where pipe wall material deterioration is occurring—underneath the insulation material and on the external surfaces of piping. CUI (and the corrosion of metal jackets and banding which is not addressed herein) is a recognized problem that must be addressed by designers, specifiers, and end-users. CUI can occur under any type of thermal insulation. The type of corrosion will depend on the metallurgy of the pipe as well as the mix of corrosive elements - - understanding that corrosive elements can be introduced during pipe production, pipe shipping/storage, installation, insulation contact, process liquid contact, weather, or other environmental influences.
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Fundamentals of Corrosion
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Corrosion rate
Corrosion prediction (likelihood)
Polarization
Protection Methods
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Corrosion is defined by the National Association of Corrosion Engineers as “the deterioration of a material, usually a metal, by reaction with its environment.” Corrosion under insulation (CUI) is not a distinct form of corrosion; rather it refers to the location where pipe wall material deterioration is occurring—underneath the insulation material and on the external surfaces of piping. CUI (and the corrosion of metal jackets and banding which is not addressed herein) is a recognized problem that must be addressed by designers, specifiers, and end-users. CUI can occur under any type of thermal insulation. The type of corrosion will depend on the metallurgy of the pipe as well as the mix of corrosive elements - - understanding that corrosive elements can be introduced during pipe production, pipe shipping/storage, installation, insulation contact, process liquid contact, weather, or other environmental influences.
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We have compiled the most important slides from each speaker's presentation. This year’s compilation, available for free, captures the key insights and contributions shared during the DfMAy 2024 conference.
3. Market Driver for Corrosion Control is
Entropy
Our “Business” is Guaranteed by a
Fundamental Law of Nature:
DSuniverse ≥ 0
4. DEFINITION OF CORROSION
Corrosion is the deterioration of a substance or
its properties as a result of an undesirable
reaction with the environment.
It is irreversible and degenerative and
related to the Second Law Thermodynamics
- NACE International
“Energy spontaneously tends to flow only from being concentrated in one place to becoming
diffused or dispersed and spread out.”
5. Everything You Need to Know
About Corrosion
4 Parts of a Corrosion Cell
Anode (location where corrosion takes place)
o Oxidation Half-Reaction
Cathode (no corrosion)
o Reduction Half-Reaction
Electrolyte (Soil, Water, Moisture, etc.)
Electrical Connection between anode and cathode
(wire, metal wall, etc.)
Electrochemical corrosion can be
stopped by eliminating any one of
the 4 components
11. U.S. Cost of Corrosion is about 3.1% of GDP
(50% to 70% Related to Civil Engineering)
2010 US GDP = $14.72 Trillion
U.S. Cost of Corrosion =
$460 Billion
12. $8.3
$7.0
$0.3
$7.0
$-
$-
$5.0
$36.0
$6.9
$-
$23.4
$2.7
$2.2
$0.5
$0.9
$1.4
$0.1
$3.7
$1.7
$6.0
$1.1
$2.1
$-
$1.5
$20.0
$0.1
$- $10 $20 $30 $40
1.00
Cost Of Corrosion Per Analyzed Economic Sector, ($ x billion)
Highway Bridges
Gas and Liquid Transm. Pipelines
Waterways and Ports
Hazardous Materials Storage
Airports
Railroads
Gas Distribution
Drinking Water and Sewer Systems
Electrical Utilities
Telecommunication
Motor Vehicles
Ships
Aircraft
Railroad Cars
Hazardous Materials Transport
Oil and Gas Expl.and Production
Mining
Petroleum Refining
Chem., Petrochem., Pharm.
Pulp and Paper
Agricultural
Food Processing
Electronics
Home Appliances
Defense
Nuclear Waste Storage
$63 B (2010) (1998)
Annual 1998$
$14B (2010)
$41B (2010)
$35B (2010)
13. Objectives of the Most Infrastructure Projects
• Provide a 50 + Year Useful
Life
• Useful life means:
– Functionality Assured
– Structural Integrity
Maintained
– Operating Costs Controlled
• How do we do this?
– Control the two time
dependent degradation
mechanisms
• Corrosion
• Fatigue
• Creep (Generally Not
Applicable)
14. Two distinct and different types of
Situations:
New Pipe (Lot of Options)
Chance to Do it Right
Right of Way Study through Construction
Existing Pipe (Limited Options)
“Sins of the father”
Condition Assessment
For both, Corrosion Control is a Process,
not a Project.
15. Material Selection/Design Details
Choose materials compatible with environment.
Do not create corrosion cell through
design/construction details.
Corrosion Inhibitors
Alter the environment adjacent to metal to
passivate and protect metal.
Concrete or mortar on steel are inhibitors
Concepts of the Four Basic Methods
Corrosion Control
16. Cathodic Protection
Electrochemically alter the surface condition of
the metal to move the anodic reactions
elsewhere.
Coatings (exterior) and Linings (interior)
Provide a barrier to the electrolyte and protect
the metal. Usually dielectric material that
prevents electron and ionic current flow.
Concepts of the Four Basic Methods
Corrosion Control (continued)
17. Coatings and Cathodic Protection
Work Together
Cathodic protection can be applied with out
coatings.
Coatings should not be used with out cathodic
protection.
Cathodic protection effectively protects defects
in the coating.
In many environments actually repairs the coating
locally by depositing minerals that plug the holes in
the coating
18. Effect of Cathodic Protection
Current
ANODE
-0.65 volt
CATHODE
-0.50 volt
Icorr= 1 mA
ANODE
-0.65 volt
CATHODE
-0.60 volt
Icorr= .3 mA
Before Cathodic Protection After Cathodic Protection
Reduction
in
corrosion
current
C.P. CURRENT
20. $$ are Directly Proportional to
Current Capacity (Amps)
Life Cycle Costs = Construction + Operating
Costs
Initial/Construction costs ~ Amps
Operating/Maintenance Costs ~ Amps
Anything and everything you do to reduce
current requirement saves $$$.
21. Pipe Material Coating System Current Requirement
(ma/sf)
Steel/Iron None 1 to 3
Steel AWWA C205 0.1 to 0.5
Steel/Iron Dielectric Coating
AWWA C214, 217, 222
0.0006 to 0.020
Ductile Iron with PE AWWA C105 0.020 to 0.040
CP Current Requirements for
Water Industry Piping
22. Water vs. Wastewater: External Corrosion
Mechanisms are identical
Corrosion Control for Exterior is Identical
Materials, Design and Construction Practices
Similar…..
But Wastewater construction does not typically
account for the eventual need for cathodic
protection
o Electrical Continuity of Pipelines and Structures
o Electrical Isolation for Appurtenances
23. Water vs. Wastewater:
Internal Corrosion
Not the Same At All.
Corrosion Rates for wastewater can be
extremely high.
More often internal corrosion leads to
problems
This is one reason why external corrosion
is ignored.
25. “Indirect” Impact of Regulations
on Corrosion
H2S crown
2-10 ppm
pH 3-4
H2S crown
~ 30 ppm
pH 1-2
C
l
e
a
n
W
a
t
e
r
A
c
t
o
f
1
9
8
0
C
l
e
a
n
W
a
t
e
r
A
c
t
o
f
1
9
8
0
Reduced metal concentrations in sewage
Elevated levels of bacterial growth
Elevated levels of bacterial growth
H2S crown
2-10 ppm
pH 3-4
H2S crown
~ 30 ppm
pH 1-2
C
l
e
a
n
W
a
t
e
r
A
c
t
o
f
1
9
8
0
C
l
e
a
n
W
a
t
e
r
A
c
t
o
f
1
9
8
0
Reduced metal concentrations in sewage
Elevated levels of bacterial growth
Elevated levels of bacterial growth
H2S crown
2-10 ppm
pH 3-4
H2S crown
~ 30 ppm
pH 1-2
C
l
e
a
n
W
a
t
e
r
A
c
t
o
f
1
9
8
0
C
l
e
a
n
W
a
t
e
r
A
c
t
o
f
1
9
8
0
Reduced metal concentrations in sewage
Elevated levels of bacterial growth
Elevated levels of bacterial growth
27. DIP for Force Main
Gas Pocket Corrosion
Internal Corrosion
28. Corrosion Control for the Outside of
CMC or Concrete Water Pipes
AWWA C205, C300, C301, or C303
Corrosivity of alignment must be
determined
Saturated ASTM G57 Soil Resistivity >
1500 Ω-cm
o Chlorides < 350 ppm in soil
o Sulfates < 2,000 ppm in soil
o No fluctuating groundwater in pipe zone.
pH > 5.0
29. References
AWWA Manual M27 – External Corrosion
AWWA Manual M28 – Rehabilitation of Water
Mains
AWWARF Report 90987 – External Corrosion
and Corrosion Control of Buried Water Mains
NACE International Standards SP0169;
SP0207; Peabody Control of Pipeline
Corrosion
31. Financial Motivation
Shrinking Budgets
GASB 34
Political Motivation
Career Limiting Events
Regulatory Motivation
Jail – Oil and Gas Model
Condition Assessment is Part of the
Asset Preservation
33. Historical Information
Design Information
Leak and Break Rates
Geographical Information
Where should I look?
Industry Metrics
Use your brain….
You can do something without
Technology!
38
57
47
80
69
48 49
42
101
0
20
40
60
80
100
120
2001 2002 2003 2004 2005 2006 2007 2008 2009
Total
Number
of
Blowouts
During
Summer
34. Steel Reservoir Condition Assessments
Raft Inspection
Confined Space
Limited View
Dry Inspections
Unpopular to WD’s
Limits Defects
and access
Hatch Inspection
Limited View
Confined Space
Dive Inspections
Hours of Boredom,
Punctuated by Moments of Terror
Clarity of View
35. Steel Reservoir Coating Condition Assessment
Based on Holistic Results 2001-2002
4 6 11 10
21
210
7
258
11
19
3
11 8
292
6 6 3 3
0
100
200
300
400
1-
Jed
Smith
#1
2-
Jed
Smith
#2
3-
Kiimberly
4-
Mulw
ood
5-
Upper
Woolsey
6
-
Warner
#1
7-
Warner
#2
8-
Calabasas
9-
Dardenne
10-
Latigo
11-
McCoy
12-
Morrison
13-
Oak
Ridge
14-
Saddle
Peak
15-
Saddle
Tree
16-
Seminole
#1
17-
Seminole
#2
18-
Tw
in
Lakes
#1
19-
Tw
in
Lakes
#2
Extrapolated
Current
Requirement
microamps/sq
ft
for
Protection
with
Existing
Coating
Condition
Coating Replacement Recommended Based on Coating
Condition Above Waterline
Existing CP System may be
Damaging Coating
36. PCCP is a Complex Pipe Material.
Composite pipe product
Internal mortar or concrete
lining
Steel Cylinder
Concrete Core(s)
High Strength
Prestressed Wires
Exterior Mortar Coating
1942 “War Pipe” substitute
high strength steel annd
concrete for steel
18 to 250-inch diameter
Up to 350 psi Pressures
Early LC-PCCP Section
0.5 to 1.3 m diameter
Early EC-PCCP Section
1.5 m to 6.5 m diameter
37. Due to its Materials of Construction,
PCCP does not Leak Before it Breaks
Each stick of PCCP contains stored energy
equal to between 20 and 200 lbs of
dynamite.
38. Wires Break – Surge or
Transient
Exterior Mortar Damaged
Compression in Concrete Core
Reduced
Concrete Core in Tension -
Cracking
Steel Cylinder
Corrodes
Pipe Leaks or Fails
The Integrity of PCCP is Directly Related to The Integrity
of the Wires
39. For PCCP, Based on its Era of Design
Initial Estimate of Risk Can Be Made
40. Old School
Condition Assessment
Internal Inspections
• Pre-1992, the only way to
inspect PCCP was to dewater
the pipeline and perform internal
inspections.
• Visual inspection identified
unusual cracking or poorly
detailed joints.
• Sounding techniques located
hollows or delaminations
resulting from a loss of
prestress.
• Human ear, 20 to 20k Hz
• After age 40, 20 to 16k Hz
41. Electromagnetic Inspection:
“New” Assessment Technology
In 1999 & 2001, supplemented the internal
“sounding” procedures with Remote Field Eddy
Current/Transformer Coupling measurements
(RFEC/TC).
“A simple analogy: think of RFEC/TC system as a radio
receiver
The prestressing wire behaves like the radio antenna
With no breaks in the continuity of the prestressing
wire, the radio receives a clear signal from the
transmitting station
If the continuity of the prestressing wire is broken, the
clarity of the signal received is also reduced.”
45. Imagine trying to play an entire round of
golf with a 7-iron.
You can do it but you don’t score well.
Generally, you need a driver and a putter…at
least I do.
Technology provides data, not
information.
Technology is only one club in the
Condition Assessment Golf Bag
46. There are four ways to control corrosion
Material Selection and Design
Corrosion Inhibitors and Monitoring
Coatings and Linings
Cathodic Protection
Technology is a powerful and expensive
tool that needs to be used wisely
There is no substitute for laying eyes and
hands on the structure.
Closing Shots and Thoughts