Atmospheric Corrosion

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Atmospheric Corrosion

• NiSource
• Exposed pipelines

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Team Objectives

• Create a standardize process for identifying and
  repairing atmospheric corrosion in the NiSource
  system.
• Standardize on the documentation
• Standardize on the repair methodology
• Standardize on the timeframe of execution
• Standardize on the data storage and collection

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Codes and Compliance of Atmospheric Corrosion

• DOT subpart I 192
• Revised on Atmospheric corrosion codes
• December 15, 2003

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Codes and Compliance of Atmospheric Corrosion

• DOT definition
• 192.461 External corrosion control Protective
  coating
• (a) Each external protective coating, whether
  conductive or insulating, applied for the purpose
  of external corrosion control must

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Codes and Compliance of Atmospheric Corrosion

• DOT definition (a) continue
• (1) Be applied on a properly prepared surface
• (2) Have sufficient adhesion to the metal surface
  to effectively resist underfilm migration of
  moisture
• (3) Be sufficiently ductile to resist cracking

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Codes and Compliance of Atmospheric Corrosion

• DOT definition (a) continue
• (4) Have sufficient strength to resist damage
  due to handling and soil stress
• (5) Have properties compatible with any
  supplemental cathodic protection.
• (b) Each external protective coating which is an
  electrically insulating type must also have low
  moisture absorption and high electrical
  resistance.

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Codes and Compliance of Atmospheric Corrosion

• DOT definition
• 192.479 Atmospheric Corrosion Control General
  (Revised)

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Codes and Compliance of Atmospheric Corrosion

• DOT definition
• (a) Each operator must clean and coat each
  pipeline or portion of pipeline that is exposed
  to the atmosphere, except pipelines under
  paragraph (c) of this section.
• (b) Coating material must be suitable for the
  prevention of atmospheric corrosion.

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Codes and Compliance of Atmospheric Corrosion

• (c) Except portions of pipelines in offshore
  splash zones or soil to-air interfaces, the
  operator need not protect from atmospheric
  corrosion any pipeline for which the operator
  demonstrates by test, investigation, or
  experience appropriate to the environment of the
  pipeline that corrosion will--
• (1) Only be a light surface oxide or
• (2) Not affect the safe operation of the pipeline
  before the next scheduled inspection.

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• Metal loss Atmospheric Corrosion

• Rust(oxidation) non-Atmospheric Corrosion

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Codes and Compliance of Atmospheric Corrosion

• DOT definition
• 192.481 Atmospheric Corrosion Control
  Monitoring. Revised

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Codes and Compliance of Atmospheric Corrosion

• DOT definition
• (a) Each operator must inspect each pipeline or
  portion of pipeline that is exposed to the
  atmosphere for evidence of atmospheric corrosion,
  as follows each operator shall,
• at intervals not exceeding 3 years for onshore
  pipelines not to exceed 39 months,
• at least once each calendar year, but with
  intervals not exceeding 15 months, for offshore
  pipelines,

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Codes and Compliance of Atmospheric Corrosion

• DOT definition
• (b) During inspections the operator must give
  particular attention to pipe at soil-to-air
  interfaces, under thermal insulation, under
  disbonded coatings, at pipe supports, in splash
  zones, at deck penetrations, and in spans over
  water.

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Codes and Compliance of Atmospheric Corrosion

• DOT definition
• (c) If atmospheric corrosion is found during an
  inspection, the operator must provide protection
  against the corrosion as required by Sec.
  192.479.

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Phases

• Phase One
• Corrosion personnel communicates with Leakage
  Inspector in order to Document all Exposed
  Pipelines
• Exposed Pipelines Evaluation sheet Used
• Corrosion Personnel visits sites of exposed
  pipelines to confirm condition for proper
  documentation
• Corrosion Personnel hands off to Appointed
  Clerical personnel for Database entry (Vicki
  Tehan).
• Corrosion Personnel will be required to Check off
  on Exposed Pipelines Inspection Sheet once every
  three years.

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Phases

• Phase Two
• All Information Collected entered on Data Base
  System (Common MRC Drive)
• Information Entered by Location Number or by
  State/City
• Excel Spread Sheet Used Exposed Pipeline
  Evaluation
• Corrosion Personnel Identifies Areas of
  Atmospheric Corrosion Based on Data Collected
• Target Set for Remedial Action to be Taken
• 33 each year
• 100 Completed within a Three Year Timeframe
• Communication to Operational Center of Status and
  Goal

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Phases

• Phase Three
• Corrosion Personnel works with the operational
  center as an adviser to assure quality of work in
  the remedial process
• May require for the Corrosion Personnel to fill
  in as Contract Inspector
• Corrosion personnel will specify the material to
  be used on the pipeline for proper repair
  methodology
• Corrosion Personnel Updates on Standard form
  Evaluation of Exposed Pipelines updated on
  Network Common Drive (MRC)
• Corrosion FLL evaluates data base system for
  status on target goals, once a year

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Process Map of Exposed Pipelines Atmospheric
Corrosion
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Process Map cont.

• A developed program
• Standardize
• DOT compliance
• PUC compliance
• Policy and Procedure compliance
• Best Practice
• Cost Effective

What is the Atmospheric Corrosion Program ????
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Process Map cont.

• Create Exposed Pipeline Evaluation
• Communicate with Leakage for Data input
• Create book or binder for data information
• Create RTs
• Make copies of inventory maps, store maps into
  binder (highlight areas of exposure)

What is the Atmospheric Corrosion Program ????
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Process Map cont.

• Inspection performed by Leakage program
• Normal Program Timeframes
• Check for Status Change on Pipeline in
  comparison to last inspection by use of Exposed
  Pipeline Evaluation sheet

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Process Map cont.

• Inspection performed by Corrosion personnel
  every three years not to exceed 39 months
• RT Created for sections or segment of pipeline
  (33 of total area per RT)
• Job Type 2312 Maintenance of Mains
• 33 goal set up per year, 3 RTs per Area
• Update Exposed Pipeline Evaluation Sheet (per
  RT)

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Process Map cont.

• Visual Inspection Performed
• Coating Damage
• Pipe Support Damage
• Corrosion/Pitting

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Process Map cont.

• Corrosion/Leakage Inspector Documents on
  Standard Form of Visual Inspection
• Exposed Pipelines Evaluation Form Used
• Identifies Specific Areas of Atmospheric
  Corrosion
• Identifies Inspector
• Meets the DOT Compliance for 3 yr Interval
  survey

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Process Map cont.

• Leakage inspector hands off to Corrosion
  personnel of any updated status of exposed
  pipeline
• Corrosion Personnel will hand off to appointed
  clerical for data base entry (Vicki Tehan)

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Process Map cont.

• Common MRC Drive used
• Installed by Location number or state/city
• Entered by Clerical help
• Accessible by MRC staff
• FLL checks Status annually

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Process Map cont.

• If Further Action is Required
• Corrosion Personnel will need to create a
  further action job order (2312 job type) for
  remedial action to be taken
• Job order needs to be updated with commit date
  and with specific target dates

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Process Map cont.

• Corrosion Personnel recommends Corrosion
  materials to be used
• Corrosion Personnel to assist Operations
  centers in coordinating repairs
• Contacting OCMs, Corrosion FLLs, FOLs
  RPs
• Communicates status of Exposed pipelines
  needing remedial action for budgeting
• Setting up timeframes for work completion
• May need to follow up for QA

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Process Map cont.

• After Completion of Work on Exposed Pipeline -
  Repeat Process
• Corrosion Personnel Performs a Final
  evaluation of Pipeline
• Positive Documentation on Exposed Pipeline
  Evaluation form to be entered on Common MRC drive

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Generalized Corrosion

• If any pipeline identified with atmospheric
  corrosion will need to be evaluated for the
  severity of the corrosion. (Generalized or
  Localized)
• If Corrosion Personnel determines pipeline as
  Generalized Corrosion, the section will need to
  be replaced or repaired before any coating
  application.
• Snap Wraps or Clock Springs could be
  considered as a repair method.

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Generalized Corrosion - Definition

• Generalized Corrosion
• Pipe wall less than 30
• Place a clamp onto the pipe, it will crush the
  pipe
• Wall thickness less than required for the Maximum
  Allowable Operating Pressure

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Repairing Generalized Corrosion

• Best practice
• Snap Wrap application
• Max 20 SYMS
• Max 500lbs pressure
• Minimum Wall thickness no less than 10
• Cost about 300.00 to 400.00 per kit
• Shelve life, normally a year

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Snap Wrap Application

• Give 12 hours for setting up
• Manufacture recommends 4 hours
• Remove the metal bands
• Coat with epoxy paint to prevent damage from the
  UV rays
• Applicable for underground use

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Coating Application

• For Bridge crossings (Recommendation)
• For New or Replacement applications
• Pipeline - use Power Crete coated pipe for extra
  UV protection, Option - Fusion Bonded Epoxy
  min.40 mil thickness
• Joints Use Protal 7200 on replacements, Protal
  ST for repairs
• Supports - insulated and coated with the Protal
  7200
• Urethane coating shall be applied for extra UV
  protection for all application (can be requested
  at the pipe coating mill)

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Coating Application

• For Bridge crossings
• (Recommendation)
• For Repair Application
• Cold Applied Tapes Used
• Wax Tapes
• Petrolatum Tapes with the PVC outer wrap
• Two part liquid epoxy used -
• Protal ST
• Do not use polyethylene (extruded) coating -
  normally a yellow jacketed coating. Not approved
  for above ground use.

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Exposed Pipeline Evaluation Sheet
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Information Required

• RT Number
• RT number created, three total for each area, 33
  of workload per RT.
• Location area, city, map , and town
• Street Location Needed or Intersecting Streets,
  add specific additional information for location
  of pipeline.

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Exposed Pipeline Evaluation Sheet
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Information Required

• Pipe Diameter
• Measured in Inches
• Length
• Total length of exposure measured in feet
• Hangers, Rollers and Shields
• Total number of each if applicable
• Comments of pipeline surface and coating
• Over the entire exposure with particular
  attention to the soil to air interfaces, deck
  penetrations, and supports

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Exposed Pipeline Evaluation Sheet cont.
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Information Required

• Atmospheric Corrosion (Y or N)
• We want to identify if metal loss has taken
  place.
• Remedial Job Orders
• Remedial job order Job order number.
• Target Date Date set to make repairs.
• Corrosion Technician initials and date
• Corrosion technician initials and documents the
  date of the inspection