Pipeline Corrosion Report - FINAL - Pipeline and Hazardous ...

1 PPiippeelliinnee CCoorrrroossiioonn FINAL Report Submitted to Department of Transportation Pipeline and Hazardous Materials Safety Administration Office of Pipeline Safety Integrity Management Program Under Delivery Order DTRS56-02-D-70036 Submitted by Michael Baker Jr., Inc. Contributing Author Raymond R. Fessler, BIZTEK Consulting, Inc. November 2008 Table of Contents Pipeline Corrosion November 2008 Page i Table of Contents 1 1 Corrosion Overview.

2 1 Corrosion in 2 Frequency and Consequences in the United States .. 2 Transmission 3 Natural Gas Distribution 5 Gas Gathering 6 Experience .. 6 State of Knowledge Regarding Corrosion .. 8 2 Background .. 10 Problem 10 Project Scope .. 10 Report Outline .. 10 3 Corrosion in 11 Understanding the 11 Uniform vs. Localized Corrosion .. 12 Pitting .. 12 Selective Seam Corrosion .. 13 Microbial Corrosion .. 13 External 14 Factors that Affect External Corrosion .. 14 Onshore Buried Pipelines.

3 14 Offshore Pipelines .. 15 Methods to Prevent or Mitigate External Corrosion on Buried 15 Cathodic Protection .. 19 Other Preventive/Mitigative Measures .. 20 Monitoring Techniques for External Corrosion .. 21 Internal 22 Gas Pipelines .. 22 Liquid Pipelines .. 22 Preventive/Mitigative Measures for Internal 23 Dehydration .. 23 Inhibitors ..24 Buffering ..24 Cleaning 24 Biocides ..24 Additional Preventive 25 Preventive/Mitigative Measures for Selective Seam Corrosion .. 25 Preventive/Mitigative Measures for MIC on Gas Pipelines.

4 25 Monitoring Internal Corrosion .. 25 Environmentally Assisted Cracking .. 26 Stress- Corrosion Cracking (SCC) .. 26 External SCC .. 26 Internal SCC .. 27 Corrosion 27 Table of Contents Pipeline Corrosion November 2008 Page ii Hydrogen 28 Hydrogen-Stress 28 Hydrogen-Induced Cracking .. 29 Loss of Ductility .. 29 Implications for Pipelines in a National Hydrogen Economy .. 29 Sulfide-Stress 4 Corrosion Threat 31 Overview .. 31 External 31 Internal 31 Stress Corrosion Cracking .. 31 5 Corrosion Damage-Assessment Methods.

5 33 Overview .. 33 In-line 33 Hydrostatic Testing .. 35 Direct Assessment .. 36 External Corrosion Direct Assessment .. 37 Internal Corrosion Direct Assessment for Gas Pipelines .. 38 Stress Corrosion Cracking Direct Assessment .. 40 Emerging Technologies .. 40 Long-Range Guided-Wave Ultrasonic Testing (LRGWUT or GWUT) .. 40 Remote Field Testing (RFT) .. 41 Robotic Investigation .. 42 Sound-Wave Testing ..43 NoPig .. 43 Buried Reference Cell Monitoring .. 43 Specialized Techniques .. 44 Microbiologically Influenced Corrosion Monitoring Techniques.

6 44 Assessing the Severity of 44 Assessing the Severity of Stress Corrosion 45 6 Standards 46 Overview .. 46 Standard Development Organizations .. 46 NACE International ..46 American Society of Mechanical Engineers .. 46 American Petroleum 46 ASTM International ..46 American Society for Nondestructive Testing .. 46 American National Standards Institute .. 46 International Organization for Standardization .. 47 Det Norske Veritas .. 47 British Standards Institute ..47 Regulations and Standards .. 47 47 Standards.

7 47 Relevant 50 Role of Industry Best Practices Regarding Corrosion .. 50 7 Corrosion Risk Management .. 51 Overview .. 51 Risk Assessment Methodologies .. 51 Subject Matter Expert Model .. 52 Table of Contents Pipeline Corrosion November 2008 Page iii Relative Risk 52 Probabilistic Model .. 53 Characteristics of an Effective Risk 53 54 8 Corrosion Research .. 55 Overview .. 55 Corrosion R&D Funding Organizations .. 55 Current Corrosion R&D Efforts .. 55 Prevention .. 55 Detection .. 56 Assessment.

8 56 Mitigation .. 56 Corrosion R&D Requirements .. 57 Summary of Corrosion R&D Activities .. 57 9 Elements of an Effective Corrosion Integrity Management 58 Overview .. 58 Technology .. 58 Components of an Effective Integrity Management Program .. 58 Resource Requirements (after Byrd, 2004) .. 59 10 Summary and 61 Frequency and Consequences of Corrosion 61 Prevention of Corrosion in 61 Corrosion Threat Identification ..63 Assessing the Severity of 63 Regulations and 65 Regulations .. 65 Standard Development Organizations.

9 65 Corrosion Risk Management .. 66 Corrosion Research .. 67 Corrosion Integrity Management Programs .. 68 11 Bibliography .. 69 12 Appendix A .. 71 Listing of Relevant Current Research .. 71 PRCI funded R&D (from Web Site):.. 71 PHMSA Funded R&D (not listed elsewhere).. 71 NYSEARCH (Part of NGA) .. 72 72 List of Abbreviations Pipeline Corrosion November 2008 Page iv List of Abbreviations AC Alternating Current AGA American Gas Association AGM Aboveground Marker ANB Anaerobic Bacteria ANSI American National Standards Institute AOPL Association of Oil

10 Pipelines APB Acid-Producing Bacteria API American Petroleum Institute ASME American Society of Mechanical Engineers ASNT American Society for Nondestructive Testing ASTM ASTM International (formerly the American Society for Testing and Materials) AWWA American Water Works Association BSI British Standards Institute CEPA Canadian Energy Pipeline Association CFR Code of Federal Regulations CP Cathodic Protection CSE Copper/Copper Sulfate Electrode DA Direct Assessment DC Direct Current DNV