Escolar Documentos
Profissional Documentos
Cultura Documentos
131
In this issue:
Across the Generations - Jack Tighe Ltd Page 6
Aberdeen Branch News Pages 8-9
Through the Looking Glass - 50 Years in Polymer Repair Page 17
CorrosionManagement | May/June 2016
2
CORROSION MANAGEMENT
A JOURNAL OF THE INSTITUTE OF CORROSION May/June 2016 No.131
CONTENTS
Published on behalf of the Institute of Corrosion
Square One Advertising and Design Limited Institute News
84 Queen Street, Sheffield S1 2DW,
United Kingdom. The President Writes 4
Publisher and Managing Editor
Debbie Hardwick London Branch News 5
Tel: 0114 273 0132
Fax: 0114 270 0422 Jack Tighe Ltd 6-7
Email: debbie@squareone.co.uk
Technical Editor Aberdeen Branch News 8-9
Prof. Robert Akid CEng, FIMMM, FICorr
Email: robert.akid@manchester.ac.uk
CED Working Day 10
Design
Square One Advertising & Design
www.squareone.co.uk
North East Branch 11
Advertising Manager
Jonathan Phillips
Tel: 0114 273 0132 Technical Article
Fax: 0114 272 1713 Enhancing Pipeline Integrity Using External Corrosion
Email: jonathan@squareone.co.uk
Editorial copy date for July/August 2016
Direct Assessment: Case Study of United Energy Pakistan 12-15
issue is: 10th june 2016
Subscriptions
UK 70.00 Advertorials
Europe 80.00
Outside Europe 90.00 airmail Belzona Polymerics Ltd. 16-17
80.00 surface mail
Enquiries and subscriptions to the Institute of Arc Energy Resources Limited 18
Corrosion at the address below
Alfred Bagnall & Sons Limited 18
The Institute of Corrosion
President
John Fletcher Sustaining Members 19-23
Immediate Past President
Trevor Osborne
Vice President ICATS Registered Companies 24-27
Sarah Vasey
Hon. Secretary
Dr. Jane Lomas
Diary and Branch Contacts 28
www.icorr.org
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INSTITUTENEWS INSTITUTENEWS
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INSTITUTENEWS INSTITUTENEWS
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INSTITUTENEWS INSTITUTENEWS
6
INSTITUTENEWS INSTITUTENEWS
Kelpies
Thames Barrier
The Orbit
Although he has been involved with many major him and the drive to succeed that has made Business continuity was always in his thoughts
contracts, his Company undertook the blast- him successful in anything he turned his hand and in conjunction with his management team
cleaning and coating of the Thames Barrier to. he has structured the group of companies
Gates at Cleveland Bridge during the 1970s, Throughout his life he has been associated in such a way as to safeguard the jobs of its
which has proved to be so successful. with the application of protective coatings employees and ensure business continuity
Jack is probably one of the best known names in to some of the most iconic structures such as upon his demise, in his words it must be
the coating industry. the Millennium Dome, Millennium Stadium, business as normal when Im gone.
David H. Deacon - 50th Committee Chairman Wembley Stadium, Kings Cross Station, Jack Tighe will be sadly missed by his family,
Olympic Structures The Orbit, Kelpies, Hydro friends and staff.
Not being one to stand still he has actively Electric Pipelines and Thames Barrier but to
encouraged his staff to look at ways to expand name a few.
the business, perhaps it was the sportsman in
8
INSTITUTENEWS INSTITUTENEWS
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INSTITUTENEWS INSTITUTENEWS
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INSTITUTENEWS INSTITUTENEWS
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TECHNICALARTICLE TECHNICALARTICLE
Abstract
External corrosion is a well-known threat to
structural integrity of buried pipelines in the
oil and gas industry. Regulatory authorities
along with a current slump in oil and gas prices
are putting increasing pressure on pipeline
operators to safeguard pipeline integrity and
minimize maintenance cost. NACE standard
SP0502 completely defines the pipeline
external corrosion management, though, the
order in which pipeline defect locations are
interrogated is at the discretion of pipeline
operators. This paper presents a novel cost
effective approach to quantify the pipeline
defects severity and to prioritize the pipeline
excavations comprising minimal number of
digs to precisely locate the pipeline defects.
Buried carbon steel oil and gas pipeline
network spanning over 70 kilometres is
assessed to evaluate and obviate the threat
of external corrosion. Alignment of indirect
Figure 1: Anomalies Record (2012-2015).
inspection data obtained from multiple indirect
inspection surveys is also presented. Finally,
the proposed criterion is assessed and found
the safety, environmental performance and 2.1.1 Data Collection
economics of pipelines operations.
to be very effective showing 50% reduction in
Pipeline External Corrosion Direct Assessment
and Pipeline Risk
cost and improved pipeline integrity.
methodology is described in NACE SP0502.This Ranking
1. Introduction standard practice does not provide absolute For current work, a comprehensive pipeline
Structural integrity of buried onshore pipelines severity classification and excavation criteria, risk ranking assessment was carried out in
in the oil and gas industry is of particular allowing pipeline operator to classify defects which the data related to pipeline design,
importance as their failure can result in severity and develop excavation prioritization construction, soil, environment, corrosion
safety hazards, substantial economic losses on their judgement and in accordance with the control, cathodic protection and operational
and environmental damage. United Energy specific conditions of the pipeline. history is taken into account in combination
Pakistan (UEP) is a private firm operating in The objective of this paper is to present a with the data which has an impact on business,
Pakistan primarily focusing on exploration and workable newly developed approach that can environment and people. The pipelines risk
production of oil and gas in the Sind province be used as a basis to prioritize the excavations is calculated based on the probability and
of Pakistan having buried onshore pipeline resulting in an enhanced pipeline integrity consequence of a corrosion event. Out of 40
networks spanning over 1100 kilometres. spending minimal cost. pipelines, 10 high-risk pipeline regions were
Under the Integrity Management System, UEP shortlisted through a rigorous risk-ranking
uses Pipeline Integrity Management Scheme 2. The Four-Step process and categorized into different regions
(PIMS) to identify the potential threats to Methodology (discussed later). The regions consist of around
the pipelines due to external corrosion and 70 kilometres of buried onshore CS pipelines
As stated in SP0502, ECDA involves four steps
their continuous mitigation. As a part of PIMS, of different lengths. All pipelines shortlisted are
which are discussed in detail in the subsequent
External Corrosion Direct Assessment (ECDA) of API 5 L grade, coated with fusion bonded
sections.
is carried out on an annual basis in UEP to epoxy.
boost pipelines integrity in accordance with 2.1 Step 1: Pre Assessment 2.1.2 ECDA Feasibility
the NACE standard SP0502. This step requires sufficient amount of data
The historical distribution of major pipeline collection, integration and examination Assessment
defects recorded on the pipeline system of UEP related to pipeline construction, operations The data gathered in the data collection phase
operations is summarized in Figure 1. Given and environment to decide whether ECDA is was amalgamated and scrutinized to check
the share of external corrosion, it is apparent feasible for the pipeline to be evaluated along for any condition, which can make the use
that appropriate external corrosion control with the selection of indirect inspection tools. of indirect inspection tools impracticable or
methods would have a foremost influence on could impede the ECDA application, such as
12
TECHNICALARTICLE TECHNICALARTICLE
Cathodic
Construction Prior
S.No Pipeline Diameter (in) Length (m) Material & Coating Protection
Year Corrosion
Type
pavements, frozen grounds and inaccessible provide the pipe to soil potential profile of the builds a solid footing for direct examinations.
areas. However, majority of the pipeline pipeline, CIPS is performed to explore the ON After identification of the faults, they are
regions were found to be feasible for ECDA and Instant-OFF potentials over the entire classified in accordance with their severity. For
assessment, except a few locations such as pipeline regions. In addition, CIPS also gauges this study, a stringent severity classification
paved road crossings and water crossings the performance of the CP system. In short, criterion is devised and incorporated into
which may pose a challenge to apply ECDA the tools were selected such that the strength prioritization criterion shown in Table 2.
and requires an alternate integrity assessment of one tool compensates the limitations of The criterion provides specific quantifiable
method extending beyond the scope of another. and explicitly definable conditions and is
this study. An ECDA region is a region that has similar developed on the basis of previous corrosion
physical characteristics, corrosion histories, activities on pipelines, CP system performance
2.1.3 Selection of expected future corrosion conditions, and uses and pipelines physical and operational history,
Indirect Inspection the same indirect inspection tool. In this work, complying with one of the aims of this
the selected pipeline regions have different work. A similar criterion has been described
Tools & ECDA Regions physical conditions, cathodic protection, previously [1]; however, more realistic and
Determination corrosion history and construction year and stringent numbers are used here for accurate
Consistent with SP-0502, the regions where are all buried in dissimilar soil environment. classification according to specific pipeline
ECDA is to be applied, a minimum of two Therefore, 10 different non continuous regions conditions.
indirect inspections tools should be selected. are defined, details of which is presented in
However, based on their ability to accurately Table 1. 2.2.1 Defect
detect coating defects and corrosion activity,
2.2. Step 2: Indirect Prioritization
the following three techniques used for
indirect inspections are chosen from the ECDA Inspections Criterion
tools selection matrix given in SP 0502: Faulty regions identified during the indirect
The central focus of indirect inspection is
inspection step necessitate efficient
Pipeline Current Mapper (PCM) to identify and address coating faults and
excavations to expose the pipe surface so that
Direct Current Voltage Gradient (DCVG) corrosion activity along with the other
measurements and pipeline health assessments
associated defects without exposing the pipe
Close Internal Potential Surveys (CIPS) [7] can be made, which is the principal target of the
surface. This is a key stage as it produces a
These tools are selected based upon the direct examinations. Based on the likelihood
direct examination plan that will minimize
individual strengths associated with each tool. of current corrosion activity, the magnitude
the direct examination costs while achieving
PCM works on a current attenuation principle and severity of prior corrosion and approach
the required confidence level. In this work,
and helps to detect the exact pipeline location, of optimal digs and reduced cost, severity
the three tools mentioned above were used
burial depth, casing shorts, unauthorized classification and prioritization criterion is
one by one between short time intervals
pipeline connections and spots the area of presented in this study as shown in Table 2. The
over the entire buried length of the pipeline
reduced coating quality, though it does not severity and prioritization crieterions are both
to circumvent any changes in the survey
identifies the exact coating defect location incorporated into a single matrix, contrary to
conditions such as change in temperature and
unless a secondary holiday pinpoint survey is the previously proposed criterions which are
soil moisture content. The complete survey
used. On the other hand, DCVG overcomes the described separately [1],[2]. Referring to Table
on a 70 Km pipeline network took around
limitation associated with the PCM, and is used 2, the results obtained through DCVG and
25 days. Data collected from three surveys
to pin point the coating defects by providing PCM are plotted against CIPS to prioritize the
during indirect examinations were pooled
the approximate defect size, defect severity pipeline excavation. The pipeline prioritization
and evaluated in combination with each
estimation and corrosion state of a coating and excavation scheme (dig & no dig areas)
other. It is noteworthy that correlating and
holiday. Moreover, the DCVG survey is said is clearly defined in the criterion. Table 2 also
aligning the data gathered from three different
to locate the coating holidays more precisely contains the notes describing the excavation
surveys plays a pivotal part in determining
than any other survey [7]. Since DCVG doesnt prioritization.
the effectiveness of indirect examinations and
13
CorrosionManagement | May/June 2016
TECHNICALARTICLE TECHNICALARTICLE
14
TECHNICALARTICLE TECHNICALARTICLE
inside the blisters having a basic pH which determining the overall effectiveness of the approach of ECDA survey technique has been
might have caused the coating disbondment. ECDA process. Here, except at two locations demonstrated as well, which when used with
All the coating damage was repaired through no external corrosion damage was found. As the proposed decision matrix has resulted in a
liquid epoxy coat. After the coating repair, stated in SP0502, the reassessment intervals at dig efficiency of 97%.
cathodic protection current demand of the the corrosion areas were taken as one-half of This study is intended to provide the onshore
pipeline was decreased by 20%. Similar data the calculated remaining life. To estimate the pipeline operators with a value adding tool to
analysis and repair methodology was adopted remaining life due to corrosion damage, Fitness evaluate the condition of their buried pipelines
for the 9 remaining pipeline regions. Overall for Service evaluation was also performed for in an effective and consistent way. The use
cost of performing ECDA is around $1000 corrosion areas using API 579. of this technique will help pipeline operators
per Km which includes indirect surveys, dig In order to validate the ECDA effectiveness, to perform a correct interpretation of ECDA
excavations and inspection and coating repair one dig was additionally performed on all survey results and to make the right selection
cost. At the locations where corrosion activity ECDA regions categorized as monitor and no for inspection dig locations, resulting not only
was found, calculations were performed to indication in Table 2. The excavated locations in cost saving but will also improve the overall
estimate their remaining operational life along were found to be defect free, thus legitimizing integrity of the pipeline.
with Root Cause Analysis of the events to the success of the complete process.
mitigate any corrosion in future. 4. Acknowledgements
2.4.1 Continuous We would like to express our sincere gratitude
2.3.2 Assessment of
Improvement in Pipeline to the management of United Energy
Proposed Severity Pakistan for their support. Also, the work of
Integrity the contractors involved in this process is
Classification ECDA is a continuous improvement process gratefully acknowledged.
and Prioritization and its effectiveness is established on a
long-term basis. Compare to previous ECDA References
Criterion surveys, the survey under discussion is far [1] Corrpro, 2010. Improvement to the External Corrosion
The defect severity and prioritization criterion is more effective and efficient as presented in Direct Assessmemnt Process, Houston, Texas: Corrpro
evaluated to check if it is a true representation the Figure below. Companies, Inc..
of the magnitude of corrosion and coating
As shown in Figure 4, significant cost reduction [2] Corrpro, 2010. Improvement to the External Corrosion
damage found after pipeline excavations.
of 50% has been attained along with a dig Direct Assessmemnt Process (Severity Ranking of ECDA
After performing the schedule and immediate
efficiency of 97% as coating and corrosion Indirect Inspection Indications), Houston, Texas: US
excavations, the findings of the entire activity
damage is found at almost all digs. The dig Department of Transportation.
with reference to the actual corrosion and
efficiency achieved in this work is exceptional [3] Corrpro, 2010. Improvements to the External
coating damage found is summarized in Figure
3 below. Corrosion Direct Assessment Process (Cased Pipes),
Houston, Texas: US Department of Transportation.
As shown above, the proposed criterion is
found to be very effective. Though, there is [4] Kowarski, A. R., 2011. Direct Assessment Techniques
one location where criterion disagrees with for Underground Petroleum Pipelines. Paris, International
the practical damage found, which could Gas Union Gas Research Conference.
[5] Melo, C. A., 2010. ECDA Implementatiion on EDEN
YUTURI 18 Gathering Pipelines. Quito, Ecuador, s.n.
[6] Os, M. V., 2008. External Corrosion Direct Assessmengt
at Gasunie. Paris, International Gas Union Research
Conference.
[7] SP0502, N., 2012. Pipeline External Corrosion Direct
Assessment Methodology, Houston, Texas: NACE.
15
CorrosionManagement | May/June 2016
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T: 01698 373770 T: 01469 575603 T: 01454 633351
MIS North East Ltd P H Shotblasting & Spraying Services Sherwin-Williams Protective & Marine Coatings
Units 2, 5/5a Mill Hill, North West Ind Estate, 43a Drumrainey Road, Castlecaulfield, Dungannon, Tower Works, Kestor Street,
Peterlee, SR8 2HR Co Tyrone, BT70 3NY Bolton, lancs. BL2 2AL
T: 0191 514 2804 T: 028 8776 7722 T: +44 (0)1204 521771
Moore Steel Developments Ltd Pipeline Induction Heating Shirley Industrial Painters & Decorators Ltd
Station Road, Thorney, The Pipeline Centre, Farrington Road, Rosendale Rd Grand Union House, Bridge Walk,
Peterborough PE6 0QE Industrial Estate, Burnley BB11 5SW Acocks Green, Birmingham, B27 6SN
T: 01733 270729 T: 01282 415323 T: 0121 706 4000
TO ADVERTISE CONTACT SQUARE ONE Tel: +44 (0)114 273 0132 Email: jonathan@squareone.co.uk
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ICATSREGISTEREDCOMPANIES ICATSREGISTEREDCOMPANIES
Shutdown Maintenance Services Ltd Stream Marine Training Ltd Vale Protective Coatings Ltd
Kingsnorth Industrial, Hoo, Rochester, Kintyre House, St Andrews Crescent, West Campus, Building 152 - Langar North Industrial Estate, Harby
Kent, ME3 9ND Glasgow International Airport, Paisley, PA3 2TQ Road, Langar, NG13 9HY
T: 01634 256969 T: 0141 212 8777 T: 01949 869784
Stobbarts Ltd
Tarn Howe, Lakes Road, Derwent Howe Industrial
Plymbridge Road, Estover,
Plymouth, PL6 7LX
T: 01752 752480
ICATS website
Estate, Workington, Cumbria CA14 3YP
T: 01900 870780 www.icats-training.org
Universal Coatings & Services Ltd
Port Clarence Offshore Base, Port Clarence,
Story Contracting Ltd Middlesbrough, TS2 1RZ
Burgh Road Industrial Estate, Carlisle, T: 01642 544060
Cumbria CA2 7NA
T: 07730 764414
visit the
two day event with presentations Venue: Amsterdam, the
Joint Meeting with LMS and workshops, revealing Netherlands
Venue: Imperial College, Skempton intriguing insights into various Topics:
Building, London SW7 2BB Water Management disciplines How does corrosion occur?
Description: Corrosion of hip
replacements Is it a problem?
Timings: 18.15 Doors Open,18:30 Talk,
ICorr and delivered by Masters in their
field.
Venue: National Conference
What surface preparation is
necessary for an endurable coating?
Which ingredients does a coating
19.30 Social and networking
-Refreshments provided, 21.00 Finish
For further information please
website Centre
Solihull, B92 OEJ
Further details: http://www.
comprise and what are their roles?
What are the current trends in
corrosion protection coatings?
contact: icorrlondon@gmail.com or
george.winning@element.com or call www.icorr.org wmsoc.org.uk/conferences.
php?id=470
What distinguishes water-borne
from solvent-borne systems?
07495671806. How do self-healing coatings
work?
Wednesday 6th July 2016 Website: www.european-coatings.
Thursday 10th November 2016 Marine Corrosion Forum com/Events/European-Coatings-
London Branch Meeting meeting seminars-2016/Anticorrosive-
London Branch meeting Venue: National Motorcycle coatings
Details to be announced. Museum, Birmingham. Further Contact: Kristin Heuer Kristin.
details: heuer@vincentz.net
www.marinecorrosionforum.org T: +49 511 99 10 272
Thursday 8th December 2016
London Branch Christmas Lunch
To be held at ROSL, London, SW1A Monday 5th - Tuesday 6th
TO ADVERTISE CONTACT JONATHAN AT SQUARE ONE Tel: +44 (0)114 255 7911 or Email: enquiries@squareone.co.uk
London Branch publish a monthly Newsletter; to be included on the circulation list please contact Sarah Vasey sarah.vasey@sherwin.com
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