Professional Documents
Culture Documents
IN THIS ISSUE
AUGUST 2014
VOL. 53, NO. 8
24
MATERIALS PERFORMANCE
66
SPECIAL FEATURES
24
76
CATHODIC PROTECTION
30
CP Blog
32
38
CL Blog
CHEMICAL TREATMENT
46
50
CT Blog
56
66
72
MSD Blog
IN THIS ISSUE
AUGUST 2014
VOL. 53, NO. 8
MATERIALS PERFORMANCE
HELP. NEED
PHOTO
14
18
DEPARTMENTS
6
8
14
104
MP (Materials Performance) is published monthly by NACE International
MP
Performance)
published monthly
NACE and
International
(ISSN(Materials
0094-1492;
USPS No.is 333-860).
Mailing by
address
Editorial
(ISSN
333-860).
address and
Editorial
Offces:0094-1492;
1440 SouthUSPS
CreekNo.
Drive,
Houston,Mailing
TX 77084-4906;
phone:
+1
Offces:
15835
Park
Ten
Place,
Houston,
TX
77084;
phone:
+1
281-228281-228-6200. Internet address: www.nace.org. Preferred periodicals
6200.
Internet
address:
www.nace.org.
Preferred
periodicals
nonproft
nonproft postage paid at Houston, TX and additional mailing offces.
postage
paid at
Houston, TX
andAgreement
additional #40612608.
mailing offces.
Canada
Post:
Canada Post:
Publications
Mail
Canada
Returns
Publications
Mail Agreement
CanadaON
Returns
to be
sent to
to be sent to Pitney
Bowes, PO #40612608.
Box 25542, London,
N6C 6B2.
Copyright
Pitney
PO Box 25542,
London, ON
6B2. Copyright
by
2014 byBowes,
NACE International.
Reproduction
of N6C
the contents,
either as2014
a whole
NACE
International.
Reproduction
of the contents,
either
as a whole
in
or in part,
is forbidden
unless permission
has been
obtained
fromorthe
part,
is forbidden
permission
been obtained
from of
thethe
publisher.
publisher.
Articles unless
and editorials
hereinhas
represent
the opinions
authors
Articles
and editorials
herein
represent
the opinions
of theasauthors
and not
and not necessarily
those
of NACE.
Advertising
is included
an educational
necessarily
of NACE.
Advertising
included ascarry
an educational
service, andthose
products
and/or
servicesismentioned
no impliedservice,
or real
and
products and/or
services mentioned
carry no
implied
or real
endorsement
or recommendation
from NACE.
NACE
reserves
theendorseright to
ment
or
recommendation
from
NACE.
NACE
reserves
the
right
to
prohibit
prohibit any advertisement that is not consistent with the objectives of
any
advertisement that is not consistent with the objectives of NACE.
NACE.
POSTMASTER: Forwarding charges guaranteed. Send address changes to
POSTMASTER:
Forwarding
guaranteed.
Send address
changes
to
NACE FirstService,
15835charges
Park Ten
Place, Houston,
TX 77084.
SUBNACE
FirstService,
SouthasCreek
Houston,
TX U.S.
77084-4906.
SCRIPTION
RATES: To1440
members
part ofDrive,
annual
dues $12;
nonmemSUBSCRIPTION
RATES:
To members
as libraries
part of $205;
annualoverseas
dues $12;
U.S.
bers $115; overseas
nonmembers
$130;
libraries
nonmembers
nonmembers
$130; libraries
overseas
$220; single $115;
copy overseas
$20, availability
permitting.
Rates to$205;
nonmembers
libraries
$220;
singleSubscriptions
copy $20, availability
Rates made
to nonmemsubject to
change.
must be permitting.
prepaid. Claims
within
bers
subjectoftoissue
change.
must be availability
prepaid. Claims
made within
6 months
dateSubscriptions
flled at no charge,
permitting.
Non6airmail
months
of
issue
date
flled
at
no
charge,
availability
permitting.
Nonoverseas subscribers must wait 60 days from issue date to claim
airmail
overseas
subscribers
must
wait
60
days
from
issue
date
to
claim
a replacement issue. Individual back issues may be available for up to
a2 years.
replacement
issue.
Individualchanges
back issues
be available
up to of2
Requests
for address
shouldmay
include
previous for
address
years.
Requests
for ofaddress
should
include
previous
of
subscriber.
Change
addresschanges
should be
provided
6 weeks
prioraddress
to ensure
subscriber.
address should
be provided 6U.S.
weeks
prior
to ensure
continued Change
deliveryof(phone:
1 800-797-6223
and
Canada
or
continued
delivery (phone:
1 800-797-6223
U.S. and Canada or +1
281+1 281-228-6223
worldwide
or e-mail: frstservice@nace.org).
Cancel228-6223
e-mail:Refunds
frstservice@nace.org).
Cancellation
must
lation must worldwide
be made inorwriting.
will be prorated less
a $20 processbe
in writing. on
Refunds
will be
prorated
less acan
$20beprocessing
fee.
ing made
fee. Information
becoming
a NACE
member
obtained from
Information
on becomingServices
a NACEDepartment
member canatbethe
obtained
from the
NACE
the NACE Membership
above phone
number
Membership
ServicesPRINTED
Department
at the
above phone number and e-mail
and e-mail address.
IN THE
U.S.A.
address. PRINTED IN THE U.S.A.
Up Front
The MP Blog
Material Matters
14. 3D scanning tool uses structured light to create images of pipe surface corrosion
18. Permanently installed guided wave testing tool facilitates frequent pipeline
monitoring
21. Company News
22
96
98
111
Product Showcase
116
Corrosion Basics
NACE NEWS
100
103
104
105
106
107
109
UP FRONT
Pipeline Coating Assessment
Facility Opens in Australia
The National Facility for Pipelines Coating Assessment, an initiative of the Energy
Pipeline Co-operative Research Centre
(CRC), was recently launched at Deakin
Universitys Waurn Ponds campus in Victoria, Australia and will be jointly managed by the universitys School of Engineering and Institute for Frontier
Materials. The independent facility will
perform coating testing for oil and gas
pipelines and provide research that supports pipeline coating selection and development. The Energy Pipelines CRC is a
collaboration between Deakin, the University of Wollongong, Adelaide University, the Australian National University,
and the Australian Pipeline Industry Association. Source: Deakin University,
www.deakin.edu.au.
Spray-Applied
Composite Protects
Metals from Corrosion
gear wheels, tools, machine parts, etc., adheres to the metal substrate after thermal
curing at 150 to 200 C, and is suitable for
steels, aluminum, magnesium, copper,
and metal alloys. For more information,
visit www.inm-gmbh.de.
Self-Protecting Coatings
Contain Inhibitors to
Prevent Corrosion
A team of researchers from Max Plank
Institute of Colloids and Interfaces (Potsdam, Germany) explored how self-protecting anticorrosion coatings that contain
embedded spherical nanocontainers filled
with a corrosion inhibitor can be used to
autonomously protect expensive and
often difficult-to-reach metal parts and
infrastructure from surface corrosion.
Most conventional coatings are thinner
than 100 m, so nanocontainers should be
at least three times smaller in size to be
properly integrated into the coating. However, the total amount of a crack sealant
that can be loaded into these containers
isnt adequate to completely fill a typical
submillimeter-size scratch in the coating.
THE
BLOG
EDITORIAL
DIRECTOR, CONTENT DEVELOPMENT/ Gretchen A. Jacobson
MANAGING EDITOR
Editor:
In the May 2014 issue of MP there were
two excellent articles on corrosion and
materials for carbon capture and sequestration (CCS). Although corrosion is
certainly a consideration when liquid
water is present, it is not when water is
soluble in supercritical CO2 (SC-CO2) and
no free water phase is present. However,
for transport of SC-CO2 to the location of
injection for CCS, the most common
material for pipelines is carbon steel,
which has been the mainstay of the oil
and gas industry for over 30 years for
enhanced oil recovery (EOR). Yet while
corrosion is not an issue, the most important design consideration for transport of
SC-CO2 is the risk of a long-running
ductile fracture. This requires modeling
of the decompression behavior of the CO2
being transported coupled with the
so-called Battelle two curve method.
There are numerous references and
sources on this design requirement;
however, I felt the readers should be made
aware, since this is Materials
Performance, and not just a corrosion
publication, that even after corrosion is
considered for SC-CO2 there are still
major materials properties that must also
be evaluated for CCS.
Bruce Craig, Subject Matter Expert,
Materials and Corrosion, Stress Engineering
Services, Inc., Houston, Texas, USA
ASSOCIATE EDITOR
EDITORIAL ASSISTANT
Suzanne Moreno
CONTRIBUTOR
Husna Miskinyar
GRAPHICS
ELECTRONIC PUBLISHING
COORDINATOR
Weld degradation
from muriatic acid
Q:
TECHNICAL EDITOR
GRAPHICS DESIGNER
Teri J. Gilley
Michele S. Jennings
ADMINISTRATION
CHIEF EXECUTIVE OFFICER
GROUP PUBLISHER
ADVERTISING
SALES MANAGER
ACCOUNT EXECUTIVES
Diane Gross
diane.gross@nace.org,
+1 281-228-6446
Teresa Wright
t.wright@nace.org,
+1 281-228-6472
Erica R. Cortina
erica.cortina@nace.org,
+1 281-228-6473
Brian Daley
brian.daley@nace.org,
+1 281-228-6455
Pam Golias
pam.golias@nace.org,
+1 281-228-6456
Jody Lovsness
jody.lovsness@nace.org,
+1 281-228-6257
Leslie Whiteman
leslie.whiteman@nace.org,
+1 281-228-6248
ADVERTISING/BOOKS
COORDINATOR
Brenda Nitz
brenda.nitz@nace.org,
+1 281-228-6219
Broomfield Consultants
Consultant
Arthur Freedman
Associates, Inc.
Arthur Freedman
Associates, Inc.
PG&E
Holland Technologies
Corsult Associates (1980),
Ltd.
iCorrosion, LLC
CITGO Petroleum Corp.
Mears Group, Inc.
Jonas, Inc.
Mears Group, Inc.
John Smart Consulting Engineer
L.D. Lou Vincent PhD LLC
BLOG
Continued from page 8
A:
A:
A:
Condenser materials
Q:
A:
A:
10
A:
A:
A:
A:
A:
Continued on page 12
11
BLOG
Continued from page 11
A:
Caustic embrittlement
in reinforced concrete
Q:
12
A:
A:
has a chloride content corrosion threshold about five times that of a lower alkali
content concrete with a pH of 13.2.
The pH of cements used in Europe and
concretes made in North America with
pozzolans like fly ash and silica fume is
lower than standard mixes made with
Type I/II cements. This is because slag
cements are often used in Europe, and
because pozzolans react with Ca(OH)2
and the pH is reduced. Given the number
of structures that have been built with
non-pozzolan Type I/II cements, if
caustic embrittlement were a problem,
the cement alkali content would long ago
have been restricted.
Editors Note: Additional MP Blog items appear in the individual technical sections:
cathodic & anodic protection (p. 30), coatings & linings
(p. 38), chemical treatment (p. 50), and materials selection & design (p. 72).
Use of silver
Q:
A:
A:
A:
13
MATERIAL MATTERS
A technician uses the 3D structured light scanning tool to take scans of external corrosion on a pipe
in the Algerian Desert. Photo courtesy of Joseph Pikas.
14
Information on corrosion
control and prevention
pipe and an additional inspection is necessary to verify the severity of the anomaly. Most types of anomalies that can be
observed visually can be assessed with
the 3D structured light scanning tool.
These include corrosion, gouges, and
dents. Taking a 3D image is similar to
capturing an image with a two-dimensional camera. The camera is aimed at the
anomaly to be inspected and the measurement is captured and stored digitally
on the laptop computer that is part of the
system. It takes less than one second to
acquire a 3D image.
The procedure for examining the pipe
with the 3D structured light scanning
tool is similar to the procedure used when
examining a pipe manually with a conventional pit gauge. Before taking a scan,
Currently the 3D scanning tool is being tested for submarine and offshore applications. Photo
courtesy of Seikowave.
Continued on page 16
15
MATERIAL MATTERS
Continued from page 15
Left: A 3D image generated from a scan of a segment of corroded pipe with an original wall thickness of 0.5 in (13 mm). Right: A corrosion analysis of
the corroded pipe. The 3D river bottom profle is shown in the upper right photo, and a graph of the corrosion profle is shown beneath it. Images
courtesy of Joseph Pikas.
16
Bibliography
Bellis, M. Measuring anomalies with the 3D
Toolbox. Pipelines International March
(2014).
Pikas, J. Understanding 3D Structured Light to
Assess Corrosion Defects. Technical Toolboxes Consulting, Ltd.
Summa, J. Improving Field Verification in
Pipeline Integrity Management Programs.
Pipeline & Gas Journal June (2014).
References
1
Trade name.
17
MATERIAL MATTERS
The GWT tools transducer array is attached with adhesive to the pipe surface at a particular axial
location, enclosed with a cover, and connected by cable to the pulser-receiver through a junction
box interface. Photo courtesy of Plant Integrity, Ltd.
18
The scan displays repeatable data from the tool. The responses in blue and green, grouped in
terms of temperature, were taken weeks apart but show minimal comparable error when overlaid.
The error can be quantifed by taking a residual between the two signals, which is displayed here as
the red trace. Image courtesy of Plant Integrity, Ltd.
Two symmetric wave modes are transmitted and received by the pulserreceiverlongitudinal waves, which are
similar to compression waves, and torsional waves, which have more of a twisting motion. Jackson explains that where
there is a change in the cross-sectional
area of the pipe wall, such as a weld, bend,
or defect caused by corrosion, these
waves will convert into a flexural wave.
This change in acoustic impedance is
reflected back to the transducer array as
an echo. The distance of the detected feature from the transducer array can be
determined using the speed of the initial
wave and the receive time of the echo.
The test data collected by the pulserreceiver can be probed in two ways. At the
junction box, an operator can either collect and interpret the data in situ via a laptop computer and the accompanying software program, or swap out the replaceable
data storage component on the pulserreceiver unit and interpret the data at a
different location. In remote locations, a
battery-operated pulser-receiver can be
connected to the transducer array at the
junction box for several weeks to collect
data in bursts, then be removed and
Continued on page 20
19
MATERIAL MATTERS
Continued from page 19
Reference
1 BS EN 60529:1992+A2:2013, Degrees of protection provided by enclosures (IP code) (London, U.K.: BSI, 1992).
Bibliography
Jackson, P., Guided wave activity at TWI, http://
youtu.be/Jhf5e7P515M ( June 17, 2014).
K.R. Larsen
20
COMPANY NEWS
Sherwin-Williams Receives
Military Coatings Project
Award of Excellence
The Sherwin-Williams Co. (Cleveland,
Ohio) was awarded the SSPC: The Society
NACE INTERNATIONAL: VOL. 53, NO. 8
ISHM Announces
2014 Laurence S. Reid
Award Recipient
The International
School of Hydrocarbon Measurement (ISHM)
(Norman, Oklahoma) proudly announces that
Edward E. Francisco, Jr. is the recipient of the 2014
Laurance S. Reid Award, which was presented posthumously. This award is
presented each year in recognition of outstanding individual contributions to the
MP welcomes submissions of
Company News. Please send photos and
information to Husna Miskinyar;
e-mail: husna.miskinyar@nace.org.
21
PRODUCT SHOWCASE
Fire Safe Flange Isolation Kits
Lamons (Golden, Colorado), a manufacturer of fire safe flange isolation kits for
critical offshore platform and refinery
applications, introduces the DEFENDER
FSTM sealing/isolating gasket. The product
is designed to withstand the rigorous API
standard 6FB (Third Edition) test and
therefore provides a solution for those who
want to electrically isolate their flange,
provide a seal for media, and protect
against the introduction of fire in and
around the flange. Available in ANSI, API,
and PN pressure classes with a nominal pipe size range of through 36 in (13
through 914 mm), the gasket utilizes a Kammprofile design with a standard Type 316
(UNS S31600) stainless steel core (Inconel and duplex available upon request). Isolation materials are G10 or G11 and the Kammprofile seals are faced with Teflon and
Mica seal elements. Tel: +1 303-405-6812, Web site: www.lamons.com.
PosiTector PC Powder
Checker Now Available
DeFelsko
(Ogdensburg,
New York) is
pleased to
introduce the
next generation
of non-contact
powder thickness gages. The
PosiTector PC
Powder
Checker
measures uncured powder coatings
using ultrasonic technology to automatically calculate and display a
predicted cured thickness. The
PosiTector PC helps to control powder
consumption to ensure adequate coverage and reduce waste. The updated
PosiTector PC Powder Checker features
a color liquid-crystal display (LCD), an
expanded internal memory, and free
access to a full suite of PosiSoft
Solutions. The gage continually
displays/updates basic statistics and
automatically generates formatted
reports with measurement summaries
and charts. Notably, the PosiTector PC
22
EOS (Krailling, Germany) metals portfolio now includes new titanium and
stainless steel (SS) for end-use production on its direct metal laser-sintering
(DMLS) systems. Lightweight EOS
Ti64ELI alloy has excellent corrosion
resistance and biocompatibility plus a
high grade of purity. It is extremely
well-suited for the additive manufacture of medical implants for orthopedics. EOS Type 316L SS (UNS S31603)
combines corrosion resistance with
high ductility and is appropriate for
surgical instruments, endoscopic
surgery, orthopedics, and implants.
Parts built from the new steel have a
chemical composition corresponding to
that specified in ASTM F138 (a standard
for SS bar and wire for surgical
implants). The steel also has potential
applications in the watch and jewelry
industries, as well as in harsh and
demanding environments such as the
aerospace or marine industries. Tel: +1
248-306-0143, Web site: www.eos.info.
PPG to Reintroduce
DURANAR ADS Coatings
for Architectural Metals
PPG Industries (Pittsburgh,
Pennsylvania) coil and building products coatings group announced that it
will reintroduce DURANAR ADS (airdried system) f luoropolymer coatings
this summer, three years after the products were withdrawn from the market.
This next-generation line of DUR ANAR
ADS coatings, based on a newly formulated f luorinated copolymer resin
combined with PPG proprietary chemistry, is designed to repair f luoropolymer coatings on architectural metals
damaged during production or after
field installation. In addition, these
high-performance coatings can provide
23
FEATURE ARTICLE
Updating
NACE SP0169
for Controlling
External Corrosion
on Underground or
Submerged Metallic
Piping Systems
24
25
FEATURE ARTICLE
To learn more about the recent
revisions made to SP0169 and their impact
on industry, Materials Performance asked
several members of NACE TG 360 and
others interested in the standard revision
to comment on the updated portions of
the standard. Panelists are Jim Chmilar
with Chmilar & Associates Consulting
Ltd.; Drew Hevle with Kinder Morgan;
Mark Lauber with Laclede Gas Co.; and
Norm Moriber with Mears Group. (See
their biographies in the sidebar, Meet the
Panelists.)
MP: How does industry use NACE
Standard SP0169? Why is this standard
important?
Drew Hevle
Drew Hevle is
manager of corrosion control for
Kinder Morgans
natural gas pipeline group, based
in Houston, Texas.
He has a Bachelor
of Science degree in mechanical engineering and holds several NACE certifcations, including Corrosion Specialist, CP Specialist, and Level 3 Coating
Inspector. Hevle heads several NACE
technical committees, is vice chair of the
NACE Technical Coordination Committee (TCC), and is also a NACE instructor.
His hobbies are corrosion control and CP.
Mark Lauber
Mark Lauber is
the manager of
pipeline safety
compliance for
the Laclede Gas
Co., which serves
eastern Missouri,
including St. Louis,
and western Missouri, including Kansas
City. A NACE-certifed CP Specialist since
1997, he is responsible for integrity management programs for the companys
gas transmission, gas distribution, and
hazardous liquid pipelines. This includes
corrosion control, main replacement,
and public awareness programs. In addition, Lauber has overall responsibility
for pipeline safety regulation compliance
for Laclede Gas. He holds a Bachelor of
Science degree in electrical engineering
from the University of Missouri-Rolla.
Lauber is a member of several NACE
technical committees, including TG 360.
26
Norm Moriber
Norm Moriber is
chief engineer for
Mears Group, Integrity Solutions
Division, in San
Ramon, California.
He is a graduate of
the Massachusetts
Institute of Technology and a Registered
Professional Corrosion Engineer in California with more than 40 years of experience
in the corrosion control industry. His areas
of specialization include CP design and
evaluation; external corrosion direct assessment, focusing on cased piping; and stray
current evaluation and mitigation. He has
served on the NACE International Board
of Directors, as chair of the Public Affairs
Administrative Committee, has been a
member of the Materials Performance Editorial Advisory Board since 2001, and is now
a technical editor for MP. He is a member
of TG 360 and has chaired Technology
Exchange Group (TEG) 179X, Cathodic
Protection, since 2004.
27
FEATURE ARTICLE
greater flexibility is now available for
operators to make choices that will meet
their corrosion control objectives. New
sections have been added to address CP
for copper, aluminum, and SS, along with
cautions about additional requirements to
address specific conditions. These include
MIC, high temperatures, SCC, overprotection and hydrogen evolution effects,
dissimilar metal piping systems, acidic
and high-resistivity environments, electrical shielding, and AC corrosion. Because
this standard addresses corrosion control
rather than CP alone, the section on
protective coatings was greatly expanded
and updated. This includes the removal of
references to numerous obsolete coating
standards and the addition of modern
coatings for steel and ductile iron. Other
sections address a variety of reference
electrodes and temperature correction for
potential measurements. New appendixes
describe CP criteria and other features
contained in ISO and European standards
in addition to those used in six other
countries.
A CP technician checks the rectifier outputs for a cathodically protected pipeline. Photo
courtesy of Mears Group, Inc.
28
References
1 Code of Federal Regulations (CFR)
Title 49: Transportation, Part 195
Transportation of Hazardous Liquids
by Pipeline, Subpart HCorrosion
Control (Washington, DC: Office of the
Federal Register, 2014).
2 TM0497-2012, Measurement
Techniques Related to Criteria for
Cathodic Protection on Underground
or Submerged Metallic Piping Systems
(Houston, TX: NACE International,
2012).
3 Code of Federal Regulations (CFR)
Title 49: Transportation, Part 192
Transportation of Natural and Other Gas
by Pipeline: Minimum Federal Safety
Standards (Washington, DC: Office of the
Federal Register, 2014).
29
BLOG
Continued from The MP Blog, p. 13.
The following items relate to cathodic &
anodic protection.
Please be advised that the items are
not peer-reviewed, and opinions and
suggestions are entirely those of the inquirers and respondents. NACE International does not guarantee the accuracy
of the technical solutions discussed.
MP welcomes additional responses to
these items. They may be edited for
clarity.
Q:
Four parallel underground pipelines with only 0.15 ft (0.5 m) between each one will be cathodically protected by impressed current. Each line is
8-in (203-mm) diameter and 1.9 miles (3
km) long, but their coatings and construction dates are different. Because the previ-
30
A:
A:
A:
A:
A:
A:
A:
A:
A:
31
32
Surface Preparation
The life of a coating depends as much
on the degree and quality of surface preparation as on the selected coating system,
because most coating failures can be attributed to inadequate surface preparation or
lack of coating adhesion. Surface preparation, therefore, should receive thorough
NACE INTERNATIONAL: VOL. 53, NO. 8
(a)
(b)
(c)
(d)
FIGURE 1 (a) Pitting corrosion on a tube sheet, (b) retubed tube sheet, (c) pitting on a water box,
and (d) outlet spool internal corrosion.
Initial Inspection
Tube Plugging
The SS tube interior needed to be protected from abrasive blasting. All tubes
were plugged with plastic plugs after the
tube sheets had dried out (Figure 2) and
Trade name.
33
Abrasive Blasting
Unplugging and
Re-plugging Tubes
On the completion of the surface preparation, the tube plugs were removed. The
surface then was blown off to ensure the
cleanliness of the prepared surface and all
tubes were re-plugged with new plugs for
the coating application.
Coating Application
First Coat
After final inspection of the surfaces,
the primer material was applied by a longnap roller. There was no wet film thickness
(WFT) requirement. The primer was
required to cover the tube ends regardless
of the surface terrain (Figure 4[a]).
FIGURE 3 A tube sheet surface prepared to NACE No. 1/SSPC-SP 5.
Second Coat
prior to abrasive blasting. From this point
on, the environmental measurement was
performed in the beginning of each shift
and at 4-h intervals. The dehumidifier and
heating system started working continuously for the rest of the process. Since the
condenser was located indoors, environmental control was relatively easy with
advanced equipment. Surface temperatures
34
(b)
(c)
(d)
FIGURE 4 Coating application. (a) First coat, (b) build-up coat applied, (c) surfaces ground and
voids flled, and (d) plugs removed.
Cathodic Protection
Evaluation
The condenser utilizes fresh circulating
water. After many cycles, the water
becomes more corrosive from the accumulated concentration of the soluble salts in
the water. The circulating water resistivity
was ~400 {cm. Corrosion attack on the CS
tube sheets and the water boxes was caused
mainly by dissimilar metal corrosion
between SS (~50 mV vs. a copper/copper
sulfate [Cu/CuSO 4 ] electrode [CSE] of
native potential) and CS (~550 mV vs. CSE
of native potential). Because of the huge
number of SS tubesa large cathode
areaa 500 mV potential difference could
cause severe corrosion on CS.
Initially, 22 aluminum anodes were
installed on the water boxes around the
tube sheets for cathodic protection (CP)
(Figure 6). The 4-lb (1.8-kg) anode dimensions were 12 by 6 by 1.25 in (305 by 152 by
32 mm) with the top surface exposed. The
anodes were replaced right before the
epoxy cladding project and still in a likenew condition. Twenty-two aluminum
anodes can provide only ~1/4 of the
Conclusions
The corrosion of condenser tube sheets
was caused by dissimilar metal corrosion
between SS tubes and the CS tube sheets
due to an under-designed CP system and
lack of maintenance. Epoxy cladding has a
proven record as a cost-effective way to retrofit severely corroded CS tube sheets.
35
Because of the low driving voltage, aluminum or zinc anodes may not be suitable for
CP of condenser water boxes. Magnesium
anodes would serve better than aluminum
or zinc anodes, but frequent replacement
would be expected because of their low efficiency. A small impressed current CP system
can provide full protection for over 25 years.
References
1
SSPC-VIS 1, Guide and Reference Photographs for Steel Surfaces Prepared by Dry
Abrasive Blast Cleaning, SSPC Publication
02-12 (Pittsburgh, PA: SSPC).
36
ASTM D4285-83 (reapproved 2006), Standard Test Method for Indicating Oil or Water
in Compressed Air (West Conshohocken,
PA: ASTM).
WANTED
Practical Technical Articles
Distinctive Cover Photos
News Product Releases
Send corrosion-related articles, photos,
and other information for publication to:
Director, Publications, NACE
International, 15835 Park Ten Place,
Houston, TX 77084
For MP article submission guidelines
and more detailed information on types
of information sought, call +1 281-2286207, e-mail: gretchen.jacobson@nace.
org, or see the Publications section of the
NACE Web site: www.nace.org.
BLOG
Continued from The MP Blog, p. 13.
The following items relate to coatings
& linings.
Please be advised that the items are
not peer-reviewed, and opinions and
suggestions are entirely those of the inquirers and respondents. NACE International does not guarantee the accuracy
of the technical solutions discussed.
MP welcomes additional responses to
these items. They may be edited for
clarity.
Q:
A:
coating has absorbed moisture and possibly other chemicals. If you continue with
this evaluation, you will spend a few
thousand dollars, but this is extremely
cheap insurance if the value of the existing coating is anything above zero. In
other words, you could easily spend a lot
of money to overcoat the existing system
only to fnd that money wasted plus it
destroyed the existing coating for any of
several reasons.
Adhesive failures between coats
is cause for concern! But when
you say cohesive failures of the topcoat,
what values are you using? Glass
fake-flled vinyl ester lining material
cohesive values are generally not that
high, (as compared to epoxies, and
urethanes). Do you have any documentation from the installation of the lining in
question (i.e., installing contractor, or
manufacturer of the lining material
itself)? Consulting the manufacturer for
A:
A:
blast the vessel and line it with an appropriate product for the new intended
service. A lining having lasted for 17 years
has most defnitely done its job.
One thing to remember is that the
pull tests performed showed you
only the weakest link in the chain. Tat
doesnt mean the underlying coating is
strong, just stronger than what failed. If
you can get a clean pull on the holding
primer that you mentioned, or the actual
primer coat of vinyl ester, I would try
that, too.
Secondly, remember that even if you
get a reasonable pull on the holding
primer, how much life can remain in a
17-year-old coating? At some point you
are going to have the coating against the
substrate fail before the coating on top of
it. Ive also seen times where putting a
new coating over on old coating stresses
the old coating as the new application
begins to cure and contract.
A:
Fireproofing
Q:
39
BLOG
A:
A:
A:
Continued on page 42
41
BLOG
Removal of epoxy
intumescent fireproofing
Q:
A:
A:
A:
A:
42
Adhesion testing
Q:
A:
A:
A:
The fear with the induction method is that it will melt the
steel (which it wont) or that it will arc to the substrate
(which it cant).
A:
Q:
A:
Continued on page 45
43
October 6 - 8, 2014
Myrtle Beach, South Carolina USA
CORROSION
Cased Crossings
ILI (Pigging)
AC Mitigation
Atmospheric Corrosion
Stray Current
Pipeline Rehabilitation
CUI
New Products/Technology
COATINGS
Major Highway/Bridges
Submarine or Large Commercial Ships
Oil Platform
Water Tanks
Major Pipeline Coating Rehab
New Technology/Future Related to:
Pipeline Coatings
Paints
Applicators
MATERIALS
PERFORMANCE
BLOG
Q:
A:
A:
45
CHEMICAL TREATMENT
46
Biodegradability
Ecological
Toxicity
NPDES
Status
Heavy
Metal
Drinking
Water
Safety
Total
(%)
Molybdate
45.8
Zinc
41.7
Tin
70.8
Phosphate/polyphosphate
58.3
Polyaminophosphonate
66.7
Hydroxyphosphonic acid
66.7
Phosphonocarboxylic acid
70.8
87.5
Coffee extract
95.8
(A)
Based on six criteria outlined in the article under Green Chemistry Criteria. The total score for an inhibitor has been normalized to 24, the
maximum possible green score. Values of 1/2/3/4 represent poor/fair/good/excellent scores, respectively.
phosphorous molecule may render it less
effective as an inhibitor, but possibly a good
biological food source. Finally, organic
inhibitors can be deactivated by cationic
microbiocides such as the quaternary
ammonium compounds and other cationic
substances that may be present.6
Tin is one inorganic inhibitor recently
available that is less regulated than other
metals. It can be used in drinking water,
carries some U.S. Food and Drug Ad
ministration (FDA) accepted food uses,
and is considered quite safe for the envi
ronment7 and human safety in general.8 Tin
used for corrosion inhibition in cooling
towers currently has patents associated
with its use.9
Green chemistry has become a design
criterion in water treatment programs and
the chemical industry over the past decade.
The definition of green chemistry is con
stantly evolving to include new environ
mental regulations and customer expecta
tions. In general, it may be assumed that
green chemistr y is environmentally
friendly, but may have other connotations
that apply to safety, good manufacturing
practice, and even efficiency.
Methodology
Green Chemistry Criteria
In the pursuit of a green corrosion
inhibitor, the goal is to make an inhibitor
NPDES Status
The National Pollution Discharge
Elimination System (NPDES) issues per
mits regulating chemical discharge for the
protection of the environment. The materi
als that are regulated on these permits and
the concentrations allowed for discharge to
the environment will affect the green rank
ing of a material.
Heavy Metal Status
The EPA has established a list of heavy
metals, also called target analyte metals,
that are used to determine environmental
assessments such as NPDES permitting.
Materials listed as target analyte metals are
considered less green than others.
Drinking Water Additive
Certain additives are allowed by the
EPA as corrosion inhibitors in drinking
water systems. These normally carry a
maximum allowed use level. These materi
als usually carry a thirdparty certification
from the National Sanitation Foundation
confirming they are safe for use in drinking
water. A drinking water additive could be
considered greener than materials that
cannot be added to drinking water.
Safety
Materials are rated for safety by several
factors: the U.S. Occupational Safety and
Health Administration through a Safety
47
CHEMICAL TREATMENT
Concentration
Unit (ppm)
Ca
543
CaCO3
Mg
140
CaCO3
HCO3
328
CaCO3
Cl
114
Cl
SO4
505
SO4
HEDP
Active
Copolymer
Active
Tolyltriazole
Active
48
Experimental Procedure
The test apparatus consisted of a circulation loop with the return water line aerated before entering the sump. This provided the necessary oxygen to simulate
cooling tower water. The flow rate was 7.0
gal/min (26 L/min) in 1-in (25-mm) diameter clear polyvinyl chloride (PVC) piping for
ease of visual inspection. This corresponds
to a linear velocity of 3.2 ft/s (0.98 m/s).
This is in the range of accepted flow rates
for corrosion coupon racks.11
The temperature for each run was
maintained at 95 F (35 C); the heat was
provided by the main circulation pump
and booster pump. Synthetic water was
used to simulate both a scaling and corrosive environment. Table 2 shows the synthetic water quality. Scale was controlled
during each run by the addition of active
1-hydroxyethane-1,1-diphosphonic acid
(HEDP) and a phosphate/iron dispersant
copolymer (AA/AMPS). Table 2 also shows
the active amounts of scale inhibitors. The
equilibrium pH for each run was 8.7 to 8.9.
This was the natural result of the amount
of synthetic bicarbonate alkalinity added,
the temperature, aeration, and test run
duration.
New CS coupons and corrator tips were
used for each run. Coupons and tips were
not passivated prior to an experimental
run. Each test consisted of a five-day run at
which time pictures were taken of the CS
coupon and corrosion data were graphed.
A copper coupon was also installed in the
loop for each run to provide a source of
Acknowledgments
The authors wish to thank the
Association of Water Technologies for
allowing this paper to be presented and to
U.S. Water Services for the resources neces
sary to conduct the research.
DONOVAN ERICKSON is the director, Research & Development, at U.S. Water Services, e-mail: derickson@uswaterservices.
com. He has more than 30 years of experience in water technology including production management, quality control, ISO
certification, and technical sales backup
to research and development and production process innovation. He holds patents
in water technology and fuel ethanol process technology. He has a B.S. degree in
physics and mathmatics and graduate
work in physics, and is a member of the
Association of Water Technologies and
Cooling Technology Institute. He is currently the vice chair of Cooling Technology Institute on Application of NonOxidizing Biocides.
References
1
AWT Technical Reference and Training Manual, 2nd ed. (Rockville, MD: Association of
Water Technologies, 2009).
49
BLOG
Continued from The MP Blog, p. 13.
The following items relate to chemical
treatment.
Please be advised that the items are
not peer-reviewed, and opinions and
suggestions are entirely those of the inquirers and respondents. NACE International does not guarantee the accuracy
of the technical solutions discussed.
MP welcomes additional responses to
Q:
A:
Contact us today!
International +1 713 266 9339
1 800 319 8802
(Toll Free in N. America)
sales@holdtight.com
www.holdtight.com
A:
A:
Continued on page 52
50
BLOG
A:
Chloride content in
a reactor system
Q:
A:
A:
Continued on page 54
52
BLOG
A:
A:
Injection systems
Q:
A:
Treatment of
abandoned pipe
Q:
A:
54
Global Scenario
In 1932, Hadfield 1 estimated the
worlds annual cost of corrosion of iron
and steel at ~600 million. Uhlig carried
out a systematic analysis on the cost of
corrosion.2-3 He primarily divided the cost
56
Indian Scenario
In 1958, Rajagopalan followed the Uhlig
method to estimate the annual cost of corrosion in India. He projected a conservative
figure of U.S. $324 million as the annual
cost of corrosion for 1960-1961. 8 During
1983, Rajagopalan and Viswanathan
worked out the total cost of corrosion for
the soap and cosmetic industry in India as
U.S. $1,472 million.9 During 1986, Rajagopalan attempted to work out the cost of corrosion in various sectors of Indian economy
following the the National Bureau of Standards (now National Institute for Standards & Technology [NIST]) and the Battelle Columbus Laboratories (NBS-BCL)
analysis model. 10 He showed that for 22
industrial sectors, the direct cost of corrosion amounted to U.S. $3.1 million (1.96% of
GNP). After a gap of 15 years, Bhaskaran, et
al. embarked upon a venture to estimate
the updated cost of corrosion for India.
They showed that for the years 1996-1997,
the annual cost of corrosion could be ~U.S.
$6.8 million (2% of GNP).11 More recently,
the direct of cost of razor blade corrosion in
India was estimated as U.S. $272 million.12
Estimation of Direct
Cost of Corrosion for the
Indian Economy using
the NBS-BCL Model
The NBS-BCL study was the first to
combine the expertise of corrosion as well
as economy specialists to determine the
impact of corrosion on the U.S. economy.
The following three worlds were envisaged
for the analysis of the cost of corrosion:
World IReal world of corrosion
World IIHypothetical world without corrosion
World IIIHypothetical world in
which the most economically efficient corrosion prevention is practiced by everyone
The total national cost of corrosion is
the difference between the GNP of World I
and the GNP of World II. The avoidable cost
of corrosion, or cost which is amenable to
reduction by the most economic and efficient use of available corrosion control
technology, is the difference between the
57
TABLE 1. DIRECT COST OF CORROSION AND AVOIDABLE COST OF CORROISON FOR INDIAN ECONOMY
DURING 2011-2012 (BASED ON NBS-BCL STUDY)
Contribution from
Industrial Sector
toward Formation
of Gross Domestic
Product (2011-2012)
Values in U.S.
$ Million
Coeffcient
Worked Out for
Direct Cost of
Corrosion
Coeffcient
Worked Out
for Avoidable
Direct Cost of
Corrosion
Direct Cost of
Corrosion for
the Years 20112012 (Values in
U.S. $ Million)
Direct
Avoidable
Cost of
Corrosion
for the Years
2011-2012
(Values
in U.S.
$ Million)
(A)
(B)
(C)
(D)
(E) [B x C]
(F) [B x D]
Agriculture
124,971.67
0.0215
0.0130
2,686.89
1,624.63
Livestock
52,244.79
0.0258
0.0159
1,347.92
830.69
17,784.58
0.0191
0.0103
339.69
183.18
8,932.92
0.0191
0.0103
170.62
92.01
10,862.08
0.0284
0.0121
308.48
131.43
627.92
0.0168
0.0080
10.55
5.02
11,676.46
0.0147
0.0041
171.64
47.87
1,642.92
0.0334
0.0159
54.87
26.12
128.96
0.0361
0.0186
4.66
2.40
Bauxite
58.96
0.0361
0.0186
2.13
1.10
Copper ore
43.33
0.0566
0.0237
2.45
1.03
Gold
25.21
0.0361
0.0186
0.91
0.47
433.54
0.0361
0.0186
15.65
8.06
Limestone
588.75
0.0186
0.0079
10.95
4.65
Mica stone
0.83
0.0186
0.0079
0.02
0.01
298.96
0.0195
0.0072
5.83
2.15
Food products
9,240.00
0.0037
0.0020
34.19
18.48
2,887.08
0.0037
0.0020
10.68
5.77
Cotton textiles
9,631.88
0.0017
0.0009
16.37
8.67
653.75
0.0161
0.0016
10.53
1.05
4,374.38
0.0181
0.0033
79.18
14.44
Fishing
II. Mining and Quarrying
A. Major Minerals
Coal
Lignite
Petroleum and natural gas
B. Metallic Minerals
Iron ore
Manganese ore
Others
C. Nonmetallic Minerals
Others
III. ManufacturingRegistered
896.67
0.0028
0.0003
2.51
0.27
Chemicals, etc.
20,349.38
0.0216
0.0028
439.55
56.98
17,262.50
0.0165
0.0013
284.83
22.44
6,416.88
0.0049
0.0025
31.44
16.04
Non-metallic products
58
TABLE 1. CONTINUED
Contribution from
Industrial Sector
toward Formation
of Gross Domestic
Product (2011-2012)
Values in U.S.
$ Million
Coeffcient
Worked Out for
Direct Cost of
Corrosion
Coeffcient
Worked Out
for Avoidable
Direct Cost of
Corrosion
Direct Cost of
Corrosion for
the Years 20112012 (Values in
U.S. $ Million)
Direct
Avoidable
Cost of
Corrosion
for the Years
2011-2012
(Values
in U.S.
$ Million)
(A)
(B)
(C)
(D)
(E) [B x C]
(F) [B x D]
16,934.58
0.0106
0.0012
179.51
20.32
Metal products
15,143.33
0.0576
0.0012
872.26
18.17
Electrical machinery
7,489.38
0.0145
0.0004
108.60
3.00
Transport equipment
14,367.92
0.0216
0.0009
310.35
12.93
Other manufacturing
4,312.08
0.0196
0.0004
84.52
1.72
Food products
5,240.83
0.0037
0.0020
19.39
10.48
1,419.58
0.0037
0.0020
5.25
2.84
Cotton textiles
7,975.21
0.0017
0.0009
13.56
7.18
5,818.33
0.0161
0.0016
93.68
9.31
1,835.21
0.0181
0.0033
33.22
6.06
1,452.08
0.0028
0.0003
4.07
0.44
Chemicals, etc.
2,140.00
0.0216
0.0028
46.22
5.99
1,162.92
0.0165
0.0013
19.19
1.51
Nonmetallic products
3,893.13
0.0049
0.0025
19.08
9.73
2,235.00
0.0106
0.0012
23.69
2.68
Metal products
6,888.54
0.0576
0.0012
396.78
8.27
Electrical machinery
1,764.58
0.0145
0.0004
25.59
0.71
Transport equipment
2,944.58
0.0216
0.0009
63.60
2.65
Other manufacturing
4,029.38
0.0196
0.0004
78.98
1.61
17,077.92
0.1008
0.0030
1,721.45
51.23
Gas
1,366.88
0.0084
0.0017
11.48
2.32
Water supply
2,141.25
0.0492
0.0119
105.35
25.48
201,635.83
0.0321
0.0086
6,472.51
1,734.07
49,631.04
0.0311
0.0059
1,543.53
292.82
173,463.96
0.0211
0.0126
3,660.09
2,185.65
15,823.33
0.0275
0.0133
435.14
210.45
17,608.13
0.0282
0.0111
496.55
195.45
IV. ManufacturingUnregistered
Electricity
VI. Construction
New construction
Repair and maintenance
Trade
Hotels and restaurants
VIII. Railways
Rail transport
Continued on p. 60
59
TABLE 1. CONTINUED
Contribution from
Industrial Sector
toward Formation
of Gross Domestic
Product (2011-2012)
Values in U.S.
$ Million
Coeffcient
Worked Out for
Direct Cost of
Corrosion
Coeffcient
Worked Out
for Avoidable
Direct Cost of
Corrosion
Direct Cost of
Corrosion for
the Years 20112012 (Values in
U.S. $ Million)
Direct
Avoidable
Cost of
Corrosion
for the Years
2011-2012
(Values
in U.S.
$ Million)
(A)
(B)
(C)
(D)
(E) [B x C]
(F) [B x D]
Road transport
52,073.33
0.0310
0.0162
1,614.27
843.59
Water transport
2,346.88
0.0352
0.0125
82.61
29.34
Air transport
2,945.00
0.0352
0.0054
103.66
15.90
Services incidental to
transport
4,532.08
0.0160
0.0078
72.51
35.35
762.08
0.0300
0.0118
22.86
8.99
437.08
0.0147
0.0080
6.43
3.50
20,342.08
0.0133
0.0014
270.55
28.48
150.21
0.0147
0.0080
2.21
1.20
X. Storage
Storage
XI. Communication
Postal
Telephones
Miscellaneous
Dwellings
44,596.25
0.0051
0.0027
227.44
120.41
Real estate
5,111.04
0.0051
0.0027
26.07
13.80
Legal services
3,353.96
0.0122
0.0056
40.92
18.78
Education
32,578.75
0.0030
0.0016
97.74
52.13
14,903.54
0.0045
0.0024
67.07
35.77
4,871.88
0.0033
0.0016
16.08
7.80
196.04
0.0076
0.0015
1.49
0.29
11,112.92
0.0492
0.0119
546.76
132.24
B. Recreation and
Entertainment Services
C. Radio and TV
Broadcasting
D. Sanitary Services
Total
26,084.79
9,275.60
60
Contribution to GDP
of Indian Economy
(2011-2012) (Values
in U.S. $ Billion)
Elements of Indirect
Cost
Percentage of
Contribution (%)
Indirect Cost of
Corrosion (Values in
U.S. $ Billion) [B x D(A)]
(A)
(B)
(C)
(D)
(E)
Social cost
4.5-5.5
16.539
Loss of product
2.0-3.0
2.629
Loss of effciency
1.5-2.0
4.241
Production loss
2.5-5.5
16.363
Overdesign
2.5-3.0
0.021
Construction
Railways
Transport by other means
Subtotal
Electricity, gas, and water
supply
Other services
Communication
Subtotal
Real estate, dwellings,
and business services
Trade, hotels, and
restaurants
Subtotal
Agriculture and allied
activities
Mining and quarrying
Manufacturing industries
registered
Manufacturing industries
unregistered
Subtotal
Storage
251.267
17.608
61.897
330.772
20.586
63.663
20.929
105.179
53.061
189.288
242.349
203.934
26.388
129.960
48.799
409.081
0.762
39.793
(A)
course is offered by a few regional engineering colleges and a few Indian institutes of
technology; and some other institutions,
including the Central Electrochemical
Research Institute (CECRI) in Karaikudi
and Indira Gandhi Centre for Atomic
Research (IGCAR) in Kalpakkam, offer this
course at the masters and bachelors
degree level and for those pursuing a Ph.D.
on this subject. Presently, most of the persons involved in designing, maintaining,
and monitoring corrosion have no formal
education in corrosion. They are basically
engineers who have been given additional
assignments in corrosion protection. This
approach is acceptable as long as systems
work well. Whenever a serious mainte-
Systematic Way to
Minimize Corrosion Loss
Preventive strategies include (i)
increasing awareness of large corrosion
costs and potential savings; (ii) changing
the misconception that nothing can be
done about corrosion; (iii) changing policies, regulations, standards, and manage-
ment practices to increase corrosion savings through sound corrosion management; (iv) improving education and
training of staff in recognition of corrosion
control; (v) advancing design practices for
better corrosion management; (vi) advancing life prediction and performance assessment methods; and (vii) advancing corrosion technology through research, development, and implementation.
Conclusions
The total annual cost of corrosion for
India during 2011-2012 is nearly U.S.
$66 billion, or 6% of Indias GDP. Out
of this, 2.4% constitutes direct cost
while 3.6% constitutes indirect cost.
61
FIGURE 2 Pattern of percentage contribution by each Indian sector to total direct cost of corrosion (2011-2012).
62
TABLE 3. STATE-WISE CONTRIBUTION TOWARD THE TOTAL COST OF CORROSION FOR INDIAN ECONOMY
(2011-2012)
Percentage of Contribution
Made by the States of
India toward Formation of
Total GDP (%)
(A)
(B)
(C)
0.719
0.08
0.053
74.750
7.93
5.224
1.073
0.11
0.072
Assam
14.697
1.56
1.028
Bihar
27.044
2.87
1.89
Chandigarh
3.000
0.32
0.21
Chhattisgarh
24.833
2.64
1.739
Delhi
42.011
4.46
2.938
Goa
4.220
0.45
0.297
Gujarat
71.268
7.57
4.987
Haryana
Andhra Pradesh
Arunachal Pradesh
33.674
3.57
2.352
Himachal Pradesh
7.034
0.75
0.494
7.186
0.76
0.501
Jharkhand
16.507
1.75
1.153
Karnataka
52.578
5.58
3.676
Kerala
38.958
4.14
2.727
Madhya Pradesh
37.039
3.93
2.589
Maharashtra
153.675
16.31
10.745
Manipur
1.409
0.15
0.099
Meghalaya
2.031
0.22
0.144
Mizoram
0.957
0.1
0.065
Nagaland
1.816
0.19
0.125
21.231
2.25
1.482
Orissa
Puducherry
2.134
0.23
0.151
Punjab
28.599
3.04
2.002
Rajasthan
41.154
4.37
2.878
0.888
0.09
0.059
76.936
8.17
5.382
2.999
0.32
0.21
Uttarakhand
10.454
1.11
0.731
Uttar Pradesh
77.115
8.19
5.395
West Bengal
64.053
6.8
4.48
Sikkim
Tamil Nadu
Tripura
65.878
63
64
Acknowledgments
The authors sincerely thank Ashok Mittal, honorable chancellor; Dr. Sanjay Modi,
dean of Academic Affairs; Dr. Rajesh Verma,
head, School of Business; Suresh Kashyap,
head, School of Business; and other dignitary members at Lovely Professional University, Phagwara, Punjab for their support
and advice. The cooperation obtained from
the Ministry of Statistical and Programme
Implementation, New Delhi is also gratefully acknowledged. The authors thank the
faculties and other members of the Lovely
Professional University School of Business
for their kind encouragement in pursuing
References
1
19 R. Bhaskaran, N. Palaniswamy, N.S. Rengaswamy, M. Jeyachandran, Global Cost of CorrosionA Historical Review, ASM Handbook
Vol. 13B: Corrosion: Materials (Materials
Park, OH: ASM International): pp. 621-628.
T.P. Hoar, Report of the Committee on Corrosion and ProtectionA Survey of Corrosion and Protection in the United Kingdom
(London, U.K.: H.M.S.O., 1971).
65
66
Experimental Work
Experiments were conducted using API
X65QT pipeline steel to determine the CO2
corrosion at temperatures ranging from 25
regions of the weld are more electrochemically active than the parent plate. For CS
that is actively corroding (no protective
passive film), the parent plate should be
more active (lower potential) than the weld
regions to ensure that the latter is the cath-
67
Figures 2 and 3 show the galvanic corrosion of a weld and HAZ at various temperatures. At pH 5, the weld zone exhibited passive behavior, except that at temperatures
of ~50 to 60 C the base metal became
active for a short period. The HAZ of Electrode E7018 was active and then became
passive at temperatures above 35 C. The
HAZ of four welds exhibited little difference in the level of passivity, whereas the
welds show distinct differences in passivity
level. This must be caused by the composition effect. The passive nature of corrosion
is caused by the effect of pH level. The weld
made with Electrode E8018 shows a higher
level of passivity, possibly caused by the
higher Si and Cr content. As the temperature increases, the passivity also increases.
This may be the result of the scaling effect
at higher temperatures. The primary factor
for the difference between the HAZ and the
weld is primarily composition and the next
factor is microstructures. The welds exhibited ferrite grain growth and the HAZ
showed refined ferrite grain structures. The
base metal exhibited pearlite with a ferrite
matrix. Hence the effect of microstructure
is comparatively uniform under a CO2 environment at this pH level.
unchanged. The effective area ratio, however, will be dependent on the potential
drop in the solution. Generally, the rate of
weld metal attack is dependent on the
nickel and copper contents of the welding
consumables and is less influenced by parent steel composition, although steel with
copper, nickel, and chromium additions
lead to more noble parent steel, hence
accelerating weld metal attack. It was noted
that low silicon content in the parent steel
leads to increased weld metal corrosion,
68
Square Error. The model fit was determined by the R-squared fit. The results fit
well with the experimental values. A useful
property is that its scale is intuitive. It
ranges from zero to one. Zero indicates the
proposed model does not improve prediction over the mean model and one indicates perfect prediction. Figures 4 through
6 show the R-squared value curves for Electrode E8018G weld. These were determined
for all the weld zones of all the tested welds
and found to be ~0.9; this is considered a
good fit. The equations are given for the
E7018, E8018B2, and E8018B6 welds, which
can be used to calculate the corrosion rate
(y) at any temperature (x).
Equations for E7018 weld and HAZ
include:
y = 2E06x6 + 0.0006x5 0.0652x4 + 3.7395x3
117.81x2 + 1932.2x 12922 (R2 = 0.998)
(1)
y = 2E05x6 + 0.004x5 0.557x4 + 35.48x3
1239.x2 + 22460x 16454 (R = 0.985)
(2)
Conclusions
The influence of composition is more
significant than the microstructure at the
tested conditions in a CO 2 environment.
The increased temperatures led to
increased passivity of the weld zones; however, the HAZ of the E7018 and E8018G
welds were active at temperatures below
45 C. The weld zone made with Electrode
E8018B6, which contains a higher Cr level,
FIGURE 6 Galvanic corrosion of E8018G weld HAZ with CO2 at various temperatures.
69
References
N.G. Thompson, J.H. Payer, DC Electrochemical Test Methods (Houston, TX: NACE, 1998).
10 ASTM G1-03, Standard Practice for Preparing, Cleaning, and Evaluating Corrosion Test
Specimens (West Conshohocken, PA: ASTM,
2011).
DATES
INSTRUCTOR
December 1-3
$400
Charlie Speed
December 1-3
$300
Peter Bock
December 2-3
$250
Bob Speck
December 4-5
$300
Charlie Speed
DATES
PRICING &
REGISTRATION
INSTRUCTOR
December 1-5
December 1-5
December 1-5
December 1-3
December 4-6
Raul A. Castillo
For pricing and to
register for these NACE
General Education
courses, go to
www.nace.org/
nolacourses
Jerry Byrd
Ray Quinter
Dannie Vickers
Dannie Vickers
Students are responsible for hotel reservations. Contact the New Orleans Airport Hilton at
+1 504-469-5000 or 1 800-445-8667 and ask for the NACE Event Rate Code: NAC. Room rate is $129/night.
70
BLOG
Continued from The MP Blog, p. 13.
The following items relate to materials
selection & design.
Please be advised that the items are
not peer-reviewed, and opinions and
suggestions are entirely those of the inquirers and respondents. NACE International does not guarantee the accuracy
of the technical solutions discussed.
MP welcomes additional responses to
these items. They may be edited for
clarity.
Q:
A:
A:
A:
Continued on page 74
72
BLOG
A:
Q:
74
A:
A:
A:
75
Index
CASING SPACERS/ISOLATORS
Advance Products & Systems, Inc.
Allied Corrosion Industries, Inc.
Cathodic Protection Management, Inc.
Corrosion Service Co., Ltd.
Farwest Corrosion Control Co.
Glas Mesh Co.
GMC Electrical, Inc.
Hoff Co., Inc.
Interprovincial Corrosion Control Co., Ltd.
Rustrol Systems
Keshar Pipeline Fittings Pvt., Ltd.
Liberty Sales and Distribution
MESA
Midwestern Pipe Line Products Co.
Pipe Wrap, Inc.
PSI-Pikotek
Public Works Marketing, Inc.
RiserClad International
CORROSION INHIBITORS
3N International, Inc.
AA Thread Seal Tape, Inc.
Advanced Corrosion Control Technologies
A J M Additives, Inc.
Allied Biochem (Shenyang) Co., Ltd.
ANMAC Service Co.
AquaTrol Division of Momar
Baker Hughes
B&W Distributors, Inc.
Basic Industries, Ltd.
Berry Plastics Corrosion Protection Group
Brant Corrosion Control
BWA Water Additives
Caradan Chemicals
76
MK Battery
Multi-Chem
Nalco Champion, an Ecolab Co.
Nalco Co.
Northtown Co.
Orca Maritime
Pittsburgh Corning
CP MODELING
Baker Hughes Pipeline Management Group
BEASY
B.S.S. Technologies
Chapman Engineering
Coastal Corrosion Control
FABRICATION/SPOOLING
Arcelor Mittal Industeel
Associated Tube Group
Basic Industries, Ltd.
Dynamic Industries
ECC Corrosion, Inc.
Edgen Murray
Ellett Industries, Ltd.
Fabricated Plastics
Genfabco, Ltd.
High-Tech Consultants, Inc.
Houston PolyTank, LLC
KLAD Manufacturing Co., Ltd.
L & M Fiberglass, Inc.
Litek Composites Corp.
MESA
P.A., Inc.
Pipeline Controls & Services
Reinforced Plastic Systems, Inc.
T Bailey, Inc. Industrial Coatings Group
Troy Manufacturing
Waldemar Suckut VDI
Zhejiang Guobang Steel Co., Ltd.
LINED PIPE
PIPE CONDITIONING
3X Engineering
Baoji Yirun Titanium Industry Co., Ltd.
Clock Spring Co., LP
Dai-Ichi High Frequency Co., Ltd.
HoldTight Solutions, Inc.
J.D. Rellek Co., Inc.
Litek Composites Corp.
Oceaneering International, Inc.
Scapa North America
TIB Chemicals AG
Waldemar Suckut VDI
PIPE FITTINGS
NON-CONTACT/NON-INVASIVE
DSI/Dalco Services, Inc.
MSES Corrosion Products Division
Roxar, Inc.
Speir Hunter, Ltd.
TesTex NDT, Ltd.
PIPE CLEANERS/PIGS
BlastingParts.com
Brance-Krachy Co. Inc.
Brand Energy & Infrastructure Services
Delta Tech Service, Inc.
Dustcontrol, Inc.
Enduro Pipeline Services, Inc.
Girard Industries
Goff, Inc.
Greenes Energy Group
HoldTight Solutions, Inc.
Hunter McDonnell Pipeline Services, Inc.
Inline Services, Inc.
Maloney Technical Products
Montipower, Inc.
Onstream Pipeline Inspection, Ltd.
Pigs Unlimited International, Inc.
Pipeline Inspection Co., Ltd.
Pipeline Pigging Products
Pipetech Corp., Ltd.
Praxair Services, Inc.
Pro-kote Engineering and Supply
PT. Sentra Inti Nusa Energi (SINERGI)
RBW Enterprises, Inc.
ROPLAST
ROSEN USA
Roxar, Inc.
Rustibus
Stuart Steel Protection Corp.
Tremco Pipeline Equipment
PIPELINE COATING/PROTECTION
A&E Anti-Corrosion Systems, LLC
Absolute Coatings
Accoat A/S
ACOTEC N.V.
77
Cortec Corp.
Custom Linings, Inc.
Dairyland Electrical Industries, Inc.
D-Angelo Industrial Coatings
De Nora Tech, Inc.
Denso North America
DNV Columbus
Ductile Iron Pipe Research Assn.
Dunkin & Bush, Inc.
Duomar, B.V.
DuraSeal Coatings Co.
Dynalog Technologies (C-Scan), LLC
Elcometer
Enviroline/International Paint Protective Coatings
Exceletech Coatings and Applications, LLC
Farwest Corrosion Control Co.
Five Star Marine, Inc.
Fyfe Co., LLC
G.M.A., S.r.l.
Gema USA, Inc.
GMC Electrical, Inc.
Great Lakes Copper, Inc.
Hartman Walsh Industrial Services
HEBNA Corp.
Hi-Temp Coatings Technology
Hyperseal, Inc.
Induron Coatings, Inc.
Industrial Coatings & Fireproofng
Industrial Marine Services
Industrial Solutions USA
International Paint
Interprovincial Corrosion Control Co., Ltd.
Rustrol Systems
IRT Integrated Rectifer Technologies, Inc.
Isotec International, Inc.
ITW American Safety Tech
Johnson Contracting Co.
Joint Specialists
78
PIPELINE INSTALLATIONS
CECO Pipeline Services Co.
Coastal Corrosion Control
Dynamic Industries
EnhanceCo, Inc.
IRT Integrated Rectifer Technologies, Inc.
Oceaneering International, Inc.
SESSafe Engineering Services &
Technology, Ltd.
Simdex
PIPELINE INTEGRITY
Accurate Corrosion Control, Inc.
Accurate Tool Co.A Division of Sentry
Equipment Corp.
A. HAK Industrial Services
All Pro Inspection and NDT Services
Alpha Pipeline Integrity Services
American Innovations, Inc.
Ammonite Corrosion Engineering, Inc.
Applus RTD
ARK Corrosion Services
BJ Pipeline Inspection Services
Borin Manufacturing, Inc.
Bouchard, Inc.
Broadsword Corrosion Engineering, Ltd.
Brown Corrosion Services, Inc.
BSI Sentry Systems
Cathodic Technology, Ltd.
CMS Corrosion Services, Inc.
Coastal Corrosion Control
Coast to Coast Inspection Services, Inc.
Coffman Engineers
Corrosion Control, Inc.
CorrosionControl.Nu, B.V.
Corrosion Control Services, Ltd.
Corrpro Companies, Inc.
Creaform
DC Voltage Gradient Technology & Supply, Ltd.
(DCVG, Ltd.)
Dynalog Technologies (C-Scan), LLC
Elecsys Corp.
ELK Engineering Associates, Inc.
Elsyca, Inc.
Enduro Pipeline Services, Inc.
PIPELINE REPAIR
Argosy International USA
Cathwell
CECO Pipeline Services Co.
Clemco Industries Corp.
Clock Spring Co., LP
Coastal Corrosion Control
PennWell Corp.
Permabond Engineering Adhesives
Pipeline Integrity, Ltd.
RiserClad International
Roxar, Inc.
Sypris Technologies Tube Turns Division
TIB Chemicals AG
Tremco Pipeline Equipment
Tuscan Corrosion Control, Ltd.
Waldemar Suckut VDI
Weatherford Pipeline & Specialty Services
WrapMaster, Inc.
PIPING INSPECTION
PIPES/TUBES
Alloy Metals & Tubes International
American Cast Iron Pipe Co.
Ameri-Ti, Inc.
Associated Tube Group
ATI Wah Chang
BALL WINCH Pipeline Services
Baoji Baoye Titanium-Nickel Industry Co., Ltd.
Baoji Shoushan Pipe Fittings Co., Ltd.
BlazeMaster Fire Sprinkler Systems
CDM Titanium
CENTRAVIS
Copper Nickel Task GroupCopper Development
Association
Corrosion Materials, Inc.
Corrotherm International, Ltd.
Corzan Industrial Systems
Crompion International
CTI
Dai-Ichi High Frequency Co., Ltd.
Ductile Iron Pipe Research Assn.
Durafex, Inc.
Dustcontrol, Inc.
Dynamic Flowform Corp.
ECC Corrosion, Inc.
Enerquip, LLC
Farmers Copper
Fiber Glass Systems, L.P.
Flexpipe Systems
Hamilton Metals, Inc.
H. BUTTING GmbH & Co., KG
Hebei Smart Steel Pipe Mill Co., Ltd.
High Performance Alloys, Inc.
HOWCO Metals Management
Jiuli USA, Inc.
Litek Composites Corp.
Mangalam Metal Corp.
Maverick Applied Science, Inc.
Metals, Inc.
Multimetals, Ltd.
Nippon Steel & Sumitomo Metal
Oceaneering International, Inc.
Outokumpu High Performance Stainless, Inc.
PAC Stainless, Ltd.
P.A., Inc.
PCC Energy Group
Prince Rubber & Plastics Co., Inc.
Pro-Mark Utility Supply, Inc.
Proto Manufacturing
Robroy Industries
Rolled Alloys
Rovanco Piping Systems
Samuel Son & Co., Ltd.
Sandusky InternationalA Division of MetalTek
Intl.
79
SCAVENGING CHEMICALS
BWA Water Additives
Force Chem Technologies
Greenes Synergy Services
Ingeveld and Associates, Ltd.
Jacam
Lonza, Inc.
ParchemFine Specialty Chemicals
Strategic Chemistry Pty., Ltd.
Sulzer Chemtech USA, Inc.
SEALANTS
Denso North America
EnDiSys
Five Star Marine, Inc.
Flexitallic, Ltd.
Foam King Industries, Inc.
Pelseal Technologies, LLC
Permabond Engineering Adhesives
Polyguard Products, Inc.
VISCOTAQ (Amcorr Products & Services)
SOFTWARE
About Time Technologies
American Innovations, Inc.
Borgtech
Borin Manufacturing, Inc.
Corrosion Software Solutions
DeFelsko Corp.
Elcometer
Electro Sciences, Inc.
Enduro Pipeline Services, Inc.
Epiqtech
EUPEC Pipeline Services Espaa, SAU
FORCE Technology Norway AS
GL Noble Denton
Honeywell Process Solutions
LiquidFrameWorks
Pipeline Software, Inc.
Roxar, Inc.
SESSafe Engineering Services &
Technology, Ltd.
Simdex
Thermo-Calc Software
TruQC
SURVEYS
Bass Engineering Co., Inc.
CEM Resources, Inc.
Cescor, S.r.l.
Coastal Corrosion Control
CorroMetrics Services, Inc.
Corrpro Companies, Inc.
Dynalog Technologies (C-Scan), LLC
Enduro Pipeline Services, Inc.
80
TAPES/PIPELINE WRAPS
Air Graphics, LLC
Berry Plastics Corrosion Protection Group
Champion Corrosion Products, Inc.
Clock Spring Co., LP
Denso North America
DeWAL Industries, Inc.
ENECON Corp.
Farwest Corrosion Control Co.
FRP Products Co. Pte., Ltd.
Georg Fischer Central Plastics, LLC
GMC Electrical, Inc.
Interprovincial Corrosion Control Co., Ltd.
Rustrol Systems
Keshar Pipeline Fittings Pvt., Ltd.
MONTI Tools, Inc.
Ningbo Ideal Anticorrosion Material Co., Ltd.
Northtown Co.
Polyguard Products, Inc.
Protection Engineering
Pro-Tect Services, Inc.
Scapa North America
SRT Solutions, LLC
Tek-Rap
Timco Global Enterprises W.L.L.
Tremco Pipeline Equipment
Tuff-N-Nuff
VISCOTAQ (Amcorr Products & Services)
WrapMaster, Inc.
WIRE PRODUCTS
Anomet Products, Inc.
Basic Industries, Ltd.
Champion Corrosion Products, Inc.
COR-MET, Inc.
Energy Economics, Inc.
Farwest Corrosion Control Co.
WATER/WASTEWATER FACILITIES
3Hach Co.
Advantage Resources Consulting, LLC
ARC Specialties, Inc.
Bray International
BSI Sentry Systems
Carboline Company
Cascade Water Services
CH2M Hill
Corrpro Companies, Inc.
3N International, Inc.
3X Engineering
Absolute Coatings
Web site: www.por15.com.
Accoat A/S
Web site: www.accoat.com.
ACOTEC N.V.
Amercoat Canada
E-mail: tsievert@wi.rr.com.
Ameri-Ti, Inc.
Web site: www.ameri-ti.com.
A J M Additives, Inc.
Web site: www.AJM-Additives.com.
82
Applus RTD
Web site: www.ApplusRTD.com.
ARC Composites
Web site: www.chesterton.com.
Baker Hughes
Web site: www.bakerhughes.com.
BEASY
Web site: www.beasy.com.
Blastech
Web site: www.blastech.com.
BlastingParts.com
Web site: blastingparts.com.
Borealis AG
Web site: www.borealisgroup.com.
Borgtech
Web site: www.borgtech.com.au.
Bouchard, Inc.
E-mail: lbouchard@cox.net.
Bray International
Web site: www.bray.com.
Bredero Shaw
Web site: www.brederoshaw.com.
Brothers Coatings
Web site: www.brotherscoating.com.
83
Cescor, S.r.l.
BSS Technologies
CH2M Hill
Canusa-CPSA Division of
ShawCor, Ltd.
Chapman Engineering
Capital Inspectors
Web site: www.capitalinspectors.com.
Caplugs
Web site: www.caplugs.com.
Caradan Chemicals
Web site: www.caradanchemicals.com.
Chromafo Technologies
Web site: www.plasticolors.com.
CL Coatings, LLC
Web site: www.nacoatings.com.
Carboline Company
2150 Schuetz Rd., St. Louis, MO 63146, USA.
Tel: 1 800-848-4645 or +1 314-644-1000. Fax:
+1 314-587-2693. Web site: www.carboline.
com. E-mail: mbentley@carboline.com. Carboline Company is dedicated to supplying
high-performance coatings, linings, and freproofng products around the world through
continuous technological improvements and
frst-class service.
See p. 1 for our ad.
Cathwell
Web site: www.cathwell.com.
CDM Titanium
Web site: www.cdmtitan.com.
CENTRAVIS
Web site: www.centravis.com.
Coffman Engineers
Web site: www.coffman.com.
Composi Sleeve
Web site: www.composisleeve.com.
COR-MET, Inc.
Web site: www.cor-met.com.
Cor-Pro Systems
Web site: www.cor-pro.com.
CorrosionControl.Nu, B.V.
Web site: www.corrosioncontrol.nu.
84
CorTech, Ltd.
E-mail: mister.darkhan@gmail.com.
CP Solutions, Inc./Sustaining
Infrastructure
DeFelsko Corp.
Creaform
Web site: www.creaform3d.com/en/ndt-solutions.
Crompion International
Web site: www.crompion.com.
CTI
Web site: www.cti-ind.com.
Cortec Corp.
4119 White Bear Pkwy., St. Paul, MN 55110,
USA. Tel: 1 800-426-7832 or +1 651-429-1100.
Fax: +1 651-429-1122. Web site: www.cortecvci.
com. E-mail: info@cortecvci.com. Cortec
Corp. is a global leader in innovative, environmentally responsible VpCI and MCI corrosion control technologies for the packaging,
metalworking, construction, electronics, water
treatment, oil/gas, and other industries. Headquartered in St. Paul, Minnesota, Cortec is
ISO 9001 and ISO 14001:2004 certifed.
See p. 49 for our ad.
Danlin Chemical
Web site: www.danlin.us.
De Nora
7590 Discovery Ln., Concord, OH 44077, USA.
Tel: +1 440-710-5300. Fax: +1 440-710-5301.
Web site: www.denora.com. E-mail: infolida@
denora.com. De Nora is a pioneer and leader
in the feld of mixed metal oxide (MMO) anodes
for over 40 years with the longest life anodes
for superior system performance. Tens of
thousands of groundbeds have been installed
worldwide using Lida anodes. De Nora
provides a full range of anode structures including tubes, wire, ribbon, and rod geometries. De Nora can provide virtually any anode
configuration to meet your special needs.
To contact one of De Noras distributors, please
visit the following Web site link: www.denora.
com/Produc ts/Ox ygenAndSpecialities/
CathodicProtection/LidaTechnologicalPartners.
aspx.
See p. 20 for our ad.
85
Elecsys Corp.
Duomar, B.V.
Durafex, Inc.
Web site: www.durafexinc.com.
Dustcontrol, Inc.
Web site: www.dustcontrol.com.
Dynamic Industries
DNV Columbus
Web site: www.dnvcolumbus.com.
DNV GL
Web site: www.dnvusa.com.
El Paso Corp.
Web site: www.elpaso.com.
Elsyca, Inc.
Web site: www.elsyca.com.
EnDiSys
Web site: www.endisys.com.
Element
Edgen Murray
Web site: www.edgenmurray.com.
Elcometer
1893 Rochester Industrial Dr., Rochester Hills,
MI 48309, USA. Tel: 1 800-521-0635 or +1
248-650-0500. Fax: +1 248-650-0501. Web
site: www.elcometer.com. E-mail: sales@
elcometerusa.com. Elcometer is a leader in
coating, ultrasonic NDT, flaw detection,
concrete inspection equipment, and rebar
and metal detection. We offer products to
measure coating thickness, surface preparation, climate, porosity, and adhesion, as well
as a wide range of physical test parameters
required for the formulation of coatings. With
a truly global presence, all Elcometer products are readily available through our own
sales offces in the United Kingdom, United
States, Singapore, Japan, The Netherlands,
Belgium, France, and Germany, and through
our extensive network of distributors in more
than 150 countries around the world.
See pp. 7, 16, and 38 for our ads.
ENECON Corp.
Web site: www.enecon.com.
86
EnhanceCo, Inc.
Fisher Co.
Enviroline/International Paint
Protective Coatings
Epiqtech
Web site: www.epiqtech.com.
Ergon Armor/Novocoat
Web site: www.ergonarmor.com.
Evonik Corp.
Web site: www.protectosil.com.
EZEFLOW, Inc.
Web site: www.ezefow.com.
Fabricated Plastics
Web site: www.fabricatedplastics.com.
Farmers Copper
Web site: www.farmers-copper.com.
Flexitallic, Ltd.
Web site: www.fangerescuegasket.com.
Flexpipe Systems
Web site: www.fexpipesystems.com.
G.M.A., S.r.l.
FOX-TEK Canada
Web site: www.fox-tek.com.
GE Gemini
Web site: www.gepower.com/pii.
Genfabco, Ltd.
Web site: www.gfabco.com.
Girard Industries
Web site: www.girardind.com.
GL Noble Denton
Goff, Inc.
Web site: www.goff-inc.com.
Grace Distributing
Web site: www.gracedistributing.com.
87
H T Engineering, Inc.
Hyperseal, Inc.
ICORR Technologies
HEBNA Corp.
ILFC, Inc.
HinderRUST, Inc.
HMT, Inc.
88
International Paint
Web site: www.international-pc.com.
Interplastic Corp.
Web site: www.interplastic.com.
Ion Science
Web site: ionscienceusa.com.
Mascoat
Jacam
LB Foster Co.
MATCOR, Inc.
E-mail: mbrumbaugh@lbfoster.com.
JANX
Leidos Health
Lena e Anticorrosion
LiquidFrameWorks
Joint Specialists
MESA
KBS Coatings
Web site: www.kbs-coatings.com.
KeyTech, Ltd.
E-mail: key.tech@ntlworld.com.
King Innovation
Web site: www.kinginnovation.com.
Lonza, Inc.
90 Boroline Rd., Allendale, NJ 07401, USA. Tel:
+1 201-316-9200. Web site: www.lonza.com.
E-mail: oilfelds.americas@lonza.com. Lonzas
specialty chemicals are used in upstream oil
and gas activities including drilling, production, stimulation, and unconventional oil and
gas recovery. Lonza focuses innovation on
environmentally responsible solutions and
high-performance chemicals for challenging
technical environments.
See p. 51 for our ad.
Metabo Corp.
Metals, Inc.
MetriCorr Aps
89
M-I Swaco
Web site: www.miswaco.com.
MK Battery
1631 S. Sinclair St., Anaheim, CA 92806, USA.
Tel: 1 800-372-9253 or +1 714-937-1033. Web
site: www.mkbattery.com. E-mail: sales@
mkbattery.com. MK Battery is the supplier of
Deka Solar Batteries for the renewable energy
industry. The Deka Solar line includes sealed
VRLA GEL and AGM batteries, in multiple
confgurations, as well as select fooded products. The Deka Solar GEL batteries are a
premiere, deep-cycling choice for renewable
energy and remote power applications including cathodic protection, telemetry, SCADA,
and chemical injection applications. You can
trust and rely on Deka Solar Batteries, which
have been designed for use in even the harshest environments.
See p. 5 for our ad.
Mobiltex
Web site: www.corTalk.com.
Montipower, Inc.
Northtown Co.
Web site: www.northtown.com.
Special Section:
Company Showcase
90
Multi-Chem
Multimetals, Ltd.
Nalco Co.
OmniMetrix
Orca Maritime
P.A., Inc.
Web site: www.painc.com.
Pittsburgh Corning
Pro-Seal Systems
Protech EIS
PennWell Corp.
Protection Engineering
PermaDri, Inc.
Web site: www.permadri.com.
Perry Electric
Web site: www.perryelectric.net.
PO Box 755, Ennis, TX 75120, USA. Tel: 1 800541-4994 or +1 281-580-5700. Fax: +1 281-5805703. Web site: www.polyguardproducts.com.
E-mail: polyguard@polyguardproducts.com.
Polyguards RD-6 corrosion coating is nonshielding wrap designed to work in conjunction with cathodic protection (CP) systems.
Our NHT-5600 is a 100% solid, volatile organic compound (VOC)-free epoxy designed
specially formulated for extended pot life.
Both the RD-6 and NHT-5600 are used for
feld joint girth welds, fttings, holiday repair,
and for pipeline coating rehab. We also offer
the ReactiveGel corrosion treatment used for
corrosion under insulation (CUI). The gel reacts
with steel to form an invisible glasslike corrosion protection layer. Polyguard IRO is a watercured fberglass and polyurethane tape. The
hardened IRO is an excellent impact and
abrasion resistant system used for harsh soils
and as a HDD coating.
See inside front cover for our ad.
Proto Manufacturing
Web site: www.protoxrd.com.
PSI-Pikotek
Web site: www.pikotek.com.
E-mail: avivkam@netvision.net.il.
91
SEMicro Division
REOD, LLC
Web site: www.reodllc.com.
Roxar, Inc.
Gamle Forusveien 17, PO Box 112, Forus, 4033
Stavanger, Norway. Tel: +47 51818800. Web
site: www.roxar.com. E-mail: info.roxar@
emerson.com. Roxar is an international provider of technology for reservoir management
and production optimization. Roxar combines
data from its instrumentation with advanced
software models to help operators monitor
production in real-time and use up-to-date
feld information when making operational
decisions. Roxars topside and subsea corrosion monitoring technology provide the industrys leading measurement technology for
detection and quantifcation of corrosion,
erosion, sand production, pressure, temperature, and fow momentum. By using quality
data on the production and control of the
pipeline, operators can make better, more
accurate decisions on a continuous basis.
Resodyn Corp.
Web site: www.resodyn.com.
RiserClad International
Ritepro Corp.
RK&K
Robroy Industries
Rustibus
Roemex, Ltd.
E-mail: Gillian@Roemex.com.
Rolled Alloys
Saekaphen
ROPLAST
Safetrack AB
ROSEN USA
Simdex
Sauereisen
Web site: www.sauereisen.com.
Skystone Engineering
Web site: www.skystone.ca.
92
Sprayroq, Inc.
Web site: www.sprayroq.com.
Technical Toolboxes
Techni-Kote, Inc.
Tek-Rap
Web site: www.tek-rap.com.
TesTex, Inc.
Web site: www.testex-ndt.com.
Thermion
Web site: www.thermioninc.com.
Sub-One Technology/InnerArmor
Web site: www.sub-one.com.
Subspection, Ltd.
Web site: www.subspection.com.
Thermo-Calc Software
4160 Washington Rd., Ste. 230, McMurray,
PA 15317, USA. Tel: +1 724-731-0074. Web
site: www.thermocalc.com. E-mail: paul@
thermocalc.com. Thermo-Calc Software is a
leading developer of software and databases
for calculations involving computational
thermodynamics and diffusion-controlled
simulations. Thermo-Calc is a powerful tool
for performing thermodynamic calculations
for multicomponent systems. Calculations are
based on databases developed using the
CALPHAD approach. Databases are available
for steels, Al-, Mg-, Ni-superalloys, Ti-, and
other materials. Databases are also available
for aqueous systems. Applications related to
corrosion include alloy design, high-temperature coatings, high-temperature oxidation,
carburization, heat treatment, metal dusting,
hot salt corrosion, aqueous corrosion, including predicting Pourbaix diagram for multicomponent alloys, and more.
See p. 75 for our ad.
Taku Engineering
Tamburini SpA
Tanknology, Inc.
TIB Chemicals AG
93
E-mail: tcp2664@yahoo.com.
TPSTechnitube
Transhield, Inc.
Web site: www.transhield-usa.com.
Trenton Corp.
Web site: www.trentoncorp.com.
Tricor Metals
Vivax-Metrotech Corp.
Web site: www.vivax-metrotech.com.
Triple D Bending
Web site: www.pipebending.com.
Troy Manufacturing
Web site: www.troymfg.com.
TruQC
Web site: www.truqcapp.com.
Tuff-N-Nuff
Web site: www.tuff-n-nuff.com.
Uni-Spray Systems
Web site: www.uni-spray.com.
Whitford Corp.
Web site: www.whitfordww.com.
Wasser Corp.
Web site: www.wassercoatings.com.
Vallourec
Web site: www.vallourec.com.
WrapMaster, Inc.
Web site: www.wrapmaster.us.
94
a Difference
This annual work week brings together more than 500 industry professionals
and includes a series of meetings focused on methods of identifying, preventing,
and combating corrosion problems impacting many industries.
Why Attend?
Develop and revise the standards and reports that
industry professionals rely on when seeking solutions
to their corrosion problems
Register Today!
FREE* for NACE Members
and Students
$150*USD for Non-Members
* Pricing refects advance registration,
which ends August 22, 2014.
Students, please contact FirstService
at 1-800-797-6223 to register.
On NACE International
Corporate Members
SPOTLIGHT
THIS MONTH: DIAMOND
CORPORATE MEMBER
PMAC GROUP
MAC Group and its subsidiary companies provide flow assurance and
integrity support services to the oil, gas,
and water industries. PMAC was formed
in 2000 and has offices in Aberdeen and
Singapore. PMACs engineers are experts
in the chemical processes affected by corrosion, and the company has designed
and developed a range of cathodic protection (CP) and subsea inspection products
that employ PMACs own proprietary
equipment and software including video
capture and data management.
Drawing on a combined knowledge of
practical experience in chemistry, corrosion, inspection, and electronic engineering, we pride ourselves in providing clients with a unique range of services, says
Chairman John Fyfe. Our success derives
from being able to manage a diverse
.nace.org/nacestore!
96
Corrosion Management
The Key to Asset
Integrity Management
REGISTER TODAY!
Ofcial Media Partners:
MATERIALS
PERFORMANCE
97
Q:
A:
Q:
A:
98
Q:
A:
Q:
A:
99
NACE NEWS
Your Association
in Action
he International Corrosion
Awareness Day was celebrated
at the Federation House in
New Delhi, India, on April 24,
2014, with more than 110
people present from industry, academia,
and government.
Honored guests included Joint
Secretary A.J.V. Prasad, Ministry of
Chemicals, Government of India; John
McCaslin, minister counselor, United
States Department of Commerce (USDC);
S. Vasudeva and S.K. Manglik, former
chairmen of Oil and Natural Gas Corp.
(ONGC), Ltd.; C.R. Prasad, former chairman of GAIL India Ltd.; R.K. Malhotra,
director (R&D) of Indian Oil Corp. Ltd.
(IOCL); Ashok Anand, director general
100
Elaine Bowman presented information about the IMPACT cost of corrosion study to
the audience.
he NACE International
Philadelphia Section
conducted its 2014 Liberty Bell
Corrosion Course from
February 12 to 13, 2014 in
Horsham, Pennsylvania. Liberty Bell
provides classes in developing corrosion
technology and state-of-the-art expertise.
The school featured three tracks including
Rectifier Troubleshooting and Repair, Basic
Corrosion Control, and Underground
Corrosion Control.
The school had 19 exhibitors and
60 students. Feedback indicated that
the program was well accepted and the
course content was enjoyed by all who
participated. We were thrilled to have
Harvey Hack, FNACE, at that time the vice
president and now the president of NACE
International, as our featured speaker for
the program. Hack spoke about the growth
the association has been experiencing and
the many benefits that NACE membership
can provide for our members.
On February 14, 2014, we conducted a
joint meeting of the Eastern Pennsylvania
and New Jersey Corrosion Committees. The
meeting was sponsored by Liberty Bell and
was held in the Liberty Bell Exhibit Hall.
(David Krause)
101
n March 6, 2014, 30
members of the NACE
International San
Francisco Section
toured the new East Span
of the Bay Bridge that links Oakland with
San Francisco, California. The original East
Span of the Bay Bridge suffered collapse of a
short section of the upper deck during the
1989 Loma Prieta earthquake. Though no
lives were lost, the incident underscored its
seismic vulnerability. Rather than retrofit
the existing bridge, it was decided to
construct a new East Span. The new $6.4
billion bridge has a 2,050-ft (625-m) long
self-anchored suspension span (SAS)
supported by a 525-ft (160-m) high central
tower. A one-mile (1.6-km) long continuous
cable bundle passes over the tower and
loops under the western end of the
suspended deck. Both ends of the cable are
anchored on the east side of the suspension
span and support the suspended bridge
deck. This is currently the longest SAS
bridge deck in the world.
The California Department of
Transportation (Caltrans) has established
a Bay Bridge Public Information Office
where the trip attendees gathered before
the boat tour to view the new Bay Bridge
East Span. Caltrans Public Information
Officer Victor Gauthier narrated an excellent slide presentation summarizing the
construction of the East Span and proudly
highlighted the innovative construction
techniques that were used to assemble this
complex, yet artistic structure. Following
the slide introduction and a brief safety
meeting, the group assembled on a
platform boat and was transported underneath the new East Span to see various
construction and environmental features
on the structure. Although the span is in
full operation, crews are still finishing the
last construction details. The beauty of this
bridge can best be appreciated after dark,
when it is bejeweled by a dazzling array of
LED lights. The bridge is also adhering to
Californias often strict environmental code
by providing nesting places for cormo-
102
NACE San Francisco Sections new Bay Bridge tour group assembled on the Caltrans shuttle boat.
ACE Internationals
Technical Activities
Department announces
that the following
standards have been
revised:
SP0177-2014 (Formerly RP0177),
Mitigation of Alternating Current and
Lightning Effects on Metallic Structures
and Corrosion Control Systems
SP0395-2013 (Formerly RP0395),
Fusion-Bonded Epoxy Coating of Steel
Reinforcing Bars
The following standards are newly
published:
Four circulars regarding NACE MR0175/
ISO 15156:
MR0175-ISO 15156-Part 1 Technical
Circular 1 (2014), Petroleum and
natural gas industriesMaterials for
use in H2S-containing environments
in oil and gas productionPart 1:
103
NACE OFFICERS
NACE NEWS
PRESIDENT
HARVEY P. HACK, FNACE*
Northrup Grumman Corp.
Annapolis, MD
VICE PRESIDENT
Jim Feather*
ExxonMobil Research
Fairfax, VA
TREASURER
Keith Perkins*
Williams Gas Pipeline Transco
Houston, TX
PAST PRESIDENT
Tushar Jhaveri*
Vasu Chemicals
Mumbai, India
EXECUTIVE DIRECTOR
Robert H. Chalker*
NACE International
Houston, TX
DIRECTORS
Jenny Been | 2012-2015 | Northern Area
TransCanada Pipelines
Calgary, AB, Canada
Timothy Bieri | 2012-2015 | Publications Activities
BP America Inc.
Houston, TX
Sylvia Hall | 2012-2015 | Western Area
HDR Inc.
Claremont, CA
Abdullah Al-Ghamdi | 2013-2016 | West Asia & Africa Area
Saudi Aramco
Dhahran, Saudi Arabia
Jane Brown | 2013-2016 | Central Area
Brown Corrosion Services
Houston, TX
Steven Hoff | 2013-2016 | Eastern Area
South Carolina Electric and Gas
Camden, SC
Scott Lillard, FNACE | 2013-2016 | Technical Research Activities
University of Akron
Akron, OH
Sam McFarland | 2013-2016 | European Area
Shell
Amsterdam, The Netherlands
Fabian Sanchez | 2013-2016 | Latin America Area
OCP Ecuador S.A.
Quito, Ecuador
Bruce Cookingham | 2014-2017 | Education Activities
BP
Houston, TX
Peter Harkins | 2014-2017 | Conferences & Expositions Activities
Tinker & Rasor Co.
San Bernardino, CA
Michelle Lau | 2014-2017 | East Asia & Pacifc Rim Area
Mach3 Engineering
Selangor, Malaysia
EX OFFICIO DIRECTORS
Neil G. Thompson, FNACE
President, NACE International Foundation
Chris Fowler, FNACE
President, NACE International Institute
*Executive Committee members
104
GOLD
Alpha Pipeline Integrity Services, Kemah,
Texas, USA
Atmos Energy, Jackson, Mississippi, USA
Bechtel Group, Inc., Houston, Texas, USA
Bharat Heavy Electrical, Ltd., Hyderabad,
India
BP US Pipeline, Naperville, Illinois, USA
ConocoPhillips Co., Bartlesville, Oklahoma,
USA
Corrosion Technology Services, LLC, Sharjah,
United Arab Emirates
Corrosion Testing Services, Taft, Tennessee,
USA
Crompion International, Baton Rouge,
Louisiana, USA
Deepwater Corrosion Services, Houston,
Texas, USA
DYCE Global, Seoul, South Korea
E-TECH Energy Technology Development
Corp., Tianjin, China
Evraz, Inc., Regina, SK, Canada
Galvotec Companies, McAllen, Texas, USA
Haynes International, Inc., Kokomo, Indiana,
USA
High Performance Alloys, Inc., Windfall,
Indiana, USA
HJ3 Composite Technologies, Tucson,
Arizona, USA
Integrated Global Services, Midlothian,
Virginia, USA
Interprovincial/International Corrosion
Control, Inc., Burlington, Ontario, Canada
Kuwait Pipe Industries and Oil Services Co.,
Safat, Kuwait
Ledcor Industrial Maintenance, Ltd.,
Edmonton, Alberta, Canada
MATCOR, Inc., Chalfont, Pennsylvania, USA
NRI, Lake Park, Florida, USA
NTPC, Ltd., New Delhi, India
Oceaneering International, Inc., Houston,
Texas, USA
Pacific Gas & Electric Co., Walnut Creek,
California, USA
Park Derochie, Inc., Edmonton, Alberta,
Canada
RK&K, Charlotte, North Carolina, USA
Rosen Group, Stans, NW, Switzerland
Southern Star Central Gas Pipeline,
Owensboro, Kentucky, USA
TransCanada Pipelines, Calgary, Alberta,
Canada
United States Coast Guard, Baltimore,
Maryland, USA
Williams, Tulsa, Oklahoma, USA
Wood Group Integrity Management, Perth,
WA, Australia
Xodus Group, Houston, Texas, USA
105
NACE NEWS
Calendar of Events
SEPTEMBER 2014
OCTOBER 2014
LATINCORR 2014
October 28-31, 2014
Medellin, Colombia
More Info: Judith Chovit, phone: +1 571-620-6801, e-mail:
directora@nacecolombia.com, Web site: latincorr2014.org
NOVEMBER 2014
CORCON 2014
November 12-15, 2014
Mumbai, India
More Info: NACE Gateway India Section, phone: +91 22
25797354, e-mail: info@corcon.org
DECEMBER 2014
FEBRUARY 2015
106
Seattle, WA
Houston, TX
Houston, TX
Mumbai, India
Houston, TX
Fahaheel, Kuwait
Houston, TX
Orlando, FL
Melbourne, Australia
Houston, TX
Houston, TX
Albuquerque, NM
Houston, TX
Houston, TX
CIP LEVEL 1
Bogota, Colombia
Chennai, India
Harrogate, UK
Beijing, China
Singapore
Houston, TX
Imabari, Japan
Ulsan, Korea
Dubai, UAE
CIP LEVEL 2
Shanghai, China
Kolkatta, India
Pattaya, Thailand
Houston, TX
Marabella, Trinidad
Mobile, AL
Newington, NH
Beijing, China
Chennai, India
Dubai, UAE
Houston, TX
Shanghai, China
Mumbai, India
Pattaya, Thailand
Houston, TX
Marabella, Trinidad
Baton Rouge, LA
Houston, TX
Spijkenisse, Netherlands
Mumbai, India
Kansas City, MO
Chennai, India
Houston, TX
Nagasaki, Japan
Houston, TX
Denver, CO
Pittsburgh, PA
Brasschaat, Belgium
Houston, TX
Houston, TX
Newcastle-upon-Tyne, UK
Newcastle-upon-Tyne, UK
Newcastle-upon-Tyne, UK
Dubai, UAE
Anaheim, CA
Dubai, UAE
Houston, TX
Milan, Italy
Houston, TX
Newcastle-upon-Tyne, UK
Newcastle-upon-Tyne, UK
Imabari, Japan
Antwerp, Belgium
Anaheim, CA
Shanghai, China
Houston, TX
Seattle, WA
Shanghai, China
Houston, TX
Melbourne, Australia
107
NACE NEWS
Houston, TX
Bogota, Colombia
Houston, TX
Beijing, China
Ulsan, Korea
Fahaheel, Kuwait
September 13, 2014
Houston, TX
Houston, TX
Darwin, Australia
Madrid, Spain
Houston, TX
Houston, TX
Johannesburg, South
Africa
Bogota, Colombia
Newcastle-upon-Tyne, UK
Cairo, Egypt
Yokosuka, Japan
Houston, TX
Houston, TX
Seattle, WA
Houston, TX
Houston, TX
Madrid, Spain
Fahaheel, Kuwait
PCS 2 ADVANCED
Dubai, UAE
Houston, TX
Dubai, UAE
Midrand, Johannesburg,
South Africa
Rosebush, MI
Dubai, UAE
Houston, TX
Houston, TX
Dubai, UAE
Houston, TX
Mumbai, India
Houston, TX
Houston, TX
Houston, TX
Dubai, UAE
Joliet, Illinois
Mumbai, India
Beijing, China
108
Advertising
All Inquiries ....................................................................................6219
Annual Conference
General Information.......................................................................6223
Exhibits ................................................................................6227, 6242
Registration ....................................................................................6223
Technical Papers ............................................................................6287
Area and Section SupportOffcers
Inquiries and Orders
USA & Canada ...............................................................................6240
International ...................................................................................6240
Awards 6276
Board of Directors/Board Committees
Information ....................................................................................6209
Books
Editorial..........................................................................................6219
Sales...............................................................................................6223
Certifcation
General Information.......................................................................6223
Professional Recognition/Status
Inquiries ..................................................................................6211
Recertifcation .........................................................................6211
Coating Inspector Program
General Information.......................................................................6223
Peer Review Scheduling
Registered Candidate .............................................................6233
Registration .............................................................................1802
Update & Renewal ..................................................................6211
Verify Certifcation ..................................................................6211
Courses and Seminars
Area/Section-Sponsored Courses ..................................................6258
General Information.......................................................................6223
Contract Courses ................................................................. 6230/6246
Home Study
General Information and
Registration .............................................................................1802
In-House Training ................................................................. 6230/6246
Instructor Applications ...................................................................6233
RegistrationAll Course Types .....................................................6223
Schedules.......................................................................................6223
Computer Software
General Information.......................................................................6223
Sales...............................................................................................6223
Technical Support ..........................................................................6255
Corrosion
Advertising.....................................................................................6219
Authors Guide ...............................................................................6223
Managing Editor ............................................................................6260
Subscriptions/Reprints ...................................................................6223
Corrosion Technology Week
Information ....................................................................................6264
Registration ....................................................................................6223
109
NACE International
Training CenterDubai
Register Today
DATE
CIP Level 1
CIP Level 2
CIP Level 1
CIP Level 2
CIP Level 1
November 1 6, 2014
www.nace.org/traindubai
* All certifcations are administered by the NACE International Institute, the independent certifcation
afliate of NACE International. Certifcations are subject to periodic reviews and revisions, please refer to
www.naceinstitute.org for the most current certifcation information.
110
C O N S U LTA N T S
Complete Corrosion
Control Systems
23 MANCHESTER DRIVE
WESTFIELD, N.J. 07090-2255
(908) 233-3509
FAX: (908) 233-8966
E-MAIL: camti@verizon.net
NACE INTERNATIONAL
CERTIFIED CORROSION
SPECIALIST NO. 622
www.destearns.com
111
ISO-9001 Certifed
Aluminum-Magnesium-Zinc/Retroft-Platform-Bracelet/Hull-Tank
Onshore/Offshore
QUALITY-PERFORMANCE-RELIABILITY
Sales Office
181 Grefer Lane
Harvey, LA 70058
Tel.: (504) 362-7776
Fax: (504) 269-1418
ANODES
Email: anodes@galvotec.com
www.galvotec.com
Ph: 504-362-7373
FX: 504-362-7331
Email: service@galvotec.com
Pin Brazing
Easybond equipment & consumables
available in the USA through sole
importers Galvotec Corrosion Services
and GMC Electrical
Contact
Dave Johnson on (504) 362 7373
or
Gary Matlack on (909) 947 6016
ER-LPR Instruments
Corrosion Probes
E-mail: msc@alspi.com
www.metalsamples.com
112
Phone/fax: 210/923-5999
E-mail: metaspec@earthlink.net
METASPEC
Co.
IndependentadviceonOilfeldChemicalsprograms
advice@strategic-chemistry.com
ConfdentialOFCstaffrecruitmentservice
recruit@oilfeldchemicalscareers.info
ConfdentialOFCjobsearch
apply@oilfeldchemicalscareers.info
www.tinker-rasor.com
www.teststations.com
TRI-STAR INDUSTRIES PTE LTD
Website: www.tristar.com.sg
Email:
sales@tristar.com.sg
Tel:
Fax:
Specialist Manufacturer of
Aluminum & Zinc
Anodes. We also provide full CP surveys, installations &
commissioning, including ICCP systems.
$120.00 $90.00
LIST PRICE
ORDER
nace.org/store
403 Pages
12 Chapters
Softbound
ISBN 15792532
Published 2012
A NACE Publication
113
AD INDEX
Advertiser ............................Page No.
De Nora T
Concord, Ohio ....................................................................... 20
Tel: +1 440-710-5300, Web site: www.lidaproducts.com
NACE International
Phone: +1 281/228-6223, Web site: www.nace.org
2014 Eastern Area Conference ......................................................................... 44
2014 Northern Area Eastern Conference .......................................................... 97
CORCON Corrosion Conference & Expo 2014 ............................................... 114
Corrosion Technology Week 2014..................................................................... 95
115
CORROSION BASICS
High-pH SCC
Near-Neutral SCC
pH range
9 to 13
5 to 7
Location
Temperature
> 40 C
No apparent correlation
Soil chemistry
Concentrated carbonate/
bicarbonate solution
Dilute bicarbonates
Intensifed by sulfatereducing bacteria
Crack morphology
Intergranularnarrow
Transgranularwide
Copper alloys
Gold alloys
Inconel
Lead
Magnesium alloys
Nickel
Carbon steels
Stainless steels
Titanium
116