Corrosion Control

Basic Corrosion Course 2017

February 21-23, 2017 Brent Shuler-Nipsco 1

Period 3

February 21-23, 2017 Brent Shuler-Nipsco 2

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

CORROSION PREVENTION

• INTRODUCTION • ISOLATE THE STRUCTURE WITH COATINGS • APPLY CATHODIC PROTECTION • ISOLATE THE STRUCTURE ELECTRICALLY • CONTROL STRAY CURRENT

February 21-23, 2017 Brent Shuler-Nipsco 3

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

REVIEW

• REVIEW GALVANIC SERIES

• REVIEW CORROSION CELL

February 21-23, 2017 Brent Shuler-Nipsco 4

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

February 21-23, 2017 Brent Shuler-Nipsco 5

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

Galvanic Series

• If we connect a piece of mild steel to a piece of pure magnesium, which metal will corrode?

• If we connect a piece of copper to a piece of mild steel, which metal will corrode?

February 21-23, 2017 Brent Shuler-Nipsco 6

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

Corrosion Cell

• Which four items do you need for corrosion to occur?

• Corrosion is an exchange of what type of energy?

• Where on the corrosion cell does corrosion occur?

February 21-23, 2017 Brent Shuler-Nipsco 7

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

CORROSION CELL

Fe Fe + 2e -

- ++

+ (Reduction at Cathode)

Fe ++ e e - -

H H H

+ + +

H 2

Electrolyte Fe Cu

Anode Cathode

Metallic Path

February 21-23, 2017 Brent Shuler-Nipsco 8

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

CORROSION PREVENTION

ISOLATE THE STRUCTURE WITH COATINGS

• APPLY CATHODIC PROTECTION

• ISOLATE THE STRUCTURE ELECTRICALLY

• CONTROL STRAY CURRENT

February 21-23, 2017 Brent Shuler-Nipsco 9

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

ISOLATE STRUCTURE WITH COATINGS

SACRIFICAL COATINGS

DIELECTRIC COATINGS

February 21-23, 2017 Brent Shuler-Nipsco 10

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

ISOLATE STRUCTURE WITH

COATINGS

SACRIFICIAL COATINGS

• Galvanizing – Zinc Plated to Steel • Zinc – Anodic • Steel – Cathodic

• Used Extensively above Ground

February 21-23, 2017 Brent Shuler-Nipsco 11

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

SACRFICIAL COATINGS

February 21-23, 2017 Brent Shuler-Nipsco 12

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

SACRFICIAL COATINGS

February 21-23, 2017 Brent Shuler-Nipsco 13

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

SACRFICIAL COATINGS

February 21-23, 2017 Brent Shuler-Nipsco 14

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

ISOLATE STRUCTURE WITH COATINGS

DIELECTRIC COATINGS

• High Electrical Resistance

• Good Bond Strength

• High Resistance to Moisture and Chemical

Penetration

• Good Resistance to Cold Flow

• Good Resistance to Soil Stresses

February 21-23, 2017 Brent Shuler-Nipsco 15

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

ISOLATE STRUCTURE WITH COATINGS

DIELECTRIC COATINGS

• Fusion Bond Epoxy (FBE)

• 100% Solid Liquid Epoxy

• Extruded Polyethylene - Polypropylene

• Bituminous Enamels

• Waxes

February 21-23, 2017 Brent Shuler-Nipsco 16

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

ISOLATE STRUCTURE WITH COATINGS

DIELECTRIC COATINGS

• Petrolatum

• Cold Applied Mastics

• Tapes

• Primers

• Field Joints

February 21-23, 2017 Brent Shuler-Nipsco 17

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

ISOLATE STRUCTURE WITH COATINGS

February 21-23, 2017 Brent Shuler-Nipsco 18

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

ISOLATE THE STRUCTURE WITH COATINGS

COATING SELECTION CRITERIA

– Environment

– Operating Temperature

– Backfill Control

– Seasonal Considerations (soil stress)

– Handling Considerations

– Co. Specs - Experience - Yours - industry

February 21-23, 2017 Brent Shuler-Nipsco 19

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

February 21-23, 2017 Brent Shuler-Nipsco 20

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

CORROSION PREVENTION

ISOLATE THE STRUCTURE WITH COATINGS

APPLY CATHODIC PROTECTION

• ISOLATE THE STRUCTURE ELECTRICALLY

• CONTROL STRAY CURRENT

February 21-23, 2017 Brent Shuler-Nipsco 21

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

February 21-23, 2017 Brent Shuler-Nipsco 22

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

APPLY CATHODIC PROTECTION – GALVANIC

February 21-23, 2017 Brent Shuler-Nipsco 23

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

APPLY CATHODIC PROTECTION – GALVANIC

February 21-23, 2017 Brent Shuler-Nipsco 24

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

APPLY CATHODIC PROTECTION – GALVANIC

February 21-23, 2017 Brent Shuler-Nipsco 25

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

APPLY CATHODIC PROTECTION – GALVANIC

February 21-23, 2017 Brent Shuler-Nipsco 26

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

APPLY CATHODIC PROTECTION – IMPRESSED

February 21-23, 2017 Brent Shuler-Nipsco 27

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

APPLY CATHODIC PROTECTION – IMPRESSED

February 21-23, 2017 Brent Shuler-Nipsco 28

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

APPLY CATHODIC PROTECTION

• Eliminate Anodes - Protected Structure

• Make the Anode Replaceable

• Protected Structure becomes a Cathode

• Galvanic Systems

• Impressed Systems

• Discussed in Detail Period 4

February 21-23, 2017 Brent Shuler-Nipsco 29

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

CORROSION PREVENTION

ISOLATE THE STRUCTURE WITH COATINGS APPLY CATHODIC PROTECTION

ISOLATE THE STRUCTURE ELECTRICALLY

• CONTROL STRAY CURRENT

February 21-23, 2017 Brent Shuler-Nipsco 30

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

ELECTRICIAL ISOLATION

PROVIDE ELECTRICAL SEPERATION

• Between Companies

• Parts of the System (Above/Below) Ground

• Different Metals

• Carrier Pipe to Casing

February 21-23, 2017 Brent Shuler-Nipsco 31

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

ELECTRICIAL ISOLATION

February 21-23, 2017 Brent Shuler-Nipsco 32

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

CASING ISOLATION

February 21-23, 2017 Brent Shuler-Nipsco 33

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

ISOLATING SECTIONS OF UNDGERGROUND PIPING

February 21-23, 2017 Brent Shuler-Nipsco 34

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

CORROSION PREVENTION

ISOLATE THE STRUCTURE WITH COATINGS APPLY CATHODIC PROTECTION

ISOLATE THE STRUCTURE ELECTRICALLY

CONTROL STRAY CURRENT

February 21-23, 2017 Brent Shuler-Nipsco 35

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

CONTROL STRAY CURRENT

Stray Current Sources

DC – Rail Transits Systems

DC – Cathodic Protection Systems

DC – Welding Machines

AC – High Voltage Transmission Lines

Telluric

February 21-23, 2017 Brent Shuler-Nipsco 36

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

CONTROL STRAY CURRENT

February 21-23, 2017 Brent Shuler-Nipsco 37

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

CONTROL STRAY CURRENT

February 21-23, 2017 Brent Shuler-Nipsco 38

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

CONTROL STRAY CURRENT

DC - Stray Current Mitigation

• Drainage Bonds

• Reverse Current Switches

• Cathodic Protection

• Coatings / Isolation Fittings

• Non Metallic Structures -

Plastic Pipe/ Fiberglas Tanks

February 21-23, 2017 Brent Shuler-Nipsco 39

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

CONTROL STRAY CURRENT

AC - Stray Current Mitigation

• Zinc Ribbon / Copper Cable

• Isolation Fittings

• Decoupling Device

• Non Metallic Structures -

Plastic Pipe/ Fiberglass Tanks

February 21-23, 2017 Brent Shuler-Nipsco 40

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

AC – STRAY CURRENT MITIGATION

February 21-23, 2017 Brent Shuler-Nipsco 41

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

AC – STRAY CURRENT MITIGATION

February 21-23, 2017 Brent Shuler-Nipsco 42

2017 Underground Corrosion Short Course Basic Corrosion Course – Period 3

COROSION PREVENTION

• SUMMARY

– Corrosion Cell

– Isolate The Structure – Coatings

– Apply Cathodic Protection

– Isolate the Structure -Electrically

– Control Stray Current