Corrosion Control

and Monitoring
ABC Company
ABC Chemical Complex
Engineering Specification
ABC Chemical Complex

Corrosion Control & Monitoring

SCOPE
This Engineering Specification includes
external and internal corrosion control and
monitoring for DOT regulated pipelines.
Design, construction, construction inspection,
construction acceptance, operation, and
maintenance of DOT regulated pipelines are
covered by this Engineering Specification.

ABC Chemical Complex

Corrosion Control &Monitoring

GENERAL
All DOT regulated ABC pipelines require
protection from the environment.
Corrosive elements in the pipeline stream must
be neutralized or the pipe material must be
resistant to the stream.

ABC Chemical Complex

Corrosion Control & Monitoring

Minimum requirements for corrosion control:

External Corrosion Control
Buried DOT regulated pipelines will be coated and
cathodically protected

Internal Corrosion Control

Known corrosion rate based on historical data
Corrosion rate from a national standard data base
Data collected from laboratory prototype testing

ABC Chemical Complex

Corrosion Control & Monitoring

Minimum requirements for corrosion

control (Continued):
Above Ground External Corrosion Control
Coat with an approved system with resistance to the
soil and internal fluid temperature

ABC Chemical Complex

Corrosion Control & Monitoring

REFERENCES
NACE RP 0169-92
Surface Preparation:
NACE No. 1, SSPC-SP 5, White Metal Blast
Cleaning
NACE No. 2, SSPC-SP 10, Near White Metal Blast
NACE No. 3, SSPC-SP6, Commercial Blast
NACE No. 4, SSPC-SP 7, Brush-Off Blast

ABC Chemical Complex

Corrosion Control & Monitoring

PERSONNEL REQUIREMENTS
Engineering design will be performed by a
Corrosion Engineer with training and
experience in the proposed corrosion control
system.
Coating, lining, and painting inspection will be
performed by an inspector with appropriate
training and experience.

ABC Chemical Complex

Corrosion Control & Monitoring

PERSONNEL REQUIREMENTS (Cont..)

Cathodic protection installations will be
inspected by an inspector with training and
experience in cathodic protection inspection.
Internal corrosion monitoring installations will
be inspected by an inspector with training and
experience in internal corrosion monitoring
inspection.

ABC Chemical Complex

Corrosion Control & Monitoring

DESIGN REQUIREMENTS, EXTERNAL

Cathodic Protection Criteria
Buried Onshore Pipelines: Pipe-to-soil potential equal to
or more negative than -0.85 volts referenced to coppercopper sulfate electrode and recorded immediately after
current interruption (Instant-off potential).
Offshore Pipelines: Pipe-to-water potential equal to or
more negative than -0.80 volts referenced to a silversilver chloride electrode with instant off potential
reading.

ABC Chemical Complex

Corrosion Control & Monitoring

Tank Bottoms: Steel-to-soil potential equal to or
more negative than -0.85 volts with a copper-copper
sulfate half cell and instant off potential.
Maximum pipeline potential: Equal to or less than
-1.5 volts to a standard copper-copper sulfate half
cell with the current temporarily interrupted.

ABC Chemical Complex

10

Corrosion Control & Monitoring

Coating Requirements
New buried pipe sections shall be coated with one
of the following types:

Fusion bonded epoxy

Coal tar epoxy
Polyolefin tape
Prefabricated films
Other coating systems approved by Central Engineering

Surface preparation shall be in accordance with

manufacturers recommendation and Appendix B.

ABC Chemical Complex

11

Corrosion Control & Monitoring

Methods Used for Cathodic Protection

Galvanic Anode Systems
Provide protection to the structure by the potential
difference generated by the electrochemical reaction
between the structure and the anode through a soil
or water electrolyte.
Typically used in soil or water with resistivity less
than 5000 ohm-cm.

ABC Chemical Complex

12

Corrosion Control & Monitoring

Methods Used For Cathodic Protection (Cont)
Impressed Current Systems

ABC Chemical Complex

Uses external source of DC power, usually an AC transformer with an AC to DC rectifier, to provide the driving
voltage to the structure to be protected.
Potential difference between the anode and the structure
creates current flow from the anode into the soil and onto
the pipeline.
Used when the soil resistivity exceeds 5000 ohm-cm
and/or more than 5 amperes of impressed current are
required.

13

Corrosion Control & Monitoring

Equipment
Galvanic Anode Systems

Anode: Magnesium onshore, Galvalum III offshore.

Junction box to connect leads from structure and anode.

Impressed Current Systems

ABC Chemical Complex

DC transformer/rectifier (supplied as a unit).

Anode(s) with inert or low reactivity characteristics.
Terminal box with resistors to adjust current flow to each
anode or anode string.

14

Corrosion Control & Monitoring

Miscellaneous
Install lightning arrestors.
Provide electrical isolation: Insulating flanges or
spools.
Minimize interference with bonding stations.
Install test stations to measure potentials.
Complete the following documentation:

ABC Chemical Complex

Bonding and/or anode bed data sheet.

Bonding station data sheet.
Test station data sheet.

15

Corrosion Control & Monitoring

Impact on Operating Equipment
Apply NEMA electrical-class safety requirements to
all equipment associated with impressed current
installations.
Install CP equipment in areas not requiring
intrinsically safe design.
Locate anode beds to minimize effect on other
structures and to minimize mechanical damage from
foreign construction.

ABC Chemical Complex

16

Corrosion Control & Monitoring

Perform interference testing on all equipment that
may be damaged by the new CP installation.
Testing shall include, but is not limited to, the
following situations:

ABC Chemical Complex

Pipelines crossing within 5 feet.

Metal Structures within 5 feet of the pipeline.
Metal Structures within 200 feet of the anode bed.

17

Corrosion Control & Monitoring

Impact on Operating Equipment
Design CP systems with capacity for current loss
through interference bonds and future current loss
due to coating deterioration.
Minimize casing installations for protection of the
carrier pipe. Perform interference testing as shown
in Company Corrosion Control & Monitoring
Specification Appendix E. Provide bonding stations
for each casing installation.

ABC Chemical Complex

18

Corrosion Control & Monitoring

DESIGN REQUIREMENTS, INTERNAL

Corrosive chemicals in the pipeline stream
May reduce stream (liquid or gas) quality or
Cause general thinning or pitting attack
Shall be handled by one of the following methods:

ABC Chemical Complex

Neutralization or removal of the corrosive chemicals.

Select a pipe material which is resistant.
Coat the internal surfaces of the pipe.

19

Corrosion Control & Monitoring

Design package will contain:
Provisions for upset/emergency conditions.
Recommended corrosion monitoring program.
Recommended corrosion monitoring equipment.
Installation of personnel safety devices and platforms
required for safe performance of duties.
Pigging procedure when pigging facilities are included
in the design package.
Compliance with regulations of local, state, and
federal jurisdiction for pigging procedures.

ABC Chemical Complex

20

Corrosion Control & Monitoring

Documentation Requirements
Determine thickness measurement locations (TMLs)
based on the most probable locations for corrosion or
erosion-corrosion damage. Select TMLs with the
assistance of the Corrosion Engineer.
Collect baseline thickness readings on all new
installations.
Install corrosion monitoring equipment where the
worst case corrosion attack is expected.
Provide corrosion monitoring data sheets.

ABC Chemical Complex

21

Corrosion Control & Monitoring

DESIGN REQUIREMENTS, ABOVE

GROUND EXTERNAL
Coat with a coating system that is recom-mended
for the environment.
Prepare surface in accordance with externalcoating-system manufacturers
recommendations. See Company Corrosion
Control & Monitoring Specification Appendix B.

ABC Chemical Complex

22

Corrosion Control & Monitoring

INSTALLATION
Quality Control, External Systems
Coatings

ABC Chemical Complex

Qualified Inspector presence - 100%.

Field applied coating systems - 100% inspection.
Shop applied coating systems - 100% inspection.
Coating repairs - 100% inspection.
Protect all stored coating materials at the construction site
from weather, particularly directly sunlight and heat.

23

Corrosion Control & Monitoring

Pad in the pipe trench

Inspect just prior to laying the pipe in the trench.

Remove all trash and construction debris.

Cables

ABC Chemical Complex

Inspect upon receipt at job site to detect nicks and damage.

100% inspection at the mill with proper mill cert..
Avoid damaging cable insulation during installation.
Splice cables aboveground in terminal boxes.
Use non-conductive conduits for cable installation.
Make cathode cable connections aboveground, if possible.
Repair buried connection in accordance with the original coating
manufacturers recommendations.

24

Corrosion Control & Monitoring

Transformer/Rectifier Systems
Install by a qualified electrician.
Test rectifier at maximum design load to assure the
DC output meets the manufacturers specifications
including the maximum AC ripple.
Calculate rectifier efficiency and record on the
rectifier data sheet.
Verify the positive cable is attached to the anode bed
and the negative cable is attached to the protected
structure or pipe.

ABC Chemical Complex

25

Corrosion Control & Monitoring

Miscellaneous Considerations

ABC Chemical Complex

Inspect cables in terminal boxes to assure correct labels.

Verify test stations, bonding stations, and associated hardware for
cathodic protection service.
Contact owners/operators of foreign pipelines to enable testing
before and after new cathodic protection project commissioning.
Record base readings on the new pipeline or structure prior to
cathodic protection system energizing. Record potentials at all
interference bonds and test stations.
Energize system in small current increments and record potentials
with each increase until protection is achieved.
Check bonding stations for interference problems.
File all commissioning data in the original equipment file.

26

Corrosion Control & Monitoring

Quality Control Requirements, Internal Surface
Inspect corrosion monitoring installations with the services
of a qualified Corrosion Technician.
Take baseline data prior to pipeline commissioning.
Install lined pipelines per design.
Repair lining of field joints as recommended.
Install corrosion monitoring devices per design.
Complete electrical installations with qualified electricians.
Document commissioning information as a part of the
original equipment file.

ABC Chemical Complex

27

Corrosion Control & Monitoring

Quality Control Requirements, Internal Surface
Delay work initiation pending review of design
package by coating inspector.
Protect coating material from weather.
Prepare surface for coating per manufacturers
recommendation immediately before coating
installation.
Follow manufacturers recommendation for dew
point and humidity.

ABC Chemical Complex

28

Corrosion Control & Monitoring

OPERATIONS
Perform cathodic protection surveys annually in
accordance with Company CP procedure.
Monitor bonding and test stations annually.
Read and record rectifier output monthly with
changes reported to the SR. Inspector for
evaluation and action.
Correct deficiencies in a timely manner.

ABC Chemical Complex

29

Corrosion Control & Monitoring

MAINTENANCE
Test rectifier stacks for proper performance
annually.
Check anode bed resistance annually.
Check insulating flanges and spools annually.
Document all maintenance tests and add to the
equipment file.

ABC Chemical Complex

30

Corrosion Control & Monitoring

Appendices
A - Coating Reference Index
B - Surface Preparation
C - Sample Data Sheets

Rectifier Data Sheet

Anode Bed Data Sheet
Galvanic Anode Data Sheet
Potential Survey Data Sheet

Predesign Testing

ABC Chemical Complex

31