vii TABLE OF CONTENTS CHAPTER 1 2 TITLE PAGE DECLARATION ii DEDICATION iii ACKNOWLEDGEMENT iv ABSTRACT v ABSTRAK vi TABLE OF CONTENTS vii LIST OF TABLES xiv LIST OF FIGURES xvii LIST OF ABBREVIATIONS xxii LIST OF SYMBOLS xxvi LIST OF APPENDICES xxvii INTRODUCTION 1 1.1 Introduction 1 1.2 Problem Statement 2 1.3 Research Aim 3 1.4 Research Objectives 4 1.5 Research Scopes 4 1.6 Importance of Research 5 1.7 Contribution of the Research 5 LITERATURE REVIEWS 7 2.1 Introduction 7 2.2 Transmission Gas Pipeline in Malaysia 8 2.2.1 External Corrosion of Transmission Gas viii Pipeline 2.3 2.4 2.5 2.6 Corrosion in Soil 11 2.3.1 13 Soil-Corrosion Mechanism Influence of Soil Physical Properties on Corrosion 15 2.4.1 Soil Texture 17 2.4.2 Degree of Aeration and Oxygen Diffusion in Soil 21 2.4.3 Soil Consistency 22 2.4.4 Soil Moisture Content 23 Influence of Soil Chemical Contents on Corrosion 24 2.5.1 Soil Relative Acidity (pH) 25 2.5.2 Soluble Ion Content 26 2.5.3 Soil Resistivity 29 2.5.4 Oxidation-Reduction Potential (ORP) 30 Corrosion Testing 31 2.6.1 Laboratory Corrosion Measurement 32 2.6.2 Field Corrosion Measurement 33 2.7 Modelling Studies 34 2.8 The Use of Power Law Model in Corrosion 37 2.8.1 Romanoff’s Model [1957] 40 2.8.2 Rossum’s Model [1969] 40 2.8.3 Mughabghab and Sullivan’s Model [1989] 41 2.8.4 Katano’s Model [2003] 42 2.8.5 Li’s Model [2004] 43 2.8.6 Velazquez’s Model [2009] 44 2.8.7 Caleyo’s Model [2009] 45 2.8.9 Anyanwu et al. [2014] 46 2.9 3 8 Summary of Research Gap 46 RESEARCH METHODOLOGY 48 3.1 Introduction 48 3.2 Overview of AFAT and OFAT Approaches 49 3.3 Pipe Samples Collection and Coupons Preparation 54 ix 3.4 3.3.1 Cutting Process 55 3.3.2 Grinding and Cleaning Process 56 3.3.3 Weighing and Labelling Process 57 Methodology of Component 1 (Field Works) 58 3.4.1 Research Area Selection 59 3.4.2 Coupon Installation 62 3.4.3 Coupon Retrieval, On-Site Measurement and Soil Sampling 3.5 66 Methodology of Component 2 (Simplified Site) 69 3.5.1 Simplified Sites Setup (Component 2) 69 3.5.2 Coupon Retrieval, On-Site Measurement and Soil Sampling 3.6 3.7 72 Methodology of Component 3 (Laboratory Test) 74 3.6.1 Laboratory Experimental Setup 75 3.6.2 Preparation of Soil Medium 76 3.6.3 Soil Medium for Chemical Content 78 3.6.4 Soil Medium for Clay Content 79 3.6.5 Soil Medium for Plasticity Index 80 3.6.6 Soil Medium for Moisture Content 80 3.6.7 Soil Medium for Particle Size 81 3.6.8 Soil Medium for Control Sample 82 Steel Coupons and Soil Parameters Assessment 83 3.7.1 Coupon Cleaning After Retrieval 83 3.7.2 Assessment of Corrosion Rate According to ASTM 87 3.7.3 Coupons Composition Analysis Using Glow Discharge Spectrometer 3.8 Field Works Soil Measurement 88 88 3.8.1 3.8.1 Soil Resistivity Site Measurement (ASTM International, 2012) 3.9 89 3.8.2 Soil pH Site Measurement 90 Soil Laboratory Testing 90 3.9.1 Soil Acidity Test 91 x 3.10 4 3.9.2 Soil Chloride Test 91 3.9.3 Soil Sulphate Test 93 3.9.4 Soil Sulphide Test 93 3.9.5 Soil Organic Test 93 3.9.6 Moisture Content (WC) Test 94 3.9.7 Plasticity Index (PI) Test 94 3.9.8 Particle Size (PS) Test 95 3.9.9 Clay Content (CC) Test 96 Data Analysis 97 3.10.1 Exploratory Data Analysis (EDA) 99 3.10.2 Transformation of Variables 100 3.10.3 Normality Test 100 3.10.4 Detection of Outliers 101 3.10.5 Single Linear Regression (SLR) 101 3.10.6 Correlation Matrix 102 3.10.7 Principal Component Analysis (PCA) 102 3.10.8 Multiple Regression Analysis (MRA) 102 3.10.9 Data Analysis Using Parametric Test 103 3.11 Development of External Corrosion Model 103 3.12 Concluding Remarks 104 ANALYSIS OF COMPONENT 1 105 4.1 Introduction 105 4.2 Field Work Description 106 4.3 Part 1: Preliminary Data Analysis 108 4.3.1 Stage 1: Data Classification According to Depth 110 4.3.2 Stage 2: Non-Parametric Test 111 4.3.3 Stage 3: Data classification According to Central Tendency 4.3.4 Stage 4: Identification of Central Tendency 4.4 112 Preliminary Studies of Corrosion Growth Pattern 114 117 xi 5 6 4.5 Preliminary Studies of Metal Mass Loss 120 4.6 Part 2: Empirical Model Development 122 4.6.1 Exploratory Data Analysis (EDA) 124 4.6.2 Transformation and Outliers of Variables 126 4.7 Single Linear Regression Model of Each Variable 131 4.8 Correlation Matrix 141 4.9 Principal Component Analysis (PCA) 143 4.10 Mass Loss Model Development 146 4.10.1 148 Multiple Regression Analysis (MRA) 4.11 Corrosion Loss Rate Model Development 153 4.12 Concluding Remarks 154 ANALYSIS OF COMPONENT 2 156 5.1 Introduction 156 5.2 Site Classification 157 5.3 Metal Mass Loss and Soil Data Collection 158 5.4 Preliminary Studies of Corrosion Growth Pattern 161 5.5 Preliminary Studies of Metal Mass Loss 166 5.6 Empirical Model Development 168 5.6.1 Exploratory Data Analysis (EDA) 170 5.6.2 Transformation and Outliers of Variable 172 5.7 Single Linear Regression Model of Each Variable 176 5.8 Correlation Matrix 184 5.9 Principal Component Analysis (PCA) 186 5.10 Metal Mass Loss Model Development 188 5.10.1 190 Multiple Regression Analysis (MRA) 5.11 Corrosion Loss Rate Model Development 193 5.12 Concluding Remarks 194 ANALYSIS OF COMPONENT 3 196 6.1 Introduction 196 6.2 Testing Procedure 197 6.3 Collection of Metal Mass Loss and Corrosion Rate xii 6.4 Data 198 Metal Mass Loss and Corrosion Data Analysis 202 6.4.1 Corrosion Growth Pattern For Each Soil Variables 6.4.2 203 Determination of k and v using Two-Way ANOVA 6.5 7 207 6.4.2.1 pH Variable 207 6.4.2.2 Chloride Content Variable 210 6.4.2.3 Sulphate Content Variable 212 6.4.2.4 Organic Content Variable 214 6.4.2.5 Moisture Content Variable 215 6.4.2.6 Clay Content Variable 217 6.4.2.7 Plasticity Index Variable 218 6.4.2.8 Particle Size Variable 220 Concluding Remarks DISCUSSION 224 7.1 Introduction 224 7.2 Measures of Central Tendency 225 7.3 Defining the Corrosion Growth Pattern and Metal 7.4 Mass Loss 226 7.3.1 Corrosion Growth Pattern 226 7.3.2 Metal Mass Loss 229 Relationship between Metal Mass Loss and Soil Properties and Chemical Content 230 7.5 Classification of Soil Variables towards k and v 234 7.6 Verification of the selected variable in k and v using OFAT approach 7.7 238 Modelling Development Based on Differential Equation of Power Law 8 222 239 CONCLUSIONS AND RECOMMENDATIONS 242 8.1 242 Introduction xiii 8.2 Conclusions 243 8.3 Recommendations for Future Work 246 REFERENCES 248 APPENDICES A-C 261-298 xiv LIST OF TABLES NO. TITLE PAGE 2.1 Acidity and alkalinity of the soil [Doyle et al., 2003] 26 2.2 Soil corrosiveness as a function of pH [Romanoff, 1957] 26 2.3 Soil corrosiveness as a function of sulphate concentration [ACI, 2011] 2.4 Soil corrosiveness as a function of chloride concentration [ACI, 2011] 2.5 29 Classification of soil corrosiveness based on resistivity [Palmer, 1990] 2.6 29 30 Soil corrosiveness index based on oxidation-reduction potential [Starkey and Wight, 1945] 31 2.7 Existing corrosion models 36 2.8 Summary of corrosion loss-time model phase [Melchers 2003a] 40 2.9 Summary of Rossum’s model 41 2.10 Summary of Mughabghab and Sullivan’s model 42 2.11 Summary of Katano’s model 43 2.12 Summary of Li’s model 44 2.13 Summary of Velazquez’s model 45 3.1 Coupon sizes of each component 54 3.2 Site selection criteria 59 3.3 List of soil type and its origin 72 3.4 Chemical electrolyte or additive added to alter the soil medium 77 3.5 Percentage of particle size for laboratory test 81 3.6 Soil parameters testing based on available standard 83 3.7 Elemental composition of steel coupon grade API 5L X70 in percentage 88 xv 3.8 Elemental composition of steel coupon grade API 5L X42 in percentage 88 3.9 Example calculation of particle size 96 4.1 Sites characteristic and their specific location 106 4.2 Soil chemical content of actual field work 110 4.3 Soil physical properties of actual field work 111 4.4 Statistic summary of T-test 112 4.5 Output of T-test for two paired samples / two-tailed test 112 4.6 ML and CR data according to mean, median and maximum 113 4.7 Descriptive statistics for each variable 124 4.8 Summary of EDA 126 4.9 Log transformation of soil chemical content with ML 128 4.10 Data transformation summary 129 4.11 ML and soil chemical content data 130 4.12 ML and soil physical properties data 131 4.13 SLR summary 139 4.14 Pearson correlation coefficient matrix 142 4.15 Pearson correlation coefficient matrix (cont’d) 142 4.16 Classification of soil variables with k and v coefficient using PCA 146 4.17 Expected combination of k and v 147 4.18 R2 of all possible combinations of k and v 149 4.19 Analysis of variance of the model 151 4.20 Predicted mass loss for each site using Model C 152 5.1 Soil characteristic and their origin 158 5.2 Soil chemical content and mass loss data for simplified site 159 5.3 Soil chemical content and mass loss data for simplified site (cont’d) 160 5.4 Soil physical properties and mass loss data for simplified site 161 5.5 Summary of v value based on theory 162 5.6 Descriptive statistics for each variable 170 5.7 EDA summary 171 5.8 Summary of data transformation 173 5.9 Log transformation data on chloride, sulphate variables 174 xvi 5.10 Log transformation data on resistivity, organic and particle size variables 175 5.11 Summary of SLR for Component 2 analysis 178 5.12 Pearson correlation coefficient matrix 185 5.13 Pearson correlation coefficient matrix (cont’d) 185 5.14 Classification of soil variables with k and v coefficient using PCA 188 5.15 Possible combination of k and v 189 5.16 Coefficient regression of Component 2 model 191 5.17 Analysis of variance of the model 193 6.1 Summary of soil parameters for laboratory test 198 6.2 Summary of metal mass loss (gram) for soil chemical content 199 6.3 Summary of metal mass loss (gram) for soil physical properties 200 6.4 Summary of corrosion rates (mm/year) for soil chemical content 201 6.5 Summary of corrosion rates (mm/year) for soil physical properties 202 6.6 Summary of OFAT analysis for soil chemical variable 205 6.7 Summary of OFAT analysis for soil physical variable 206 6.8 ANOVA test results for soil pH variable 210 6.9 ANOVA test results for chloride content variable 212 6.10 ANOVA test results for sulphate content variable 214 6.11 ANOVA test results for organic content variable 215 6.12 ANOVA test results for moisture content variable 217 6.13 ANOVA test results for clay content variable 218 6.14 ANOVA test results for plasticity index variable 220 6.15 ANOVA test results for particle size variable 221 6.16 Summary of ANOVA and soil variables graph 222 7.1 Growth pattern by exponential value, v 228 7.2 Summary of exponential value at each research area 228 7.3 The significance of each soil variable in predicting mass loss 234 7.4 Soil variables selected towards k and v 236 7.5 Comparison of different soil-corrosion models 237 7.6 Soil variables selected towards k and v using OFAT approach 239 xvii LIST OF FIGURES NO. TITLE PAGE 2.1 Peninsular Gas Utilisation (PGU) network 8 2.2 Attributed failures mechanism for pipeline 10 2.3 Exposure of buried pipeline to the soil environment 13 2.4 The basic corrosion cell consists of an anode, a cathode, an electrolyte, and an electrical circuit for electron flow 2.5 13 A buried pipe is anodic in wet soil with lower oxygen content and cathodic in better oxygenated soil [Veleva, 2005] 15 2.6 Field assessment using a hand texture chart [Rowell, 2014] 18 2.7 Soil texture triangle [Hillel, 2003] 19 2.8 Atterberg limits 22 2.9 Effect of moisture on soil resistivity [Romanoff, 1957] 24 2.10 Relationship of variables affecting the rate of corrosion in soil [Roberge, 2000] 2.11 Resistivity as a function of concentration for CaSO4 and NaCl solutions at room temperature [Beavers and Durr, 1998] 2.12 25 28 Apparatus for conducting laboratory corrosion tests in soil [ASTM International, 2004b] 33 2.13 Corrosion growth pattern in a function of time [Noor, 2009] 38 2.14 Multiphase phenomenological corrosion-time model [Melchers 2003a] 39 3.1 Flow chart of research methodology 49 3.2 Feasibility studies of Component 1 51 3.3 Feasibility studies of Component 2 52 3.4 Feasibility studies of Component 3 53 3.5 Pipe samples collection 54 xviii 3.6 Preparation of test coupons 56 3.7 Coupon grinding and cleaning process 57 3.8 Weighing and labelling of test coupon 58 3.9 Site A, located at 04o30'15.2"N, 103o25'13.7"E vicinity 60 3.10 Site B, located at 04o18'02.9"N, 103o24'22.3"E vicinity 60 o o 3.11 Site C, located at 04 02' 55.5"N, 103 23'21.3"E vicinity 61 3.12 Site D, located at 03o52'19.3"N, 103o18'3.4"E vicinity 61 3.13 Site E, located at 02o36'39.55"N, 102o50'0.96"E vicinity 62 3.14 Position of steel coupons at 0.5m and 1.0m in each dug hole 63 3.15 Distance of two metre were marked before drilling job started 63 3.16 Holes were drilled using power hand auger machine 64 3.17 Steel coupons were buried at 1.0m and 0.5m depth 64 3.18 The depth of each steel coupons were checked using measured stick 3.19 65 Each drilled holes were marked for future reference during coupons retrieval process 65 3.20 Coupon retrieval manually using shovel 66 3.21 Coupon was retrieved at 0.5 metre depth 67 3.22 Measurement of salinity, conductivity and temperature of water table using multimeter 67 3.23 Measurement of soil moisture content 68 3.24 Measurement of soil resistivity using Wenner 4-pin method 68 3.25 Soil preparation for Component 2 and laboratory testing 69 3.26 Polybag used in Component 2 with steel coupons in it 71 3.27 Polybags full with soil were ready to transport back to UTM 71 3.28 Completed site work 72 3.29 Preparation of steel coupons retrieval 73 3.30 Retrieved steel coupons for laboratory analysis 73 3.31 Preparation of soil samples for laboratory analysis 74 3.32 Laboratory corrosion test in soil 76 3.33 Completion of steel coupon buried in saturated soil medium 77 3.34 Kaolin mixed with washed sand to design soil samples with clay content of 25% 79 xix 3.35 Washed sand with different particle size distributions 82 3.36 Mechanical cleaning with light brushing 85 3.37 Preparation of admixture of acid hydrochloric, hexamethlyene tetramine and distilled water for chemical cleaning 85 3.38 Chemical cleaning process for 10 minutes immersion 86 3.39 Test steel coupon; (a) steel coupons after retrieval, (b) after mechanical cleaning, (c) after chemical cleaning 3.40 86 Mass loss of corroded specimen resulting from repetitive cleaning cycles [ASTM International, 2004a] 87 3.41 The Wenner four-electrode method in soil resistivity measurement 90 3.42 Framework of data analysis 99 4.1 Preliminary analysis (Part 1) 109 4.2 Metal mass loss (ML) data plotted with mean, median and maximum data 116 4.3 Metal mass loss of Site A for one and half year of exposure 118 4.4 Metal mass loss of Site B for one and half year of exposure 118 4.5 Metal mass loss of Site C for one and half year of exposure 119 4.6 Metal mass loss of Site D for one and half year of exposure 119 4.7 Metal mass loss of Site E for one and half year of exposure 120 4.8 Mass loss for one and half year at research areas 121 4.9 Average mass loss for 1.5 years at five research areas 121 4.10 Statistical model development flowchart 123 4.11 Linear regression between MLC1 and PHC1 134 4.12 Linear regression between MLC1 and LogCLC1 134 4.13 Linear regression analysis of SOC1 135 4.14 Linear regression analysis of SC1 135 4.15 Linear regression analysis of LogREC1 136 4.16 Linear regression analysis of WCC1 136 4.17 Linear regression of CCC1 137 4.18 Linear regression of PIC1 137 4.19 Linear regression of LogORGC1 138 4.20 Linear regression of PSC1 variable 138 4.21 PCA of k coefficient 145 xx 4.22 PCA of v coefficient 145 4.23 Actual mass loss versus predicted model 150 5.1 Location of Component 2 research area 157 5.2 Metal mass loss of Type 1 (Site A) for 1.25 years of exposure 163 5.3 Metal mass loss of Type 2 (Site A) for 1.25 years of exposure 163 5.4 Metal mass loss of Type 3 (Site B) for 1.25 years of exposure 164 5.5 Metal mass loss of Type 4 (Site C) for 1.25 years of exposure 164 5.6 Metal mass loss of Type 5 (Site C) for 1.25 years of exposure 165 5.7 Metal mass loss of Type 6 (Site D) for 1.25 years of exposure 165 5.8 Metal mass loss of Type 7 (Site E) for 1.25 years of exposure 166 5.9 Mass loss for 1.25 years at research areas 167 5.10 Average mass loss for 1.25 years at five research areas 168 5.11 Flowchart of empirical model analysis 169 5.12 Linear regression between MLC2 and PHC2 179 5.13 Linear regression between MLC2 and LogCLC2 179 5.14 Linear regression between MLC2 and SOC2 180 5.15 Linear regression between MLC2 and SC2 180 5.16 Linear regression between MLC2 and LogREC2 181 5.17 Linear regression between MLC2 and WCC2 181 5.18 Linear regression between MLC2 and CCC2 182 5.19 Linear regression between MLC2 and PIC2 182 5.20 Linear regression between MLC2 and LogORGC2 183 5.21 Linear regression between MLC2 and PSC2 183 5.22 PCA of k coefficient 187 5.23 PCA of v coefficient 187 5.24 Actual mass loss versus predicted model 192 6.1 Flowchart of OFAT approaches 197 6.2 Metal mass loss as a function of time for soil pH variable 209 6.3 Metal mass loss as a function of time for soil chloride variable 211 6.4 Metal mass loss as a function of time for soil sulphate content variable 6.5 213 Metal mass loss as a function of time for soil organic content variable 214 xxi 6.6 Metal loss rate as a function of time for soil moisture content variable 216 6.7 Metal loss rate as a function of time for soil clay content variable 217 6.8 Metal loss rate as a function of time for soil plasticity index variable 219 6.9 Metal loss rate as a function of time for soil particle size variable 220 7.1 Prediction results of Component 1 data using Component 2 model 241 8.1 Flowchart of research outcome 246 xxii LIST OF ABBREVIATIONS 5L - Specification for line pipe AFAT - All-factor-at-a-time APB - Acid-producing bacteria API - American Petroleum Institute ANOVA - Analysis of variance ASTM - American standard test anad materials C - Constant (8760 x 10 cm/y) C1 - Component 1 C2 - Component 2 CC - Clay content CaSO4 - Calcium sulphate 2 - Centimetre square cm - Centimetre CL - Chloride content CLR - Corrosion loss rate CP - Cathodic protection CR - Corrosion rate Co - Cobalt Cr - Chromium DO - Dissolved oxygen e.g. - For example EDA - Exploratory data analysis exp - exponent E - East Fe2+ - Ferrous ion Fe2O3.H2O - Hydrated ferrous oxide (brown rust) FBE - Fusion bonded epoxy cm xxiii Fe - Iron (element) Fe(OH)2 - Ferrous hydroxide Fe(OH)2 - Ferric hydroxide FeS - Ferum sulphide GDS - Glow discharge spectrometer GPP - Gas processing plant H+ - Hydron Ha - Alternative hypothesis HSD - Honestly Significant Difference Ho - Null hypothesis H2O - Water oxygen H2S - Hydrogen sulphide HCI - Hydrochloric acid ICCP - Impressed current cathodic protection ILI - In-line Inspection K-S - Kolmogorov-Smirnov ksi - Kilopounds per square inch Kn - Constant KMO - Kaiser-Meyer-Olkin LL - Liquid limit log - logarithma m - metre M - molar Max - Maximum Med - median mg/kg - Miligram per kilogram MIC - Microbiologically influenced corrosion ml - mililitre ML - Metal mass loss mm/y - Milimetres per year MRA - Multiple regression analysis mmscf - Millions of standard cubic feet Na+ - Sodium ion xxiv NaCl - Sodium chloride/ natrium chloride NaOH - Sodium hydroxide NHE - Normal hydrogen electrode Ni - Nickel O2 - Oxygen OFAT - One-factor-at-a-time OH- - Hydroxyl ion ORG - Organic content ORP - Oxidation-reduction potential P/S - Pipe-to-soil P-value - Probability value Pc - Corrosion pit dimension / environmental variables PCA - Principal component analysis Pmax,cal - Predicted value of measured pit depth PGB - Petronas Gas Berhad PGU - Peninsular Gas Utilisation PI - Plasticity index PIAM - Pipeline integrity assessment and management PS - Particle size distribution PL - Plastic limit R2 - Coefficient of determination RES / Re - Resistivity ROW - Right-of-way S-W - Shapiro-Wilk S - Sulphide SCC - Stress corrosion cracking SL - Shrinkage limit - Single linear regression - Sulphate ion SO - Sulphate Std. dev. - Standard deviation SRB - Sulphate-reducing bacteria T - Time of exposure SLR SO4 2- xxv Tcf - Trillion cubic feet UTM - Universiti Teknologi Malaysia V - Voltage WC - Moisture content X70 - Pipe having a minimum yield strength of 70ksi XLSTAT - Statistical software suite for Microsoft excel xxvi LIST OF SYMBOLS % - Percentage ºC - Degree celcius ρ - Resistivity Ω - Ohm A - Regression coefficient / area of exposure b1, b2, b3...bn - Coefficient of predictor variables b - Power coefficient d - Pit depth d - Steel density D - Steel density in g/cm3 dmax - Maximum pit depth - e - electron Eh - Oxidation-reduction potential k - Metal loss constant l - length n - Corrosion growth pattern constant t - Exposure time / thickness to - Initial time of exposure v - Corrosion growth pattern constant w - width Wo - Initial weight Wi - Final weight loss x - Time exposure y - Dependent variables xxvii LIST OF APPENDICES APPENDIX TITLE PAGE A Site Layout 261 B Component 1 Data 267 C Component 2 Data 298