NACE INTERNATIONAL CATHODIC PROTECTION TRAINING & CERTIFICATION NEWS Summer 2012 When Is Corrosion Not Corrosion? By John H. Fitzgerald III, FNACE, MP Technical Editor T his question reminds me of the old conundrum, “When is a door not a door? When it’s ajar!” Well, it’s still a door even if it’s ajar. But there are times when what looks to be corrosion is really something quite different, and you are likely to run into some situations like this as you proceed in your career. I have and here is an example of a client who just knew there was a corrosion problem and it really wasn’t. This type of experience shows why it’s important to put on your thinking cap and dig into what might be the problem. This involved what appeared to be severe external corrosion of copper tie-ins to a cast iron water distribution main. The water utility discovered that extensive water leakage was occurring along one newly piped street after only about a year of operation. Water person- nel had excavated a couple of leak sites and reported that the copper fittings at the service line connections to the main were badly corroded and water was squirting out from all the holes in the fittings. They asked us to investigate the problem, so off I went to see what was the matter. I looked into the two excavations and sure enough, the copper fittings looked terrible, all corroded into a lace pattern and the water was merrily streaming from every hole. My first thought was that the water was corrosive, but I was told that there were fittings like these all over town and there had been no problems anywhere else. Now when you are told something like that, you begin to get suspicious about the problem area. My first thought was that there might be some kind of stray current in the neighborhood that was eating up the fittings. These were flare fittings, having a flared end on the tubing that fits over a con- There are times when what looks to be corrosion is really something quite different, and you are likely to run into some situations like this as you proceed in your career. Summer 2012 vex fitting in the receptacle and is secured in place by a long flared nut that squeezes the tubing tightly against the receptacle that in turn is screwed into the main. I knew that these fittings are good electrical conductors, so how could stray current discharge from them unless, perhaps, the screw connection to the main had become high resistance? So I took pipe-to-soil potentials from the house to the main along these two services and several others where leakage was evident. The data showed no evidence of any interference near the main and the readings were typical of what one would expect on Continued on p. 3 IN THIS ISSUE... When Is Corrosion Not Corrosion?....... 1 Working Cathodic Protection Field Exhibited at CORROSION 2012.... 4 Call for NACE Instructors..................... 5 The NACE Corrosion Network—A Free Technical Resource........................... 6 NACE CP Course Schedule.................. 9 CP-Related Technical Committees..... 10 CP-Related NACE Reports and Standards........................................ 11 Stay Current 1 2 Stay Current Summer 2012 Continued from p. 1 copper service lines connected to a cast iron main. Another reason corrosion didn’t make sense was the favorable anode-cathode ratio of the copper to the cast iron. Years ago a lot of people thought that copper was quite resistant to soil corrosion. What wasn’t realized was that when copper is connected to cast iron, the copper receives cathodic protection (CP) from the iron. The copper was a small cathode connected to a large iron anode, so generally the effect on the iron was negligible. Some water companies, however, discovered that the iron was being adversely affected and they overcame continued deterioration by tape-coating every new copper service. That solved the problem because the cathode area was reduced to just the holidays in the tape. Since there didn’t seem to be any reasonable cause for the corrosion, I decided we needed to look at a couple more sites. I asked the crew to dig them out and sure enough we found the same thing. The absence of stray current and the presence of at least a little CP left me wondering if this was really corrosion. Now when your test data don’t show what’s wrong, it’s time to have a closer look. So I put on my boots and got down in the ditch to see what I could find. I had good waterproof gloves on, and took hold of a leaking fitting to see if I could move it. Much to my delight it moved! I was able to back Summer 2012 it off a bit, and then tighten it several turns until it stopped. Ah-ha! Could it be simply a loose fitting? Sure enough, I found the same situation in the other excavations. The problem was that the flare fittings had been left hand-tight during installation and never tightened up properly. The water had simply leaked through the threads of the flare nut and then eroded its way through the nut itself, and produced an appreciable leak. The water folks dug out the remaining leak sites, replaced the attachments to the main properly, and the problem was solved. It wasn’t corrosion after all! SC Stay Current 3 Working Cathodic Protection Field Exhibited at CORROSION 2012 By Kathy Riggs Larsen, MP Associate Editor O f the many technical and educational resources, public awareness activities, and networking opportunities produced by NACE International, its annual conference is one of the top reasons so many corrosion professionals thrive in their careers. This year, approximately 6,000 corrosion professionals representing industry, government, and academia gathered at the Salt Palace Convention Center in Salt Lake City, Utah, to reap the benefits of CORROSION 2012 and its outstanding technical program, committee meetings, seminars and lectures, networking venues, and the largest corrosion exhibition in the world. Participants came together from all over the globe to discuss the latest technologies and issues and bring the latest corrosion knowledge back to their workplace. The convention included a technical program that featured 36 technical symposia with 443 paper presentations covering all areas of corrosion control, four Research in Progress symposia with more than 60 presentations, and 195 technical committee meetings, 18 networking events, and a sold-out exhibit hall. Timely industry topics including pipelines, tanks, and underground systems; oil and gas production; petroleum refining; the U.S. Department of Defense; highways and bridges; water and waste water; power generation; maritime; materials selection and design; and coatings were covered in 12 industry tracks. New in the Exhibit Hall this year was a 30 by 30 ft (9 by 9 m) fullscale mock-up of a typical cathodic protection (CP) field site where attendees could take real-time, 4 Stay Current structure-to-electrolyte potential measurements and soil resistivity measurements, and perform other CP-related tests. The CP field featured several pipe configurations and test stations that would be found in a typical CP field used in a CP Tester or CP Technician certification course, with all instrumentation typical of what is used in actual field sites. The mock-up field included an L-shaped bare pipeline and a coated pipeline that crossed it, with the coated pipe connected to magnesium anodes. Both pipes had test stations connected to a rectifier. The field also included an isolated casing, complete with vents at the end, which could be shorted to the pipeline; and two pipeline segments separated by an aboveground NPS 2 insulating flange that could be bypassed. Many NACE CP instructors and senior CP professionals volunteered to walk attendees through the test site and describe the pipe configurations, show participants how the equipment worked, demonstrate how the tests were conducted, and explain what they expected to see in the measurements and why the measurements would change when conditions were altered. Participants were able to rotate through four test stations in about 20 minutes and perform tasks such as pipe locating, electrical isolation testing and sort locating, road casing testing, rectifier testing, interrupted potential measurements, and soil resistivity measurements. The field was constructed on the existing concrete floor of the Exhibit Hall without hauling in and removing truckloads of soil. This was accomplished with electronics and wire pipelines underneath the artificial turf. The circuits were designed by Brian Holtsbaum (DNV), and the electronics were preconstructed and later assembled by Michael Tarlton (Russell Corrosion) and NACE staff. Don Vickers (Vickers Inspection & Consulting, LLC) and Richard Vandergriff (Zeeco, Inc.) welded and coated the casing vents and aboveground insulating flange. SC Summer 2012 Call for NACE Instructors A t a time of unprecedented growth for NACE International—membership now exceeds 29,000 worldwide—NACE education and training programs and courses are rapidly increasing to keep pace with industry requirements. As much of the world’s infrastructure nears or reaches the end of its design life, qualified corrosion professionals are in high demand to design and execute effective corrosion control systems using best engineering practices. NACE training and certifications are being specified Summer 2012 more often and in more places as companies work to prevent safety, environmental, and economic problems that result from corrosion-induced failures. As NACE increases its course offerings, the need for new instructors from both inside and outside North America is growing to broaden the current strong network of training professionals. Becoming a NACE instructor involves a series of steps and qualifications that vary according to the course taught. Once qualified, instructors may get assignments in various parts of the world. For information on how to become a NACE instructor, contact NACE Senior Education Manager Karla Smith at +1 281-228-6230 or e-mail: karla.smith@nace.org. SC Stay Current 5 The NACE Corrosion Network A Free Technical Resource I n the late 1990s, NACE International established an e-mail-based network of corrosion professionals for the purpose of sharing technical information. Open to all interested corrosion professionals, the free NACE Corrosion Network (NCN) offers the opportunity for subscribers to post technical questions and receive expert answers from all over the world. Today, there are approximately 1,500 members of the NCN, and 1,000 members on the later-released NACE Coatings Network, a list server specific to coatings questions. To join the networks, simply go to the NACE Web site at www.nace. org, click on the Corrosion Central link, and then Online Corrosion Community List Servers. You will reach a subscriber page and access to archived questions and answers back to 2002. Following is sampling from the NCN on questions and answers related to cathodic protection. Deep anode groundbed current distribution What should be the normal difference in current distribution (amperage) of six anodes installed in a deep groundbed? Is there any reference available to confirm this? Q The top and bottom anodes may show higher current discharge than the middle four anodes because of the end effect on the coke column. A Monitoring alternating current corrosion Mitigation of overhead highvoltage alternating current (AC) that is parallel to a pipeline is Q 6 Stay Current quite common. What are monitoring methods and facilities for the corrosion control system? How do we determine whether the mitigation method is effective? Can AC corrosion be monitored with corrosion coupons? It is likely that corrosion coupons are the most effective monitoring facility for this situation. I would suggest using electrical resistance (ER) probes buried alongside the affected pipeline, with cabling incorporated into a standard test post. In this way, the ER probe could also serve as a polarization coupon. This arrangement has been in use for some time, and is now gaining wider acceptance. Use a 10mm2 coupon. As long as the current flow to earth is less than 3 mA AC, corrosion is negligible. A High IR drops We have taken “on” and “instant-off” readings with permanent reference electrodes placed below an aboveground tank. The “on” reading is as high as 13,000 mV vs. copper/copper sulfate (Cu/CuSO4) Q reference electrode (CSE) and the “instant off” is only –708 mV vs. CSE. We think this big IR drop is caused by some problems during installation of the reference electrodes. We are going to drill some test points around the tank in order to take these measurements directly to the ground with portable reference cells. To use the 100-mV CSE shift criterion, I need to disconnect the copper grounding mat and measure the open circuit potential of the steel. Have you seen this high of an “on” potential before? Is this possible? I have seen cases like yours in situations in which the builder installed reference electrodes too close to anodes around the tank. Also, I saw a case in which the reference electrode was in contact with a flexible polymer anode under a tank. A If there is no way to test the calibration of the electrodes, you must use the 100-mV shift criteria. Therefore, the rectifier must be turned off until the potentials on the CSEs stabilize and the tank is depolarized. Continued on p. 8 A Summer 2012 Summer 2012 Stay Current 7 Continued from p. 6 There is no limit to the “on” potential. It has nothing to do with the polarization, since it incorporates the IR drop as you indicate. If the cell is close to the anode it can be very high. The “instant off” potential shows the polarization potential. Did you wait for the depolarized potential? That will tell you if the tank is protected. A measurement of –0.708 V CSE is not too low if the depolarized potential is –0.608 V CSE or lower (more positive). A Remember to involve the se- A curity group before you dis- connect the tank from its grounding system. If the weather is good, without any heavy, dark clouds, that could be done without any hazard, as you have a minimum chance of discharges. The disconnecting procedures should be followed according to your company’s specifications. When you disconnect the mat, A the potentials will change. You must record the “instant off” and depolarized potentials also with the mat disconnected as well. Consider using solid state or polarization cells to provide the mat connection, if required. Is the tank full or only partially so? I have measured high “on” potentials of about 7 V vs. CSE and “off ” values at about 700 mV in these conditions. When the tank is almost empty, the tank bottom is separated from the ground, and you will have air between the tank bottom and the ground. This could be the reason for the high “on” potential. When you are checking the potential of an aboveground tank, always take note of the level of the liquid in the tank. A 8 Stay Current Shorted casing with carrier pipeline At road crossings, a transfer pipeline has steel casings. A zinc ribbon anode is installed on the process pipe for cathodic protection (CP), in case water enters the casings. During testing, we found that the zinc ribbons are in contact with casing pipe. Following is some key information: Q • The carrier pipe is totally buried. • An impressed current CP system is installed for the carrier pipe. • Polyethylene (PE) coating is used on the casing’s external surface. • PE three-layer coating is used on the carrier pipeline. • Heat shrinkable caps are used at the ends and spacers help isolate the pipeline from the casing. • Soil conditions are normal, without any water penetration. • A zinc ribbon anode is installed over the carrier pipeline inside the casing (i.e., straight anode ribbon runs over the pipeline and a thermit weld ribbon ends with the pipeline). • Vents are available on the casing. Is this situation harmful for the pipeline? Your situation is a very good A example of why I do not rec- ommend a zinc ribbon anode inside a casing. It does very little good, and has a much higher chance of shorting your pipeline to the casing. With the zinc ribbon on top of the line, it only helps the pipeline if the piping and the anode are completely immersed in water. Even then, shielding of the bottom half can be an issue depending on the diameter of the line. The zinc ribbon will be used up in a few months to a few years anyway, depending on the exposure to water, so there is very little to gain, and, as you have just discovered, much to lose. I see nothing wrong except A that zinc ribbon should not have been in contact with the casing; the internal side of the casing being bare (presumably), zinc will be consumed quickly if water does get in. Corrosion engineers need tell civil and pipeline engineers about the operational issues and potential failures that occur with cased crossings. We should all do our utmost to persuade pipeline designers and railroad authorities that cased crossings are a poor idea, and f ight hard on any new pipeline installations to eliminate them from the project! A to We specifically discourage pipeline road crossings of underground pipelines by design. It does more harm than good in the long run. We prefer the pipeline to cross any road at a minimum specified depth, which is calculated based on the estimated traffic load. For a normal road, a concrete slab is recommended (minimum 300-mm thick) at the grade level. For highways, we specify a specially designed culvert around the pipe, with the bottom open to ground to make the CP system effective. The annular space between the culvert and the pipe is filled with sand. The space is designed in such a way that the sand can be removed and the inspectors can walk through for necessary visual inspection. A cased There would be more value A in increasing the wall thick- ness of the carrier than installing a casing. However, we have to get rid of a contractor’s fear that we will make him pull the carrier back if some slight coating damage occurs during insertion. SC Summer 2012 NACE CATHODIC PROTECTION COURSE SCHEDULE JULY–NOVEMBER 2012 Coatings in Conjunction with Cathodic Protection October 7-12 Houston, TX October 15-20 Rio de Janeiro, Brazil CP Interference July 29-August 3 Houston, TX September 3-8 Bogota, Colombia September 30-October 5 Houston, TX CP1—Cathodic Protection Tester November 3-8 Houston, TX November 3-8 Dammam, Saudi Arabia November 5-10 Buenos Aires, Argentina November 10-15 Fahaheel, Kuwait July 22-27 Houston, TX November 10-15 Houston, TX September 9-14 Houston, TX November 10-15 Dammam, Saudi Arabia CP2—Cathodic Protection Technician CP2—Cathodic Protection Technician— Maritime July 2-7 Johannesburg, South Africa July 15-20 Houston, TX July 2-7 Maracaibo, Venezuela July 23-28 Bogota, Colombia July 7-12 Abu Dhabi, U.A.E. August 12-17 Houston, TX July 22-27 Houston, TX September 23-28 Houston, TX August 27-September 1 Johannesburg, South Africa October 14-19 Houston, TX September 1-6 Dammam, Saudi Arabia November 11-16 Houston, TX September 10-15 Cuernavaca, Mexico November 12-17 Buenos Aires, Argentina September 30-October 5 Houston, TX November 24-29 Dammam, Saudi Arabia October 15-20 Lima, Peru October 29-November 3 London, U.K. November 4-9 San Francisco, CA November 25-30 Houston, TX CP3—Cathodic Protection Technologist CP4—Cathodic Protection Specialist July 14-19 Abu Dhabi, U.A.E. July 29-August 3 Houston, TX August 6-11 Maracaibo, Venezuela September 8-13 Dammam, Saudi Arabia October 7-12 Houston, TX October 22-27 Lima, Peru For the most up-to-date course schedules and course information, visit www.nace.org/eduschedule. Summer 2012 Stay Current 9 CATHODIC PROTECTION-RELATED TECHNICAL COMMITTEES CATHODIC PROTECTION-RELATED TECHNICAL COMMITTEES Committee Title STG 05 STG 30 TEG 016X TEG 022X TEG 024X TEG 043X TEG 166X TEG 179X TEG 197X TEG 262X TEG 338X TEG 349X TEG 363X TEG 368X TG 011 TG 013 TG 017 TG 018 TG 019 TG 020 TG 023 TG 025 Cathodic/Anodic Protection Oil and Gas Production—Cathodic Protection Cathodic Protection and Corrosion Control Research Development Corrosion Control Coordinating Committee DC Traction Stray Current Problems Reinforced Concrete: Cathodic Protection Cathodic Protection in Seawater—Discussion of Current Topics Cathodic Protection Cathodic Protection: Pipe-Type Cable Interference Problems Cathodic Protection Monitoring: Use of Coupons Cathodic Disbondment Test Methods: Critical Review of the Existing International Standards Close-Interval Surveys and CP Surveys Electric Utility Transmission and Distribution Corrosion and Grounding: Discussion of Issues Underground Storage Tank Systems: Corrosion Control by Cathodic Protection Review of NACE Standard RP0193-2001 Anodes, Catalyzed Titanium: Testing for Use in Soils or Waters Steel, Structural: Corrosion Control of Pilings in Nonmarine Applications Pipelines: Cathodic Protection of Concrete Pressure and Mortar-Coated Steel Piping Systems, Cathodic Protection Criteria Measurement: Review of NACE Standard TM0497 High-Voltage Direct Current (DC) Transmission: Effects on Buried or Submerged Metallic Structures Alternating Current (AC) Power Systems, Adjacent: Corrosion Control and Related Safety Procedures to Mitigate the Effects Reinforced Concrete: Anode Test Procedures Reinforced Concrete: Sacrificial Cathodic Protection of Reinforced Concrete Reinforced Concrete: Test Methods for Cathodic Protection Cathodic Protection, Impressed Current—Steel Water Storage Tanks: Review of NACE SP0388 Cathodic Protection Systems, Retrofit, for Offshore Platforms Cathodic Protection Coupon Technology Review of NACE SP0196 (formerly RP0196) Direct Current (DC) Operated Rail Transit and Mine Railroad Stray Current Mitigation— Review Report 10B169 Reinforced Concrete: Stray Current-Induced Corrosion Piping Systems: Review of SP0169-2007 (formerly RP0169), “Control of External Corrosion on Underground or Submerged Metallic Piping Systems” Electrical Cables for Cathodic Protection Use: State-of-the-Art Report Testing of Cathodic Protection Systems of Underground Storage Tanks Cathodic Protection Rectifier Safety Nuclear Buried Piping Symbols Related to Cathodic Protection AC Corrosion on Cathodically Protected Pipelines: Standard Practice for Risk Assessment, Mitigation, and Monitoring Testing of Field-Grade Reference Electrodes Reinforced Concrete: Galvanic Anode Test Procedures Review or Revise as Necessary SP0387-2006 Review and Revise as Necessary NACE Standard TM0190-2006 TG 045 TG 047 TG 049 TG 167 TG 168 TG 210 TG 284 TG 297 TG 356 TG 360 TG 362 TG 364 TG 388 TG 404 TG 429 TG 430 TG 436 TG 438 TG 454 TG 459 10 Stay Current Summer 2012 CATHODIC PROTECTION-RELATED NACE REPORTS AND STANDARDS Cathodic Protection-Related NACE Reports and Standards Document Title 01102 01104 01105 01110 01210 05101 05107 11100 30105 35108 35110 35201 State-of-the-Art Report: Criteria for Cathodic Protection of Prestressed Concrete Structures Electrochemical Realkalization of Steel-Reinforced Concrete—A State-of-the-Art Report Sacrificial Cathodic Protection of Reinforced Concrete Elements—A State-of-the-Art Report Stray-Current-Induced Corrosion in Reinforced and Prestressed Concrete Structures Cathodic Protection for Masonry Buildings Incorporating Structural Steel Frames State-of-the-Art Survey on Corrosion of Steel Piling in Soils Report on Corrosion Probes in Soil or Concrete Use of Reference Electrodes for Atmospherically Exposed Reinforced Concrete Structures Electrical Isolation/Continuity and Coating Issues for Offshore Pipeline Cathodic Protection Systems One Hundred Millivolt (mV) Cathodic Polarization Criterion AC Corrosion State-of-the-Art Corrosion Rate, Mechanism, and Mitigation Requirements Technical Report on the Application and Interpretation of Data from External Coupons Used in the Evaluation of Cathodically Protected Metallic Structures Effectiveness of Cathodic Protection on Thermally Insulated Underground Metallic Structures 10A392 (2006 Edition) 1E100 (2010 Edition) 6A100 7L192 (2009 Edition) 7L198 (2009 Edition) SP0607-2007/ IS015589-2 (modified) SP0575-2007 (formerly RP0575) SP0290-2007 (formerly RP0290) SP0107-2007 SP0177-2007 (formerly RP0177) SP0572-2007 (formerly RP0572) SP0286-2007 (formerly RP0286) SP0196-2011 (formerly RP0196) Engineering Symbols Related to Cathodic Protection Coatings Used in Conjunction with Cathodic Protection Cathodic Protection Design Conderations for Deep Water Projects Design of Galvanic Anode Cathodic Protection Systems for Offshore Structures Petroleum and natural gas industries—Cathodic protection of pipeline transportation systems—Part 2: Offshore pipelines Internal Cathodic Protection (CP) Systems in Oil-Treating Vessels Impressed Current Cathodic Protection of Reinforcing Steel in Atmospherically Exposed Concrete Structures Electrochemical Realkalization and Chloride Extraction for Reinforced Concrete Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems Design, Installation, Operation, and Maintenance of Impressed Current Deep Anode Beds Electrical Isolation of Cathodically Protected Pipelines Galvanic Anode Cathodic Protection of Internal Submerged Surfaces of Steel Water Storage Tanks RP0193-2001 SP0186-2007 (formerly RP0186) RP0104-2004 SP0100-2008 (formerly RP0100) SP0169-2007 External Cathodic Protection of On-Grade Carbon Steel Storage Tank Bottoms Application of Cathodic Protection for External Surfaces of Steel Well Casings SP0207-2007 Performing Close-Interval Potential Surveys and DC Surface Potential Gradient Surveys on Buried or Submerged Metallic Pipelines (formerly RP0169) (formerly RP0207) Summer 2012 The Use of Coupons for Cathodic Protection Monitoring Applications (ANSI approved) Cathodic Protection to Control External Corrosion of Concrete Pressure Pipelines and Mortar-Coated Steel Pipelines for Water and Waste Water Service Control of External Corrosion on Underground or Submerged Metallic Piping Systems Stay Current 11 1440 South Creek Drive Houston, TX 77084-4906 Non Profit Org. U.S. Postage PAID Permit No. 579 Lebanon Junction, Kentucky Cathodic Protection-Related NACE Reports and Standards (continued) Document Title SP0285-2011 Corrosion Control of Underground Storage Tank Systems by Cathodic Protection SP0387-2006 Metallurgical and Inspection Requirements for Cast Galvanic Anodes for Offshore Applications SP0388-2007 Impressed Current Cathodic Protection of Internal Submerged Surfaces of Carbon Steel Water Storage Tanks SP0408-2008 Cathodic Protection of Reinforcing Steel in Buried or Submerged Concrete Structures TM0101-2001 Measurement Techniques Related to Criteria for Cathodic Protection on Underground or Submerged Metallic Tank Systems Measurement of Protective Coating Electrical Conductance on Underground Pipelines Test Procedures for Organic-Based Conductive Coating Anodes for Use on Concrete Structures Testing of Catalyzed Titanium Anodes for Use in Soils or Natural Waters Aboveground Survey Techniques for the Evaluation of Underground Pipeline Coating Condition Impressed Current Laboratory Testing of Aluminum Alloy Anodes Durability Test for Copper/Copper Sulfate Permanent Reference Electrodes for Direct Burial Applications Testing of Embeddable Impressed Current Anodes for Use in Cathodic Protection of Atmospherically Exposed Steel-Reinforced Concrete Measurement Techniques Related to Criteria for Cathodic Protection on Underground or Submerged Metallic Piping Systems (formerly RP0285) (formerly RP0387) (formerly RP0388) (formerly RP0408) TM0102-2002 TM0105-2005 TM0108-2008 TM0109-2009 TM0190-2006 TM0211 TM0294-2007 TM0497-2002 Join NACE International and obtain unlimited free downloads of NACE standards and reports! For information on joining NACE, or to purchase standards and reports if not a member, go to www.nace.org. 12 Stay Current Summer 2012