NACE INTERNATIONAL CATHODIC PROTECTION TRAINING & CERTIFICATION NEWS Summer 2014

Transcription

1 NACE INTERNATIONAL CATHODIC PROTECTION TRAINING & CERTIFICATION NEWS Summer 2014 Safety First By John H. Fitzgerald III, FNACE, MP Technical Editor subscribe to an excellent magazine called Underground Construc- I tion. Its theme is all about safety in construction work. The recent issue had articles on proper trench preparation, sheeting and shoring, and confined space entry. These are all items of importance to those working with underground structures. There was a supplement to the recent issue of the NACE International magazine Coatings Pro with the word SAFETY in bold letters on the cover. In the publication were several articles on safety with abrasive blasting, coating procedures, and work on large structures. This primer on safety got me thinking about an important aspect of our work that I have always stressed that we are in the safety business. Our work involves preventing leaks in pipelines and tanks containing hazardous materials; ensuring the safety of buildings, towers, and other structures; preventing corrosion on ship hulls and ballast tanks; advising on proper water treatment for boilers and hot water heating systems; and many other aspects of daily industrial, commercial, and private life. We are all familiar with the terrible tragedies and destruction that can occur from corrosion leaks in pipelines and underground tanks. Gasoline leaking from an underground tank can infiltrate into a sewer system and work its way back into homes through sewer lines. That can not only make a home unfit for living, but also cause a fire or explosion. I remember one case where a leak from a bare 20-in (508-mm) high-pressure gas main having galvanic anode cathodic protection (CP) worked its way into a remote teller enclosure at a bank, caught fire, and burned two young workers very badly. The leak occurred because of insufficient CP; whoever designed the CP was obviously unqualified to do so because the An important aspect of our work that I have always stressed is that we are in the safety business. design consisted of one 17-lb (7.7-kg) magnesium anode every 200 ft (61 m)! I doubt that a similar mistake would occur today, thanks to the operator qualification rules. Here again is a case where NA CE certification is so essential. All of us so certified need to realize that safety is one of the most important aspects of our work. As technical editor of MP, I frequently receive failure analysis articles. One of them described a guy wire-supported 1,000-ft (305-m) tall television transmitter tower that collapsed from corrosion failure of some of the guys. Fortunately there were no damages or injuries. It was apparent IN THIS ISSUE... Continued on p. 3 Safety First... 1 Coatings and Cathodic Protection.. 4 NACE International Initiates Global Study on Corrosion Costs... 6 NACE CP Course Schedule... 9 CP-Related Technical Committees...10 CP-Related NACE Reports and Standards...11 Summer 2014 Stay Current 1

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3 Continued from p. 3 that the owner had not paid attention to guy wire maintenance. Another article described how the corrosion failure of a computer chip completely disabled the computer that controlled the manufacturing functions of a plant, shutting the plant down for several days and creating a large economic loss. Just think of how someone skilled in corrosion control could have prevented those failures. I think that speaks to the need for continued corrosion control education and certification throughout the world. In one more example, I did an investigation at a school where leaking boiler tubes had been discovered. A good batch feedwater treatment was Learn How to Extend the Operating Life and Integrity of Your Pipeline with the NACE INTERNATIONAL CATHODIC PROTECTION PROGRAM in use, but it seems the maintenance personnel felt that by using less treatment than recommended, they were saving the school money. Maybe so, but if a boiler failure had occurred in the middle of winter, the lack of heat could have indeed caused many safety problems. So let s all remember that we are in the safety business, and if we do our jobs correctly, we will help prevent tragedies and catastrophes. SC Model AC-15 AC Warning System Real Time Monitoring of AC Voltage Safety concerns with induced AC around your work force? Be Sure Be Safe! Monitor the AC in real time and warn of dangerous voltage levels! Superbright LED Indicators Detects 15V AC on Structure (NACE SP0177) Provides Personnel Safety Superbright LED Indicators Loud Audible Alarms Calibration Test Unit Included Everything fits inside the case MORE with NACE Our Quality is found in our People, Products, and Customer Service! TEL: +1 (909) Info@tinker-rasor.com Summer 2014 Stay Current 3

4 Coatings and Cathodic Protection This article is an excerpt from C.G. Munger s Corrosion Prevention by Protective Coatings, now in its third revision by Associate Author Louis D. Vincent Ph.D. The third edition of the book will be released in Summer Coatings and cathodic protection (CP) have often stood on opposite sides of the fence as mutually exclusive and opposing approaches to corrosion protection. Proponents of coatings are often on one side discounting the advantages of CP and claiming that a good, well-applied coating is the only necessary protection for steel. On the other side are proponents of CP, who often claim that any immersed or buried metal structure can best be protected by a well-engineered CP installation. In some conditions, both sides may be correct in their assertions. However, under many more commonly occurring conditions, the ideal corrosion protection is actually a combination of both protection concepts. CP and coatings are both engineering disciplines with the primary purpose of mitigating and preventing corrosion. 1 Each process is different. CP prevents corrosion by introducing electrical currents from external sources to counteract the normal electrochemical corrosion reactions. Coatings form a barrier to prevent the flow of corrosion current between the naturally occurring anodes and cathodes or within galvanic couples. Each of these processes has been successful in its own right. Coatings by far represent the most widespread method of general corrosion prevention. CP, however, has protected hundreds of thousands of miles of pipe and acres of steel surface subject to buried or immersion conditions. As corrosion protection has become more critical, and all types of metal structures more valuable, a marriage of the two corrosion prevention systems has naturally occurred. Experience has shown that damage to organically coated structures is almost unavoidable during construction and service. Breaks or holidays in coatings expose metal surfaces to corrosion, particularly in underground or immersion service. Attempts to eliminate all coating holidays drastically increases costs and are usually unwarranted. Thus, under many conditions, the combination of both systems actually provides better, more reliable, and, in many cases, less costly corrosion protection. In the case of coatings for use with CP, it is necessary to use those coatings that are based on the impervious coating concept. This is because wherever coatings are used in connection with CP, they generally must be either immersed or in moist underground conditions. Without immersion or moisture, the CP mechanism will not operate properly. The impervious coating concept requires the coating to be relatively impervious to the transfer of moisture, oxygen, air, and the various ions that may be in contact with the coating. Also, it must be resistant to the passage of electrons or electric current so that it forms an impervious film over the surface to be protected. The boot-topping of large tankers is an area where the combination of coatings and CP has proven advantageous. 4 Stay Current Summer 2014

5 An example of a coating that is compatible with CP. The coating is not fully impervious to moisture vapor. Each coating material has a moisture vapor transfer rate characteristic of that particular material. Nevertheless, the coatings used in connection with CP are much more impervious than those types of coatings used in atmospheric exposures. The accompanying figure is an example of a coating that should be satisfactory with CP. To obtain maximum corrosion resistance from the combination of coatings and CP, a number of factors, which have a basic influence on their combined effectiveness, must be taken into consideration. 1. Application of coatings needs to be done in the best possible manner, with excellent surface preparation. Poor application and poor surface preparation can only lead to coating failure under the influence of cathodic current by either hydrogen or electroendosmotic blistering. 2. For the coatings to be effective, they must be highly dielectric and must maintain such dielectric properties over their entire life. 3. Coatings must be highly chemical-resistant, particularly toward alkalies, because of the strong buildup of hydroxyl ions by the cathodic current. Any coatings that have even a small tendency to saponify, or which contain pigments that are alkali reactive, should not be used. 4. Coatings should have a low moisture absorption and a low moisture transfer rate, in addition to being di-electric, in order to prevent hydrogen blistering under the cathodic current. 5. Optimum coating thickness is essential in order to act as a longtime barrier and insulator for the cathodic current. Each coating has its own optimum thickness. However, in general, it can be stated that the thicker the coating (based on its own inherent properties), the better the results when used with CP. 6. It is indicated that antifouling coatings using alkali-resistant resins and pigments, applied over a proper dielectric coating, are not affected by the application of CP potentials. 7. From all evidence, indicated from actual tests as well as field installation, the cathodic potential, where used in connection with coatings, should be below 1 V, and the optimum potential is V. If these factors are taken into consideration, the results of both laboratory testing and actual use of the combined system indicate that maximum corrosion protection can be obtained through the use of coatings and CP. SC Reference 1. C.G. Munger, R.C. Robinson, Coatings and Cathodic Protection, MP 7 (1981). Summer 2014 Stay Current 5

6 NACE International Initiates Global Study on Corrosion Costs By Alysa Reich, NACE Sr. Manager, Public Affairs NACE International has announced the commencement of its new global study on costs related to corrosion. The initiative seeks to determine the financial and societal impact of corrosion on industry sectors, including infrastructure, manufacturing, utilities, transportation, and government. The two-year study, led by NACE and supported by industry partners worldwide, is now underway. Elaine Bowman, NACE past president, is managing the effort. The DoD Corrosion Policy and Oversight Office will provide technical support for the global study. Corrosion is an inevitable, but controllable process that can result in destructive, even catastrophic incidents when not properly prevented and managed, says Bowman. Costs associated with corrosion control include direct expenses like repair and replacement of assets, or the environmental and physical impact of corrosion-related failure. This study will explore direct and indirect costs of corrosion to several industry sectors around the world and identify ways to save as much as thirty percent of those costs. A 2002 study funded by Congress with oversight by the Federal Highway Administration and support from NACE provided broad research into direct and indirect costs for U.S. industry sectors. The 2002 report, titled Corrosion Costs and Preventive Strategies in the United States, includes results indicating that the annual estimated direct cost of corrosion in the United States was $276 billion. The study led Congress to develop a Corrosion Policy and Oversight Office within DoD. The DoD Corrosion Office has demonstrated that the technology demonstration projects that it has funded and implemented in partnership with the Services have offered a 40:1 return on investment, on average. The congressional study also spurred Congressional support for the launch of the world s first undergraduate degree in corrosion at The University of Akron in Akron, Ohio. This study is an essential study for industry stakeholders and government worldwide, says Bob Chalker, NACE executive director. It will be the most comprehensive study to look at costs associated with the impact of corrosion and the resulting data will contribute to future project plans, regulations, education, and more. NACE will provide periodic updates on the progress of the new global cost of corrosion study in NACE publications, press releases, and at SC The annual estimated direct cost of corrosion in the United States was $276 billion 6 Stay Current Summer 2014

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8 MORE with NACE Learn How to Extend the Operating Life and Integrity of Your Pipeline with the NACE Cathodic Protection (CP) Program The most specified and recognized CP training and certification* in the world. NACE s CP Program provides students with the theoretical and practical fundamentals for testing, evaluating, and designing both galvanic and impressed current cathodic protection systems. This program is geared for a wide range of professionals from field personnel to engineers in management, regardless of the individual s experience. To register or for more information, visit * All certifications are administered by the NACE International Institute, the independent certification affiliate of NACE International. Certifications are subject to periodic reviews and revisions, please refer to www. naceinstitute.org for the most current certification information. 8 Stay Current Summer 2014

9 NACE CATHODIC PROTECTION COURSE SCHEDULE JULY DECEMBER 2014 COATINGS IN CONJUNCTION WITH CATHODIC PROTECTION July 27-August 1 November CP INTERFERENCE September CP1 CATHODIC PROTECTION TESTER July September October 5-10 November 2-7 November 3-8 November 9-14 November November November 30-December 5 December 1-6 December 7-12 December Liberal, KS Midrand, Johannesburg, South Africa Rosebush, MI Mumbai, India Claysville, PA Buenos Aires, Argentina Kuala Lumpur, Malaysia Chicago, IL CP2 CATHODIC PROTECTION TECHNICIAN July 7-12 Midrand, Johannesburg, South Africa CP2 CATHODIC PROTECTION TECHNICIAN November 9-14 November November November December 7-12 December 8-13 Mumbai, India Claysville, PA Buenos Aires, Argentina Kuala Lumpur, Malaysia CP3 CATHODIC PROTECTION TECHNOLOGIST July August 3-8 August September 7-12 September October 5-10 October November Bogota, Colombia Kilgore, Texas Midrand, Johannesburg, South Africa Las Vegas, Nevada Joliet, Illinois Beijing, China Edmonton, AB, Canada CP4 CATHODIC PROTECTION SPECIALIST July 27-August 1 September November 2-7 December 7-12 Bogota, Colombia Seattle, WA July August 3-8 August September 8-13 September October October 27-November 1 Tulsa, OK Midrand, Johannesburg, South Africa For the most up-to-date course schedules and course information, visit Summer 2014 Stay Current 9

10 CATHODIC PROTECTION-RELATED TECHNICAL COMMITTEES CATHODIC PROTECTION-RELATED TECHNICAL COMMITTEES COMMITTEE STG 05 STG 30 TEG 016X TEG 022X TEG 024X TEG 043X TEG 166X TEG 179X TEG 262X TEG 338X TEG 363X TEG 368X TG 013 TG 018 TG 019 TG 023 TG 025 TG 045 TG 046 TG 047 TG 167 TG 168 TG 210 TG 284 TG 297 TG 356 TG 360 TG 362 TG 388 TG 404 TG 430 TG 438 TG 446 TITLE 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 Interference Problems Cathodic Protection Monitoring: Use of Coupons Close-Interval Surveys and CP Surveys Electric Utility Transmission and Distribution Corrosion and Grounding: Discussion of Issues Review of NACE Standard RP Steel, Structural: Corrosion Control of Pilings in Nonmarine Applications Pipelines: Cathodic Protection of Concrete Pressure and Mortar-Coated Steel 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 Cathodic Protection of Prestressed Concrete Elements Reinforced Concrete: Sacrificial Cathodic Protection of Reinforced Concrete Elements Review of NACE SP Cathodic Protection Systems, Retrofit, for Offshore Platforms Cathodic Protection Coupon Technology Review of NACE SP Direct Current (DC) Operated Rail Transit and Mine Railroad Stray Current Mitigation Review Report 10B189 Reinforced Concrete: Stray Current-Induced Corrosion Piping Systems: Review of SP (formerly RP0169) Electrical Cables for Cathodic Protection Use: State-of-the-Art Report Cathodic Protection Rectifier Safety Nuclear Buried Piping AC Corrosion on Cathodically Protected Pipelines: Standard Practice for Risk Assessment, Mitigation, and Monitoring Reinforced Concrete: Galvanic Anode Test Procedures Review and Revise as Necessary SP Stay Current Summer 2014

11 CATHODIC PROTECTION-RELATED NACE REPORTS AND STANDARDS DOCUMENT TITLE 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 10A392 (2006 Edition) 1E100 (2012 Edition) 6A100 7L192 (2009 Edition) 7L198 (2009 Edition) SP (formerly RP0575) SP (formerly RP0290) SP SP (formerly RP0177) SP (formerly RP0572) SP (formerly RP0286) SP (formerly RP0196) Effectiveness of Cathodic Protection on Thermally Insulated Underground Metallic Structures 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 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 CATHODIC PROTECTION-RELATED NACE REPORTS AND STANDARDS RP SP (formerly RP0186) RP SP (formerly RP0100) SP (formerly RP0169) SP (formerly RP0207) External Cathodic Protection of On-Grade Carbon Steel Storage Tank Bottoms Application of Cathodic Protection for External Surfaces of Steel Well Casings 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 Performing Close-Interval Potential Surveys and DC Surface Potential Gradient Surveys on Buried or Submerged Metallic Pipelines Summer 2014 Stay Current 11

12 15835 Park Ten Place, Non Profit Org. U.S. Postage PAID Permit No. 579 Lebanon Junction, Kentucky CATHODIC PROTECTION-RELATED NACE REPORTS AND STANDARDS (continued) DOCUMENT SP (formerly RP0285) SP (formerly RP0387) SP (formerly RP0388) SP (formerly RP0408) TM TM TM TM TM TM TM TM TM TITLE Corrosion Control of Underground Storage Tank Systems by Cathodic Protection Metallurgical and Inspection Requirements for Cast Galvanic Anodes for Offshore Applications Impressed Current Cathodic Protection of Internal Submerged Surfaces of Carbon Steel Water Storage Tanks Cathodic Protection of Reinforcing Steel in Buried or Submerged Concrete Structures 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 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 12 Stay Current Summer 2014