cost of corrosion

Highway Bridges
Gas and Liquid Transm. Pipelines
Waterways and Ports $0.3
Hazardous Materials Storage
Ai P
Air
Ports
t Railroads Gas Distribution

$8 3
$8.3
$7.0
$7.0

$5.0

: 2,2760

: 360
(2003 )

Drinking Water and Sewer System

$36 0
$36.0

Electrical Utilities
Telecommunication Motor Vehicles
Ships
Aircraft
Railroad Cars

$6.9
$23.4
$2.7
$2.2
$0.5

Hazardous Materials Transport $0.9

$0 9
Oil and Gas Expl. And Production
$1.4
Mining $0.1
Petroleum Refining
Chem., Petrochem., Parm.

$3.7
$1.7

Pulp and Paper

Agricultural $1.1
$2.1
Food Processing
Electronics Home Appliances
$1.5

$6.0

Report No. FHWA-RD-01-156

Corrosion Cost and Preventive Strategies in the United States,
Gerhardus H. Koch, M.P.H. Brongers, N.G. Thompson, Y.P. Virmani, J.H.
Payer, Office of Infrastructure Research and Development Federal
Highway Administration, Department of Transportation, 2003

Defense
N l
Nuclear
W
Waste
t Storage
St
$0 1
$0.1
$0

$20.0
$10

$20

$30

$40

Cost of Corrosion Per Analyzed Economic Sector, ($ x billion)

ASME Causes of Gas Transmission Incidents

Third Party Damage
External Corrosion
Internal Corrosion
Natural Forces
Misc
Incorrect Operation
Unknown

Non-Pipe

Other Failures

Pipe

Constr/Instal
Mfr
Prev. Damgd Pipe
Malfunction
Stress Corrosion Cracking

5% hot tap error

6%
other

Vandalism
0.0

5.0

10.0

7% ground movements
50% external
interference

15% corrosion

17% construction and

material defects

Source: EGIG-02, data period 1970-2001

(stray current corrosion)

AC-induced corrosion

Crevice corrosion

C
Corrosion
i
under disbonded coating

15.0

Bellingham, WA
Carlsbad, NM

Edison, NJ
5

Gas explosion caused by charged soil (15 m x 34 m) due to corrosion

2.

pH

A W.
A.
W Peabody,
P b d P
Peabodys
b d C
Control
t l off Pi
Pipeline
li C
Corrosion,
i 2nd .ed.
d

CP
7

2.
-1

10

-2

10

40

-3

i, A/cm

Maxim
mum Corrrosion Ra
ate, mm/
/y

10

30

-4

10

-5

10

-6

10

-7
7

10

-8

10

-2.0

-1.5

-1.0

-0.5

0.0

0.5

1.0

1.5

E, V/CSE

20

10

-800

-600

-400

-200

Potential,, mV/CSE
/

200

100
58
25.4

31

35 2
35.2

34.2

10

01
0.1
0.04
0.018
0.01
-1000
1000

-800
800

-600
600

-400
400

-200
200

200

(mV/CSE)

(A)

(B)

(C)

: ,
: Sta.No. 621+00

D1

: 300[mm] PE 3[m] 3
- [A] ( : 2.5m)

D2

- , [B] ( : 5m)
- [C] ( : 4.5m, B )

D3

D4

(mm)

(mm)

(mm/y)

(mm/y)

(A)

1.75

3.0

0.48

0.82

(B)

1.74

3.8

0.47

1.04

(B)

D5

D6

3.

()

500
200
700

33 000
33,000
33,000

(, ) : 40
: 10km
: 2km
: 20
1 : 50( 1, Deep well 3)

- : 50 x 5 x 2(40) = 500 , : 5/ x 40 = 200

- 700
* (1.,
(1 2,
2 : 1,
1 3.
3 ,
4.
4 )
10km
- 3.3/m x 10,000m = 33,000

47 .


1)

2)

1)

2)

3)

4)

5.

- , ,
-
-

: cathodic protection (/)

-

- ()
:

5
5.

-
:

-
: ,

-
: (-850mV
( 850mV)

-
: , (CIPS,DCVG) /

CIPS

DCVG

Immediate
Scheduled
Monitored
<
>

5.

(ECDA)

(CP)

,

SOIL
CORROSIVITY

5.

(Gas Transmission IM Rule), 49CFR192.923-931 (2003)

10 HCA
5
7

(ECDA)
(pressure testing)
, e.g., In-line inspection (MFL-ILI)

/ (2003)
1MPa / / 15
5

ASME B31.8S

NACE RP0502 (Methodology for ECDA)

Shall/Must
Should Statements

T/B

ECDA

3, 4

( )

-
- microbiologically influenced corrosion; MIC
- (-)
( )

- : 3,2037,536cm
- (SO4-2) (432.74/)
- ()
(pitting)
- SRB
- ..
-
-

Pin-Hole
-

-

.
- ,

(air
penetration)
- ..
-
.
-

(ECDA)


PRE-ASSESSMENT

INDIRECT EXAM.

DIRECT EXAM.

Risk Assessment
(region)

IMMEDIATE
SCHEDULED
MONITORING

(CIPS/DCVG/)

CIPS/DCVG/

POST ASSESSMENT

SEVERE
MODERATE
MINOR

1324+0

1326+0

1339+0

1372+0

-200

(mV)

-400
400

-600

-800

-850mV
850mV

-1000

-1200
2000

2001

2002

2003

2004

2005

2006

2007

2008

2008

: . ( )
(/? ? 3 ?)

(DCVG)
(DC G)
(CIPS)
()

(, )
(, )

(anodic interference)

((cathodic interference))

(combined interference)

: Control of Pipeline Corrosion, A.W. Peabody

(mV)

100
20

50

20mV ()
200mV ()

VDE-0150
BS 7361,, ppart 1
Handbook of Corrosion
Protection Technology
Victorian Electrolysis
Committee, Code of Practice

- On/Off
-

- ON/OFF = 0
-

On
Off

Off
On

On/Off

[ON - OFF]>0

[ON - OFF]<0

[ON - OFF]=0

0
305
630
917
1210
1800
2112
2120
2125.5
2140
2160
2180
2200
2220
2240
2280
2300
2350
2360
2402
2407.2
2420
2440
2460
2480
2500
2520
2540
2560
2580
2600
2620
2640
2660
2661.7
2680
2700
2708.7
3000

200
100
0
-100
-200
-300
-400
-500
-600
-700
-800

(m)

ON/OFF
<0
>0

On/Off

Off

Off

On

On

(+)

( )

On

Off

Off

On

!!!

DCVG (pulsed-direct current voltage gradient) method

2~3m
2 3
20

15

10

Potentiial Difference (mV)

-5

Defect
-10

-15

-20

-25
0

Measure Point

40
30
20

( mV)

10
0
-10
20
-20
-30
-40
0

100

200

300

400

500

600

700

800

900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300
Dstance (m)

32 /2,400m
: 75m 1

(TB)

32

23

41

104

- (2-3m )
-
-
-

-500
-600

P/S pote
ential (mV
VCSE)

-700
-800

CP criteria

-900
900

TB 3
15.4mA

-1000
-1100
1100

TB 1
26.8mA

-1200

TB 9
25.2mA

TB 7
TB 6
19.2mA 34.3mA

TB 2
55mA

-1300

TB 8
0 mA

TB 5
11.4mA

TB 4
14 7mA
14.7mA

-1400
-1500
0

10

Distance (km)

CIPS !!!

Test points TP TP

(OFF)

(ON)

Defect

(43V, 7A)

(43.3V, 17.7A)

-850mV

-500
-1000

CSE(m
mV)

-1500
-2000

: -728mV

-2500
-3000
-3500
-4000
-4500
-5000

2400

2300

2200

2100

2006 ( , ): ,
: ,

2000

1900

1800

1700

1600

1500

1400

1300

1200

1100

1000

900

800

700

600

500

400

300

200

100

Distances(m)

(< 3000 ~5,000
5 000 ohm
ohm.cm)
cm)

Wenners four electrode method (ASTM G57)

(cm)

Defect

(43V, 7A)

(43.3V, 17.7A)

1.E+05

(ccm)

1.E+04

5,000(cm)

1.E+03

24
400

23
300

22
200

21
100

20
000

19
900

18
800

17
700

16
600

15
500

14
400

13
300

12
200

11
100

10
000

90
00

80
00

70
00

60
00

50
00

40
00

30
00

20
00

00
10

Distances(m)

(urgency of excavation)
(Immediate action required): I,
I II
(Scheduled action required): III, IV
(Suitable
(S it bl ffor monitoring):
it i ) V,
V VI

(minor)

(moderate)

(severe)

> 10,000 cm

5,000 10,000 cm

< 5,000 cm

CIPS

< -0.85V
0 85V

-0.85V
0 85V < < -0.75V
0 75V

> -0.75V
0 75V

CIPS

II

III
IV
V
VI

VI

13

32

12

11

41

(TB)

23

VCSE (mV)

1: D 63

CIPS

PCM

dBmA

2.5
2.0

1)

2)

3))

pH

: 80cm

2.8mm

3.1mm
2.1mm

1.5mm

10% (HCl)

(FeSx)
H2S


SRB

FeS x 2HCl xH2S Fe 2 2xCl (0 x 2)

3000

O
2000

Si

1000

S
Al

Fe

Ca
0
3000 0

2000

Fe

1000

Ca
Si

0
0

keV

S (SRB )

10

10

10

10

10

10

SRB (cells/g-soil)

10

10

10

10

10

SRB (cells/g-s
soil)

10

10

10

10

1
3

10

10

10

10

10

10

10

10

10

10

10

10

10

10

10

10

SRB (cells/g of soil)

S

10

10

10

10

( cm)

20

30

40

50

60

-0.2

0.0

0.2

0.4

Eh (V/NHE)

Clay Content (%)

9

10

10

10

10

10

10

APB (cells
s/g-soil)

SRB (cells
s/g-soil)

10

10

10

10

10

10

10

10

10

10

10

20

30

Water Content (%)

40

50

10

APB
2

10

10

10

10

10

10

10

SRB (cells/g-soil)

10

10

0.6

0.8


~
~
~*

~

SRB
() K
K. Kasahara
Kasahara, et al
al.,
Corrosion, 55(1) (1999) 74

2H2O 2e H2 2OH

.

: -950mV
950mVCSE

46

pH (~10)

2H 2 O 2 e H 2 2 OH
, OH- pH

pH
1)

2)

pH (
)

pH pH

pH

pH>10~11
pH>10
11

pH< 8

(ECDA) (
)

SRB

?
.

1)

2)

3)

( )

. ,

1)

: 1/TB1
,

2)

3)

4)

A.

1)

2)

3)

4)

5)

B. ECDA

2009.10.05. ~ 2010.08.30. (330)

(11.33km)

(25.12km)

R
Remote
t earth
th

(2.24km)

NO

10
11
12
1
2
3
4
5
6
/

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
(%)

100

90

100

20

100

100

100

()

100

100

0
0
0
0
0

(remote earth bed)

100

100

10

100

/
.
(, )

( )

()

STA 73
80V 9A

-300

- : ~0.2A
( 9A 2.2%)
2 2%)
: 11 ( 2A ,
2A/12A = 17% )

(STA 29+37.91)

-600

E,, mV

+()

-900

-1200

-1500

-15

-10

-5

Distance, m

10

15


(, , )

:
:

9A 3A () (~33%)

1) Metallic contact

2) Electrolytic contact

blacktop

blacktop

- ()
( , spacer )

( )
-

Potential (mV)

TB5

TB6
TB4

Time (day)

TB
(2p)

(3p)

TB
(3p)

(2p)

blacktop

Reference
electrode

1) / TB
2)

)
- (
3) (e.g., mortar)

: 11

: 30m

(, , , )

()

( 11)

8.1A (0.2x11 = 2.2A )

30m

7.1A (2.2A )

8.4A (2.5A )

2.5km
: 800mm
PE

12.8A

5.9A

- - ,

120% (5.9A 12.8A)

Wire or Wireless
Networks
(GSM, CDMA, RF,
Zigbee, etc)

GPS
GIS
Satellite
Communication

TB 1

Rectifier

Remote
Control
Rectifier

TB 2

Remote
Monitoring
Data Logger
Reference
Electrode

Anode

CP current

Rectifier

Remote
Monitoring
Data Logger

Remote
Control
Rectifier

Reference
Electrode

Anode

()

()

5,578

1,611

15,000

67

ON
OFF

0.0

0.2

0.6

0.8
ON: 6-26 18:30

(off): 06-08 15:00

1.0
START: 06-07 19:00

1.2
0

24

48

72

96

120

144

168

192

216

240

264

288

312

336

360

384

408

432

456

480

TIME,h

0.0
0.1
0.2
0.3
0.4

Potenttial,V CSE

Poteential,VCSSE

0.4

TB1

0.5

TB2
TB3

0.6

TB4

0.7

TB5
TB6

0.8
0.8

TB7
TB8

0.9
OFF

TB9

1
1.0
0
1.1

ON

START
1 2
1.2
0

24

48

72

96

120

144

168

192

216

240

264

Time,h

288

312

336

360

384

408

432

456

480

P/S

IR-free
IR free

CP criteria

Potenttial (mV)

TB5

TB6
TB4

Time (day)

19
18
17
16
15
14
13
12
11

+5V

10
9

1
2

7
6

6
7

8
9

10

13 11
12

4
15

-5V

19

18

14

16

17

T1-17

0
-0.83V

Potential, VCSE

-1

-2

T/B

-3

T1-18

-4

-5

T1 15
T1-15

T1 18 1
T1-18-1

-4.93V

-6
6
0

20

40

60

80

100

120

140

160

180

Time, s

T1-11
T/B
T1-12

T1-16
T1-14

T/B

()
(EPR)
()
T/B

-1

-2
Potential, VCSE

T1-13
T1 10
T1-10

-2.66V

-3
-3.00V

-4
0

20

40

60

80

100
Time, s

120

140

160

180

()
/
3,000km
3 000km 200km
100, TB 125

()

3,000km 400km
50, TB 406

BP

~ 5km (Rectifier 2, Data logger 10)

() -
20,
20 TB 8

Gas transmission pipelines

Municipal water pipelines
Gas distribution pipeline (Mokpo)
Samsungg BP Chemical
Planned (2010)

2010 30, TB 40

5
5.

/ (ECDA )

/ /

 4
CIPS

(ECDA )
(5~10)

POOR

DCVG

?
: -850 mVCSE
CIPS:

NO
or

NO

YES

< -850mVCSE ?

NO

<3000~5000
cm
YES

( )

YES
/
()

,
- : , CIPS, DCVG
- : ECDA

syli@correltech.com