Coatings in Conjunction with Cathodic Protection

Course Outline

Basic Corrosion Theory and CP Fundamentals

Corrosion and Corrosion Control
Basic Chemistry
Elements
Atoms
Ions
Compounds (Molecules)
Acidity and Alkalinity (pH)
Basic Electrochemistry
Oxidation and Reduction
Oxidation
Reduction
Electrochemical Circuits
Electrolyte
Ionization
Corrosion Cell
Anode Reactions
Cathode Reactions
External Circuit
Charge Transfer in the Electrolyte
Conventional Current Flow
Use of Voltmeters
Voltmeter Hook Up
Polarity Sign
Sign Convention

NACE International 1
 Reference Electrodes (Half-Cells)
General
Copper-Copper Sulfate Electrode
Cathodic Protection
Theory
Definition
Galvanic Anode Systems
Anodes
Applications of Galvanic Anode Systems
Advantages of Galvanic Anodes
Limitations of Galvanic Anodes
Component Parts of Galvanic Systems
Anode Materials
Magnesium
Zinc
Aluminum
Galvanic anode efficiency
Specifications of Galvanic Anode Systems
Size and Shapes
Backfill
Attachment to Structures
Impressed Current Systems
Anodes
Power Sources
Applications of Impressed Current Cathodic
Protection
Advantages of Impressed Current Systems
Limitations of Impressed Current Systems
Component Parts of Impressed Current Systems
Anodes
Graphite (carbon)
High silicon iron
Platinum
Aluminum
Magnetite

NACE International 2
 Mixed metal oxide
Conductive polymer
Scrap metal
Lead-silver
Backfill
Electrical Connections
Power Supply
Rectifiers
Solar panels
Engine-generator units
Wind powered generators
Thermoelectric generators
Closed Cycle Vapor Turbogenerator
(ORMAT®)
Factors Influencing Operation of Cathodic Protection
Moisture Content of Soil
Coating
Soil Texture
Clay and Silt
Sand and Gravel
Glacial Till
Temperature
Oxygen Content
Movement of Structure and Electrolyte
Make up of the Electrolyte
Electrical Shielding
Metal
Dielectric
Criteria for Cathodic Protection
NACE International Recommended Criteria
General
IR DROP
Underground or Submerged Iron and Steel
Application of these criteria

NACE International 3
 Underground or Submerged Aluminum and Copper
Piping
Dissimilar Metal Situations
Offshore Platforms in Salt Water
Interiors of Steel Water Storage Tanks
Oil Heater-Treaters
Above Ground Storage Tanks
Other International Standards
British Standards Institute
Norway - Det Norske Veritas Industri Norge AS
Canada
Germany
Japan
Australia

Structures with Coating and Cathodic Protection

Environmental Affects on the Corrosion Rate
Marine (offshore oil rig and ships)
Industrial, high humidity (coastal oil refinery, chemical plant)
Industrial, low humidity (inland oil refinery)
Rural, low humidity (inland rural railroad bridge)
Pipelines and Related Structures
Code of Federal Regulations – Coating Requirements
Coating Performance
Other Structures that can be Coating and Cathodically Protected

Cathodic Protection and its Relationship to Coatings

Electrochemical Circuits
Coatings
Effects of cathodic protection on the coating through electron exchange
Chemical reactions
Reduction
Oxidation Reactions
Essential Coating Characteristics (Corrosion Prevention by Protective Coatings
C. G. Munger)

NACE International 4
 Water resistance
Water Absorption
Moisture Vapor Transfer
Hydrogen Evolution and Over voltage
Pourbaix Diagrams
Susceptibility to Hydrogen Damage
Cathodic Protection Polarization
Current Requirements
Use Coating Damage Factors (DNV-RP-B401)
Coating Conductance (NACE Standard TM0102)
Cathodic Disbondment

Surface Preparation and Coating Application

Surface Preparation Overview
Surface Cleanliness
Surface Preparation Standards and procedures
Blast Cleaning
Dry Grit Blast Cleaning
Blast Cleaning Equipment
Direct Pressure Unit
Blast Cleaning Equipment
Vacuum Unit
Suction Unit
Jet-Feed System
Blast Cleaning Cabinets
Centrifugal Blast “Wheelabrators”
Manual Blasting Technique
Surface Profile
Surface Profile Coupons
Keane-Tator Surface Profile Comparator
Replica Tape
Dial Gauge Depth Micrometer
Other Profile Measuring Techniques

NACE International 5
Coating Application
Application Methods
Coating Application by Brush and Roller
Brush Application
Roller Application
Pressure Rollers
Finish Coat Appearance
Coating Application by Conventional Spray
Conventional Air Spray
Advantages
Disadvantages
Airless Spray
Advantages
Disadvantages
Spray Safety Overview
Fire and Explosion Hazards
Breathing Apparatus
Air-Supplied Hood Respirator
Air-Supplied Mask Respirator
Organic Vapor Cartridge Respirator
Dust Respirator
Personal Protective Equipment
Conventional Spray Equipment
Conventional Air Spray - Air Control Equipment
Coating Application by Airless Spray
Airless Spray Safety
Airless Spray Equipment
Airless Spray Pumps
Airless Spray Material Containers
Airless Spray Hose and Fittings
Hose Safety
Airless Spray Guns
Selection of Airless Spray Tips
Airless Spray Application Technique
Spray Techniques

NACE International 6
 Operation
Airless Spray Guns: Selection of Tips
Adjustable Spray Tips
Tip Cleaners
Paint Mixing
Applying the Coating
Corners and Edges

Nondestructive Test Instruments

Wet Film Thickness Checks
Wet-Film Thickness Gauge
Procedure for using a wet-film Gauge
Dry-Film Thickness Checks
Magnetic DFT Gauges
Potential Problems with Magnetic Probes
SSPC-PA 2 - DFT Measurement with Magnetic Gauges
Magnetic Pull-Off DFT Gauge
Pencil Pull-Off (SSPC PA 2 Type 1B)
Constant Pressure Probe DFT Gauge
Calibration
Calibration Procedure Using NIST Standards
NIST Calibration Standards
Calibration Using Nonmagnetic Shims
Edge Effect
MIO Pigmented Paints

Holiday Detection
Low-Voltage (Wet Sponge) Holiday Detector
High-Voltage Pulse Type DC Holiday Detector
High-Voltage AC Holiday Detector

Coatings Used in Conjunction with Cathodic Protection

Types of Pipe Coatings
Desirable Properties of a Pipe Coating
Durable bond to the pipe

NACE International 7
 Moisture Resistance
Mechanical Strength
Dielectric Strength
Cathodic Disbondment
Economics
Resistance to Soil Chemistry and Bacteria
Aging
Methods of Application
Storage and Handling
Exposure to Sunlight
Types of Mill Applied Underground Coatings
Bituminous Enamels
Extruded Polyolefin and Polyethylene
Tape Coatings
Fusion Bonded Epoxy
Two-Component Liquid Resin Coatings
Girth Weld and Other Field Coatings
Field Surface Preparation
Field Application
Inspection Procedures
Importance of Temperature of Substrate on Liquid Coatings
Curing Mechanism
Introduction
Types of Cured Coatings
Solvents
Characteristics of Solvents
Evaporation Rate
Aliphatic Hydrocarbon Solvents
Aromatic Hydrocarbon Solvents
Ketone Solvents
Ester Solvents
Alcohol Solvents
Alcohol Ethers/Glycol Ethers
Miscellaneous Solvents
Solution Kickout

NACE International 8
 USA Regulations on Volatile Organic Compounds (VOCs)
Weather Conditions

Fusion-Bonded Epoxy Pipeline Coatings

Introduction
Application Process for FBE
Plant Layout
Pre-inspection Station
Surface contaminants (visible and/or invisible soluble chemical
salts)
Pre-clean Station
Pre-blast Station
Abrasive-Blast Cleaning Station
Vacuum Cleaning Station
Pipe Grinding Station
Chemical Pre-treatment Station
Heating Station
Powder Application Station
Water Quenching or Air Cooling Station
Final Inspection Station
DFT Measurements
Holiday Inspection
Repairs to Holidays
Pipe Identification Markings
Preparation of Pipe for Storage or Loading Out
Laboratory Testing
Installation of FBE-Coated Pipe
Coating Field Welds
Variation in FBE Coatings

Multi-layer coatings and Extruded Polyolefin

Introduction
Plant applied specifications
Plant application process
Field applied specifications

NACE International 9
 Repairs

Coal Tar Enamel and Asphalt Enamel

Plant applied specifications
Coating Performance
Plant application process
Surface Preparation
Coating Application
Inspection and Testing
Coating System Inspection
Holiday Inspection
Adhesion Testing
Cathodic Disbondment Testing
Field applied specifications
Field application process
Hand Application
Repairs
Coal Tar Enamel
Coal Tar Epoxy Coatings
Inspection Criteria for Coal Tar Epoxy
Coal Tar Epoxies

Liquid Coating Systems

Performance Requirements
Field applied specifications
Surface preparation
Field application process
Repairs
Rehabilitation
Chemically Induced Polymerization Coatings
Epoxy-Two Component (co-reactive) Coatings
Epoxy-Modified Phenolic Coatings
Inspection Criteria for Epoxy-Modified Phenolic Coatings
Heat-Induced Polymerization Coatings
Epoxy-Phenolic Coatings

NACE International 10
Tape coatings
Plant Applied Specification
Field Applied Specification
Polyethylene Tapes
Tape Application
Stationary Plant
Field Application
Some Problems with Pipeline Tape Coatings
“Fail-Safe” Tape Coatings
Coating Disbondment from Soil Stress
Fail-safe Tape System
Test Results
Disadvantages of Fail-safe Coatings
Conclusions

Petrolatum and wax Coating Systems

Petrolatum Tapes
Typical Uses for petrolatum
Application
Wax Tapes
For underground applications
For aboveground use:
Pipeline reconditioning
Pipe Wrap Description
Rehabilitation
Girth Weld Coating
Pile-Shield System

Shrink Sleeves
Field applied specifications

Asphalt Mastic
Field applied specifications

NACE International 11
Urethanes & Polyureas
Plant applied specifications
Plant application process
Field applied specifications
Field application process
Repairs
Rehabilitation
Abrasive resistant overcoats
Plant applied specifications
Plant application process
Repairs

Concrete Coatings
Concrete Coated Pipe
Coating Selection (related to the environment)

Synergistic Relationships
Effects between Coating and CP
Dielectric strength of coatings
Coating conductance
CP shielding
Disbonded coatings
Cathodic disbondment
Other causes of disbondment
Soil Stresses
Poor Surface Preparation
Temperature
Microbiological Influence Corrosion
Chemical Attack
Other reasons for coating failures
Determining CP requirements vs. coating breakdown
Coating Damage Factor
Current Requirements for Coated Pipelines
Recommendation for removal of asbestos containing coal tar and asphalt
coatings safely

NACE International 12
Coating Performance Testing
Cathodic disbondment testing
Hot water soaks
Flexibility
Dielectric strength
Adhesion
Stretch (tapes) or peel strength
Abrasion Testing
Fail-safe properties
Coating Disbondment from Soil Stress
Fail-safe Tape System
Disadvantages of Fail-safe Coatings
Conclusions
Soil Stress
Coating Thickness Testing
Magnetic DFT Gauges
Holiday detection
Low-Voltage (Wet Sponge) Holiday Detector
High-Voltage Pulse Type DC Holiday Detector
High-Voltage AC Holiday Detector

Inspecting Buried Pipeline Coatings

Finding Failed Coatings
CP requirements
NACE International Recommended Criteria
Underground or Submerged Iron and Steel
Offshore Platforms in Salt Water
Interiors of Steel Water Storage Tanks
Oil Heater-Treaters
Above Ground Storage Tanks
Internal inspection tool data (smart pig)
MFL for Metal Loss
UT for Metal Loss
Bell Hole Inspection
The ECDA Standard - NACE Standard RP0502

NACE International 13
 Pre-assessment (Step 1 of ECDA)
ECDA Indirect Inspections (Step 2 of ECDA)
Close Interval Potential Survey (CIS)
Direct Current Voltage Gradient (DCVG)
ACVG
ACVG Equipment
Procedure
Pearson Survey
Electromagnetic Tools
AC Current Attenuation Survey (Electromagnetic)
Equipment
Procedure
Evaluation of Indirect Inspections

Excavation Examination
ECDA Direct Examinations (Step 3 of the ECDA Process)
External direct examination
Inspecting Buried Pipe Coating
Pipeline Excavation/Assessment – General
CP Measurements (Pipe-to-soil)
Condition of Coating
pH Measurements
Identification of Deposits
Structure Failure
Determine type of failure
Determining failure cause
“Fail-safe” coatings
Pre-Excavation
Location Verification Methods
Excavation
Prior to Coating Removal
Coating Evaluation / Removal
Pipeline Condition As-is
Laboratory Analysis
Feature Assessment and Defect Repair Criteria

NACE International 14
 Data Requirements
Industry Standards

Evaluating Corrosion
Pipeline Industry
External corrosion Attack
Pressure and Stress
MOP for Pipelines
Materials Behavior
Comparison between ASME B31G and RSTRENG
Corrosion Assessment Criteria
Flow Stress
Folias Factor
Area Calculation
Safety Factors
Safe Operating Pressure
Measuring Corrosion
Hand tools
Ultrasonic Thickness Gauges
Documentation

NACE International 15