National Center for Corrosion Research and Education Chemical and Biomolecular Engineering Corrosion Forum. Homero Castaneda, Ph.D.
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1 Corrosion/damage assessment for coating/substrate underground pipelines Interfaces (Defining a failure vs. risk vs. reliability with multiscale concept) National Center for Corrosion Research and Education Chemical and Biomolecular Engineering Corrosion Forum Homero Castaneda, Ph.D.
2 Overview Liquid Oil & Gas - Pipelines have been the preferred mode of transportation over competing modes such as road and rail for several reasons: they are less damaging to the environment, less susceptible to theft, and more economical, safe, convenient, and reliable than other modes. Three different threats are identified in buried systems ASME B31.8S 2004 : Static (materials and construction) Time independent (third party, external damage) Time-dependent (IC, EC, SCC) corrosion is considered in each one 2
3 New concept: Damage evolution for organic coating/substrate Definition of a failure vs. risk vs. reliability Stage I Stage II Stage III Stage IV O 2 Cl - Cl - O 2 Cl - Cl - O 2 Cl - Initiation Coating/damage Transition Metal damage Grow/dissolution Hours-days-years Hours-years Days-years Days-years Time
4 Why multi-scale analysis? Castaneda et al, Journal of Solid State Electrochemistry, 2005, 9, From web site Hepel, Electrochimica Acta (2006), Small scale Transport mechanisms Characterization tools Random nature of the system Large scale Monitoring tools Damage evaluation Life time prediction Integrity and reliability
5 Example of application: Adaptation and enhancement of the technologies used for corrosion management for Mexican pipeline system Includes multiscale analysis for external corrosion, electrolyte/coating/metal 5
6 Motivation Integrity Management for Pipeline Network On shore Pipeline Network: ~*65, 000 km total Off shore Pipelines >100,000 km Gulf of Mexico and will be more >100 new platforms Mexico is the 3 rd crude provider to US Canada is 1 st 6
7 average magnitudes in mm precipitation during 86 years Adaptation of Step 1 Mathematical modeling for the electrolyte(soil)/interface(coating)/pipe Macro tools Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec Month of the year Location of the system is important due to climate, geographical and global position of the pipeline section. Electrolyte properties. 7
8 Water capacity layers (from 0cm to 1.20cm) 8
9 Ionic concentration (mmol/l) Macromodeling-micromodeling ph CO3= HCO3- Cl- SO4= Distance (km) 9
10 Analysis of information, Math-computer 10
11 States of the Coating/Steel Most models assume the damage function of the metal or the preexistence of coating damage. Initiation stage-water uptake time
12 Water Uptake process-initiation of degradation Electrolyte Coating Metal
13 Z'' Impedance Results with Time for Initiation -4e7-3e7 1EISC5z.z 2EISC5z.z 3EISC5z.z 4EISC5z.z 5EISC5z.z 6EISC5z.z 7EISC5z.z 8EISC5z.z 9EISC5z.z 10EISC5z.z -2e7-1e7 0-1e7 0 1e7 2e7 3e7 Z' NS 3 solution, ph=5.8 after 70 days of exposure
14 water uptake factor (phi) water uptake factor (phi) Deterministic Analysis to determine the initiation/growth threshold ph-10.3 ph-7.0 ph-5.8 Capacitor /water uptake with time ph-10.3 ph-7.0 ph time (days) NS4 solution log C( t) / 80 Co Time (days) NS3 solution
15 Statistical Approach Time dependent Time constant, t=70days
16 Capacitor vs. time Red dots observed Circle fitted Z eqi 1.119e e Ec 1.45e t 5.22e ph 9.4e Cl
17 Electrochemical set up for different conditions Constant immersion Wetting characteristics Cycling conditions w/o environmental parameters Fog or artificial chamber-design in construction with different % RH and wetness time
18 Electrochemical testing Micro and submetric scale Constant Immersion 18
19 Metric scale 19
20 Macro scale real scale validation of the laboratory and theoretical approach 20
21 Damage depth at the metal-damage of the system Simulation 30 um thickness, ph=5 60 um thickness, ph=5 100 um Thickness, ph=5 Reliability engineering in different corrosive environments failure definition
22 Topics for unification in corrosion science and engineering in substrate/coatings assessment for underground pipelines Complementary or new testing for damage evolution for coating/substrate system In situ sensing (real time monitoring) Deterministic and stochastic probabilistic modeling Multiscale modeling (macro-scale to nano scale) Characterization tools for coatings Reliability (failure defined in terms of mathematical, physical or standard criteria) 22
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