Corrosion Prevention

for Steel Water Pipe

Presented to:

Water Wastewater Section

AUCSC
Northwest Pipe Company
Presenter: Ronald S. Brown
 Steel Water Pipe
Corrosion Prevention

Presentation Overview

History

Applications Steel Pipe Manufacturing

Pipe Coatings-Importance Corrosion Prevention, Asset Mgt.

History and Overview

Applications

Water Transmission
History and Overview-

Manufacturing Capabilities
z Spiral welded pipe
– 17” to 156” diameter
– Lengths up to 60’
– 0.105” to .875” wall thickness
z Rolled & welded pipe
– ≥42” X 2.0”
z Linings and coatings
– CML, epoxy, polyurethane, & paint systems
– CMC, CTE, tape, Pritec®, epoxy, polyurethane, & paint
z End treatments
– Welded & non-welded gasket joints
History and Overview

Applications

Water transmission pipe Gasketed joint

History and Overview

Applications

Power Plant Long Spans

History and Overview

Applications

Horizontal Directional Drilling

Engineered Systems

Field fit-ups
History and Overview

Secaucus NJ 72” Lock-Bar Pipe

– 1919. (Riveted Pipe 1904)
History and Overview

Applications

Sanitary Force mains with push-on,

restrained or flanged joints
 Corrosion Protection

Polyurethane Lining
Steel Basics
AWWA Standards Conformance
z Steel water pipe per M-11 Design Guide
– C200--Manufacturing Standard
z Fabrication/fittings
– C208
z Flanges
– C207
z Linings & coatings : C205, C209, C210,
C214, C216, C218, C222
 Design
Criteria
Welded Steel Pipe - AWWA C-200
Northwest Pipe Company

Pressure Class Design

AWWA DESIGN GUIDE--M-11

1. Internal pressure
2. Handling
3. External load
4. Joints both push-on and restrained
5. Corrosion protection
Northwest Pipe Company
Steel
C200 Steel Yield Point
Grades psi
ASTM A1011 GR 30-70 30,000-70,000
ASTM A1018 GR 30-70 30,000-70,000
ASTM A139 GR B,C,D,E 35,000-52,000
ASTM A570 GR 33-50 33,000-50,000
ASTM A36 36,000
Back to Basics of Design...
Spiral Welded Pipe Rolled & Welded Pipe
Photos Photo

Return to Engineered Systems

Additional Services

Hydro Testing
z AWWA & ASTM
Standards
– 75% of yield of steel
Engineered Systems

Joint Systems

Typical Pipeline Joints

O-ring Joint Lap Joint

Butt Strap Joint Butt Weld Joint

Engineered Systems

Joint Systems

Bell and Spigot Lap Weld

z Used for higher pressures or other critical

locations
z Bell can be mitered for greater angular
deflection
z Restrained, providing economical thrust
resistance
z Can be welded ID or OD
Engineered Systems

Joint Systems

Bell and Spigot O-ring

z Economical push-together assembly

z Suitable for typical operating pressures
z Can accommodate some angular deflection
z Non-restrained
z Rolled groove provides economy
 Basic Considerations
Corrosion Control--Slow down rate--defined
service/design life
Corrosion Protection /Prevention
z Pipelines will operate indefinitely without failures
from natural or manmade corrosive environments.
Protection of taxpayer and/or owner
investment –ASSET MANAGEMENT
z The pipeline will operate continuously for as long as
needed with the lowest full life-cycle cost.
Design Criteria

How can we protect our pipeline

infrastructure for 100 plus year
design life?
z High-quality coatings
z Electrical continuity—for gasket joints
z Test stations
z Cathodic protection- Use an independent
NACE corrosion specialist who will follow NACE
SP0169 standards
z ISOLATION of dissimilar pipe systems if needed
“Control of External Corrosion
on Underground or
Submerged Metallic Piping
Systems”
NACE Standard SP0169-2002
“This standard presents
acknowledged practices for the
control of external corrosion on
buried or submerged steel, cast iron,
ductile iron, copper, and aluminum
piping systems.”
 Cathodic Protection
Definition ( NACE
International )

“ A technique to reduce the

corrosion of a metal surface
by making that surface the
cathode of an electrochemical
cell ”
 Types of Cathodic
Protection

– Galvanic
• Current supplied by metal more
anodic than the structure (pipe)
• Naturally occurring current flow
– Impressed Current
• Current supplied by electrical
device to convert AC to DC current
• Forced current flow--through rectifiers
and groundbeds
EXTERIOR COATINGS
Expectations of a coating
z Long term protection from
Corrosion, MIC, stray currents
z Tight bond to surface (adhesion)
z Ease of Installation/Maintenance or
Repair
z Compatible with Cathodic Protection
z Cost effective
 Design Criteria

Corrosion Protection
z Cementitious--Coatings
– Raises pH
z Bonded Dielectric Coating
– Eliminates all corrosion including Stray Current
Migration
– Eliminates Oxygen & Water
migration,eliminates corrosion
Steel Water Pipe

Exterior Coatings
Common Coatings
seen in U.S.
z Dielectrics z Cement Mortar
– PE Tape (80 mils)30” or grout (¾” thick)
up
– Spray-applied Systems
• Polyurethane (25 mils)
• Epoxies (16 mils)
• Zinc (4 mils)
– Wax Tapes
– Fusion Bond Epoxy (12
mils) API pipe—not avail for
spiral weld pipe
– Coal Tar Enamel (3/32”)
Steel Water Pipe

Common AWWA Standards

Pipe Cylinder Linings
•AWWA C200 - Manufacture •AWWA C205 - Cement Mortar
•AWWA M11 - Design •AWWA C210 - Epoxy
Flanges •AWWA C602 - Field Applied Mortar
•AWWA C207 •AWWA C222 - Polyurethane
Welding Coatings
•AWWA C206 •AWWA C203 - Coal Tar Enamel
•AWWA C205 - Cement Mortar
Fittings •AWWA C209 - Joint Tape
•AWWA C208 •AWWA C210 - Epoxy
•AWWA C214 – Tape
•AWWA C215 - Pritec
•AWWA C216 - Heat Shrink Sleeves
•AWWA C218 - Exposed Paint Systems
•AWWA C222 - Polyurethane
 Corrosion Protection

Coatings--per AWWA Criteria

z Cement--C205
z Dielectric
– Bonded PE Tapes--
C214
– Paint systems
• Epoxies-C210
• Polyurethane-C222
Diversity of Materials Requirements
C-210 16 mil 400 lb/sq in Vapor Trans RPO 188 1978
C-213 12 mil Knife test NA RPO 490 1979
C-214 50-80 mil 200 oz/in width 0.20% 6000 V min 1983
C-215 49-69 mil NA 0.20% RPO 274 1988
C-216 40-60 mil 8 lbs/lin in Vapor Trans Required 1989
C-217 wax 40 mil NA Vapor Trans NA 1990
C-218 3.5 -14 mil V cut NA NA 1991
C-222 20-25 mil 750-2000 psi 3.00% RPO 188 1999
C-224 nylon 24-40 mil 2000 psi 2.70% RPO 188 2001
C-225 50-75 mil 32 ft lb/ in width0.20% RPO 188 2003

All above standards require a min SSPC SP 6 /NACE 3 blast cleaning

Familiar Knowledge ?
 Field Joint Coating per
AWWA C-205
Place diaper around Assemble joint and pour
pipe soupy cement mixture
from one side of diaper
Expectations of a lining
z Good Flow Characteristics
z Protects Pipe from Corrosion and
Abrasion
z Ease of Installation/Maintenance
z Cost effective
 Corrosion Protection

Linings
z Cement
z Paint systems
– Epoxies
– Polyurethane
Steel Water Pipe

Interior Linings

Cement Mortar Lining

z Stulls used for
shipping and handling
z Joint recess usually
pointed
z Easily repaired and
modified in the Field
z Low Cost
Interior Joint Grouting
Pack joint with Remove excess grout
grout
Polyurethane coatings
z AWWA C-222
z 25 mils Thickness
z Extremely
abrasion resistant
z sensitive to blast
and temperature
z Good dielectric
strength
z More costly
Corrosion Protection
POLYURETHANE COATING--AWWA C222
Polyurethane Coating
Repair
AWWA C-222
Repair coating if
necessary
PAINTED COATINGS

Epoxies
Zinc Rich Paints
Primers
AWWA C214-Machine Applied Polyethylene
Tape

YGIII®® System
YGIII System Components
Components
956 UVI OUTER LAYER
955 MIDDLE LAYER
989 INNER LAYER

PRIMER
Linings and Coatings

Tape Coating
Steel Water Pipe

Exterior Coatings
AWWA C214 Tape
z 80-mil, three-layer factory
applied system
z Effective as dielectric
coating
z Ease of field use
z 25+ year history in water
industry ( 50 oil & gas)
z Low Cost
Advantages of Shop Applied
Multi-Layered Coatings ,per
AWWA C214
zProven long-term Performance
z Highest Dielectric Strength
zWorld Class Coating System
zUtilized on High-Pressure Oil & Gas TM
zImpermeable to Oxygen & Water
zLow Cathodic Protection Current Requirements
zAdhesion to primed steel--exceeds 300 oz/in
zCathodic Disbondment Results G8--.25 in radius
zEasily Repaired on the jobsite--with field tape
zPE backings--identical to landfill liners--
 Water
Water Absorption
Absorption
ASTM
ASTM G-62
G-62
33

2.5
2.5
Absorbed
Water Absorbed

22

1.5
1.5
% Water

11
%

0.5
0.5

00
Coal
Coal Tar
Tar Fused
Fused Epoxy
Epoxy YG-III
YG-III
Method of Delivery
z Flat Bed Truck
z Vans
z Rail
z Barge
Stringing/Storing Pipe
z Stringpipe in accordance with the
supplied lay diagram/schedule
z Place pipe on dirt berms, padded
boards, or sand bags
Pre-Installation Prep Work
z Inspect factory applied coating
– Visual
– Mechanically with Holiday testing
equipment
– Repair all damage to coatings
Polyethylene Coating Repair
AWWA C-209
Repair coating if
necessary
Engineered Systems

Joint Completion
z Joint bonding
– Gasketed joints
– Electrical continuity
– Allows monitoring
– Provides for future CP
Engineered Systems

Joint Completion

Hand-applied tape
Heat-shrink sleeve

Return to Engineered Systems

Field Joint Coating
Shrink Sleeves per AWWA
C-216
Shrink Sleeves applied with propane
torch
Corrosion Protection Methods
in Any Soil Environment
GRADE

TERMINAL BOARD
TEST BOX ANODE HEADER
CABLE
TEST LEADS THERMITE ANODE HEADER
WELDED TO PIPE CABLE SPLICE

PIPELINE REFERENCE ELECTRODE

ANODES
In -Ground Performance
In-Ground Performance
Š Bell hole examinations
9 no coating degradation

Š CP survey
9 2 to 6 µA per ft2
9 > 99.95% coating efficiency
Discussion Points
Discussion Points
Discussion Points
Discussion Points
Cost - to - Benefit
Ratio

7 - to - 1
Save $7 for every $1
spent
 Steel Water Pipe

Exterior Coatings
Polywrap not recommended

•Not tightly BONDED to pipe

•Easily damaged during installation – 8 mils
•Does not prevent moisture (perforations and
joint leakage) from forming corrosion cell.
•Cathodic Shielding
•Encasement not a coating
•DOES NOT COMPLY WITH NACE SP01-69-02
Steel Water Pipe

Corrosion Engineering

Common Corrosion Protection

Practices for Buried Pipe
z Use high-quality proven bonded coatings
z Assure electrical continuity with bonded joints or
welding.
z Install test stations for periodic monitoring
z Use cathodic protection as specified by corr. report
z Isolate Pipelines as necessary
Corrosion Prevention for
Steel Water Pipe

Questions?