STRESS-CORROSION CRACKING DIRECT ASSESSMENT Current Research and Future Needs

Raymond R. Fessler BIZTEK Consulting, Inc.

820 Roslyn Place. Evanston. IL 847-733-7410 BIZTEKrrf@aol.com

Government/Industry Pipeline R&D Forum New Orleans

February 8, 2007
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SCC DA
Identifying locations of highest probability of SCC is critical to success NACE RP 0204 provides general guidance on factors to consider but little specific guidance Some companies have developed useful correlations from extensive dig programs or ILI runs
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J. A. Beavers and W. V. Harper, SCC Prediction Model NACExpo 2004

Gas transmission pipeline, primarily asphalt enamel coating, DSAW Near-neutral-pH SCC Conclusions
18 times more likely to find SCC with one manufacturer than with other manufacturers A 3 times more likely to find SCC with asphalt than with other coatings (coal tar, epoxy urethane, FBE and wax) (No tape coating on the line) 4 times more likely to find SCC with glaciofuvial soil than with lacustrine soil

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IPC04-0586: SCC Integrity Management Case Study - KinderMorgan Natural Gas Pipeline of America, J. D. Davis, et. al.
Near-neutral pH SCC on a gas pipeline Verified model with 6 digs
5 true positives 1 true negative No false positives or negatives

Three important parameters

Mild corrosion (<10% w.t.) determined with high-res. MFL tool Intact (but disbonded) asphalt coating as determined from closeinterval on/off P/S survey (No SCC under coal tar) Alluvial deltaic modified sands where drainage was influenced by topography

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IPC04-0267: A Statistical Model for the Prediction of SCC Formation Along a Pipeline, O. Youzwishen, et. al.
Tape coated, ERW, liquid pipeline Near-neutral-pH SCC Model based on ~120 digs, confirmation based on 11 digs
7 true positive, 1 true negative, 3 false positives 48% of corrosion digs found SCC

Most important parameters: Proximity to mild corrosion and CP level Other relevant parameters: CP shift, ground depression, bend angle of the pipe, direction of the bend More confirming activities are planned
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IPC04-0375: SCC Detection and Mitigation Based on In-Line Inspection Tools, W. Kresic, et. al.
1

Near-neutral-pH SCC on liquid line Developing correlation with pressure cycles and soil/terrain

0.9

R Ratio

0.8

0.7

0.6

0.5 1.0E-05 1.0E-04 1.0E-03 Frequency, Hz 1.0E-02

1.0E-01

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The Enbridge 15-5-1 Approach

- Loading Rate Analysis
Line A SCC Loading Rate Analysis Normalized Against Line B-2001Q4-Pressure Analysis.xls Enbridge 15-5-1 Weighting Factors

Data can be analyzed for different operating pressure ranges

1.25 1 Loading 0.75 Rate Analysis 0.5 0.25 0

20 05 20 Q2 05 20 Q1 04 20 Q4 04 20 Q3 04 20 Q2 04 20 Q1 03 20 Q4 03 20 Q3 03 2 0 Q2 03 20 Q1 02 20 Q4 02 20 Q3 02 20 Q2 02 2 0 Q1 01 20 Q4 01 2 0 Q3 01 20 Q2 01 2 0 Q1 00 20 Q4 00 2 0 Q3 00 20 Q2 00 1 9 Q1 99 19 Q2 99 1 9 Q1 98 19 Q4 98 19 Q3 98 19 Q2 98 19 Q1 97 19 Q4 97 19 Q3 97 19 Q2 97 19 Q1 96 19 Q4 96 1 9 Q3 96 19 Q2 96 Q 1

Station 6 Station 5 Station 4 Station 3 Station 2 Station 1

USCD ILI tool: Stations 1,2,3, and 4 shallow SCC (metal loss -ML) Stations 5 and 6 shallow (ML) + significant SCC
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Quarter

Factors Correlating with SCC Sites from Past Field Studies

High pH Gas P/Ls Proximity to other SCC failures Discharge of compressor station Suction of compressor station Temperature Class I location Age (> 15 years) Coating type (tape, coal tar, asphalt) Coating condition (disbonded) Soil moisture level Mild corrosion Stress cycles (R & frequency) Soil type Terrain Strong Strong Negative Strong Strong Strong Strong Strong Medium None ?? None Weak NN pH Gas P/Ls Strong Medium 1 case None Strong Strong Strong Strong Medium Medium ?? Area specific Area specific NN pH Liquid P/Ls Strong Medium Medium None Strong Strong Strong Strong Medium Medium Strong Area specific Area specific

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SCC DA -- Current Research

Guidelines for the Identification of SCC Sites and the Estimation of Intervals for SCC DA
NRTC plus various subcontractors Funding from PHMSA and PRCI Initial approach: Mechanistic model based upon information from literature Added approach: Validate model with field experience from industry survey
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SCC DA -- Current Research

SCC Data Mining
BIZTEK Consulting plus subcontractors Funding from PRCI Approach: Correlate severity of SCC as determined from ILI, hydrotesting, or extensive dig programs with operational and environmental factors
Gas and liquid pipelines High-pH and NN-pH SCC

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SCC DA -- Current Research

JIP on Management of SCC in HCAs on Gas Pipelines
BIZTEK Consulting and Macaw Engineering Funding from El Paso, Great Lakes, Panhandle, Spectra, and TransCanada Approach: Develop more specific guidelines based upon industry experience

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SCC DA -- Current Research

Field Studies to Inspect for SCC
Various pipeline companies Self funded Approach: Develop algorithms for locating SCC based upon ILI, hydrotest, or dig programs

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SCC DA -- Remaining Gaps

Crack growth rate models based on measurable parameters, with emphasis on the effects of pressure fluctuations
Useful for selecting sites, determining intervals, and possibly prevention or mitigation Parameters
High pH and NN pH High and low amplitudes, high and low frequencies Differentiate between corrosion fatigue and SCC

More field correlations

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