corrosion control corrosion control of storage … · corrosion control by rafael e. rodríguez...
TRANSCRIPT
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CORROSION&
CORROSION CONTROL
By Rafael E. RodríguezJohn Bosco
Corrpro Companies, Inc.Preserve and Sustain Global Assets & Infrastructure
CorrproAn Insituform Company
Corrosion Control of
Storage Tanks
Liabilities to Assets
Presented by:
Rafael E. Rodriguez
Project Manager
Corrpro Companies, Inc.
Houston, Texas
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Corrosion Control of Storage TanksLiabilities to Assets
Cost of Corrosion
Definition of Corrosion
Common Causes of Corrosion
Corrosion Control
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According to a Study Conducted by The U.S.Department of Transportation’s FederalHighway Administration and NACEInternational the Total Cost of Corrosion in theUSA is $276 Billion/Year
– Utilities: $47.9 billion/year (34.7%)
– Transportation: $29.7 billion/year (21.5%)
– Infrastructure: $22.6 billion/year (16.4%)
– Government: $20.1 billion/year (14.6%)
– Product & Manuf: $17.6 billion/year (12.8%)
The Costs of Corrosion
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Traffic
Disruptions Water Loss
Fire
Protection
Legal &
Environmental
ClaimsDamages
The Costs of Corrosion
Product Loss
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Definition of Corrosion
Practical
Tendency of a Metal to Revert to its Native State
Scientific
Electrochemical Degradationof Metal as a Result of a Reactionwith its Environment
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STEEL CORROSION IRON OXIDE
IRON OXIDE REFINING MILLING
Definition of Corrosion
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Electrochemical Reactions
Fe Fe2+ + 2e- (iron oxidation)
H+ + 2e- H2 (hydrogen reduction)
½ O2 + H2O + 2e- 2OH- (oxygen reduction)
Definition of Corrosion
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Why Provide Corrosion Control?
Regulatory Compliance
Preserve Assets That Could Become LIABILITIES!
Dramatically Reduce Likelihood of Product Releases
Significantly Reduce Maintenance Costs
Environmental Preservation
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Metallurgical Differences Heterogeneous Electrolyte Low Resistivity Electrolyte Dissimilar Metals Oxygen Concentration Stressed Areas
Common Causes of Corrosion
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Elements of a Corrosion Cell
1) ANODE
2) CATHODE
3) ELECTROLYTE
4) ELECTRICALCONNECTION
Anode
-600mVCathode
-550mV
-575mV
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Anodic Area
-600mVCathodic Area
-550mV
SAND
CURRENT FLOW
External Corrosion of
Tank Bottom
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SANDCURRENT FLOW
Corrosion Cell Caused
by Foreign Material in
Sand Cushion
CLAY
Steel Tank Floor
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DRY
SAND
MOIST SAND
WATER
Corrosion Caused by
Poor Water Drainage
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New Bottom (Anode)
CURRENT FLOW
SAND
SAND
New Steel Coupled to Old Steel
Old Bottom (Cathode)
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CURRENT FLOW
Bimetallic Corrosion
Steel Tank
Floor
Copper
Ground
Rod
SANDCorrosion occurs
on tank bottom
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Anode Cathode
Water / Sediment
Fuel Product
Internal Corrosion
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Effect of Corrosion
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Preserve Assets
Reduce Maintenance Costs
Reduce Inspection Costs
Environmental Compliance
Preserve The Environment
Importance of Corrosion Control
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Approximately 25% of States now require
cathodic protection be installed and
maintained on new, refurbished, or repaired
tanks in contact with soil or sand
foundations.
A number of other states are in the process
of implementing regulations governing
AST’s.
State Level Requirements
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Proven electrochemical technique to stop corrosion
Used extensively in the oil and gas industry
Applied to new or existing structures
Cost effective
Minimum maintenance and easy to test
Cathodic Protection
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Galvanic Anode Cathodic Protection
Impressed Current Cathodic Protection
Cathodic Protection
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Galvanic Anode Cathodic Protection
Structure
(Cathode)
Magnesium
Anode
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Tank Floor
Soil
Wire
Anode
External Galvanic Protection
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CoatingAnode
Bolt
Tank Bottom
Internal Galvanic Protection
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Galvanic System
• Difficulty in meeting NACE -850mV
Criteria
• Sand Quality impacts anode
performance / life
• Typically Very Short Life / Poor Track
Record
• Not recommended for large diameter
AST’s
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Tank(-)(+)
Anode
Rectifier
Impressed CurrentCathodic Protection
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Distributed Anode CP System
Sand
Anodes
Rectifier
+
-
Concrete
Ringwall
Tank
AnodesRectifier
-
+
Tank
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Anodes
Junction
Box
Rectifier
Deep Anode CP System
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Directional Bore Under Tank for Anode or Reference Cell Placement
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3” PVC 20%
Exposure
Anode Material
Anode Tube
Test/Access
StationGrade
Aboveground
Storage Tank
Directional Bore Under Tank
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Prepackaged Linear AnodeUnder Tank Retrofit CP System
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Computer Guided HorizontallyBored Anode System
Tank
Rectifier
(+)
(-)
Anode
Splice Box
Anode
Pipe
Monitoring
Pipe
Anode Pipe
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New Tank Construction with Liner
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Anode
Reference
Cells
Tank
Junction
Box
(-)
(+)
Rectifier
Impressed Current CPStorage Tanks with Liner
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Anode & Reference Cell Placementin High Resistance Sand
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Liner
Floor
AnodeConduit
CP Installation on Double Bottom Tank
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Inspection of CP System
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• Easy test methods
• Established criteria
Cathodic Protection Testing
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Recommended Practices
API-651 - Cathodic Protection of Aboveground Petroleum Storage Tanks
NACE RP0193 - External Cathodic Protection of On-Grade Carbon Steel Tank Bottoms
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NACE Standard Recommended Practice
NACE Standard RP0193
Section 4.3.1.1. A negative cathodic potential of at least 850 mV-CSE with the cathodic protection applied. Voltage drops other than those across the structure to electrolyte boundary must be considered...
Section 4.3.1.2. A negative polarized potential of at least 850 mV-CSE
Section 4.3.1.3. A minimum 100 mV of cathodic polarization
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Summary
- Be aware of all regulations that may pertain to your tanks and piping. When in doubt talk to the governing agencies.
- Engage NACE qualified & experiencedpersonnel to engineer/maintain yourcathodic protection system.
- Refer to NACE/API Standards for guidance.
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THANK YOU
QUESTIONS?
CorrproAn Insituform Company