BEST MANAGEMENT PRACTICE

Mitigation of External Corrosion

on Buried Pipeline Systems

June 2009

2009-0011
The Canadian Association of Petroleum Producers (CAPP) represents 130
companies that explore for, develop and produce more than 90 per cent of
Canada’s natural gas and crude oil. CAPP also has 150 associate member
companies that provide a wide range of services that support the upstream oil and
natural gas industry. Together, these members and associate members are an
important part of a $120-billion-a-year national industry that affects the
livelihoods of more than half a million Canadians.

Review by July 2013

Disclaimer

This publication was prepared for the Canadian Association of Petroleum

Producers (CAPP). While it is believed that the information contained herein is
reliable under the conditions and subject to the limitations set out, CAPP does
not guarantee its accuracy. The use of this report or any information contained
will be at the user’s sole risk, regardless of any fault or negligence of CAPP or
its co-funders.

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 Contents

Overview ...................................................................................................................................1

1 Failure Statistics (Alberta) ...........................................................................................2

2 Corrosion Mechanisms and Mitigation.......................................................................3

2.1 Localized and General Corrosion ...................................................................3
2.2 Soil Types.........................................................................................................4
2.3 Plant Applied Protective Coatings..................................................................4
2.3.1 Thermally Insulated Pipelines ............................................................6
2.3.2 Field Applied Protective Coatings .....................................................6
2.3.3 Installation Quality for Field Applied Coatings ................................7
2.3.4 Coating Degradation – Heat Damage, Disbondment & Blistering ..8
2.3.5 Coating Degradation - UV Damage...................................................9
2.3.6 Shielding of Cathodic Protection Current..........................................9
2.4 Contributing Factors........................................................................................9
3 Recommended Practices ............................................................................................13

4 Corrosion Mitigation Techniques..............................................................................18

5 Corrosion Monitoring Techniques ............................................................................19

6 Inspection Techniques ...............................................................................................20

7 Leak Detection Techniques .......................................................................................21

8 Repair and Rehabilitation Techniques......................................................................22

9 Additional Resources .................................................................................................24

Figures
Figure 2-1: Operating Pipeline Failures Caused by External Corrosion...........................................2

Tables
Table 2-1: Soil Resistivity Effect on Corrosion Rates4 ......................................................................4
Table 2-2: Contributing Factors and Mitigation of External Corrosion.................................... 10-12
Table 4-1: Recommended Practices - Design and Construction ............................................... 13-15
Table 4-2: Recommended Practices - Operating ........................................................................ 15-17
Table 5-1: Corrosion Mitigation Techniques....................................................................................18
Table 6-1: Corrosion Monitoring Techniques ..................................................................................19
Table 7-1: Inspection Techniques......................................................................................................20
Table 8-1: Leak Detection Techniques ....................................................................................... 21-22
Table 9-1: Repair and Rehabilitation Techniques ...................................................................... 23-24

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Recommended Practice for the Mitigation of External
Corrosion on Buried Pipeline Systems
Overview

Corrosion is a dominant contributing factor to failures and leaks in pipelines. To

deal with this issue, the CAPP Pipeline Technical Committee has developed
industry recommended practices to improve and maintain the mechanical integrity
of upstream pipelines. They are intended to assist upstream oil and gas producers
in recognizing the conditions that contribute to pipeline corrosion incidents, and
identify effective measures that can be taken to reduce the likelihood of corrosion
incidents.

This document addresses the design, maintenance and operating considerations

for the mitigation of external corrosion on buried pipelines constructed with
carbon steel materials. This document does not address failures due to
environmental cracking such as stress corrosion cracking (SCC) and hydrogen
induced cracking (HIC).

This document is complementary to CSA Z662 and supports the development of

corrosion control practices within Pipeline Integrity Management Programs, as
required by CSA Z662 and the applicable regulatory agency. In the case of any
inconsistencies between the guidance provided in this document and either Z662
or regulatory requirements, the latter should be adhered to.

This document is intended for use by corrosion specialists involved with the
development and execution of corrosion mitigation programs, engineering teams
involved in the design of gathering systems, and operations personnel involved
with the implementation of corrosion mitigation programs and operation of wells
and pipelines in a safe and efficient manner. It contains a consolidation of key
industry experience and knowledge used to reduce external corrosion; however, it
is not intended to be a comprehensive overview of all practices.

Additional corrosion mitigation recommended practices available are:

• Best Management Practice for Mitigation of Internal Corrosion in Sour
Gas Pipeline Systems
• Best Management Practice for Mitigation of Internal Corrosion in Sour
Gas Pipeline Systems
• Best Management Practice for Mitigation of Internal Corrosion in Oil
Effluent Pipeline Systems
• Best Management Practice for Mitigation of Internal Corrosion in Oilfield
Water Pipeline Systems
These documents are available free of charge on the CAPP website at
www.capp.ca.

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Recommended Practice for the Mitigation of External
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1 Failure Statistics (Alberta)

• In 2008, 13% of the total incidents in Alberta were due to external corrosion.

Unknown (17),
2% Earth Mo vement
(13), 1%
Operator Error Overpressure
(21), 2% (21), 2%
Weld Failure
(Girth or Seam
Rupture) (24), 2%

Mechanical or
Valve/Fitting
Failure (82), 8%
Internal Corrosion
(384), 39%
Construction
Damage/
Installation
(93), 10%

External
Miscellaneous/ Corrosion
Pipe Failure (131), 13%
(90), 9%
Damage by
Others (98), 10%

Figure 1-1: Operating Pipeline Failures Caused by All Causes

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Recommended Practice for the Mitigation of External
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2 Corrosion Mechanisms and Mitigation

Corrosion of underground structures such as pipelines is controlled by the use of

protective coatings and by maintaining adequate levels of cathodic protection
(CP). The role of the coating is to act as a physical and dielectric (low or non-
conductive) barrier. The protective coating acts as the primary or first line of
defense against corrosion; however no coating systems are perfect. To protect the
pipe against corrosion at coating voids, or breaks referred to as holidays, cathodic
protection current is applied. Effective cathodic protection will reduce the soil
side corrosion rate to a negligible level.

CSA Z662, Oil and Gas Pipeline Systems, specifies requirements for external
coatings and cathodic protection of pipelines.

2.1 Localized and General Corrosion

External corrosion of pipelines typically occurs where coating defects allow

contact of the steel with the wet soil. The common features of this mechanism are:
•
Coating defects such as holidays1, wrinkling or disbanding2
• Moisture from the soil is in contact with the metal surface
• Cathodic protection is shielded3 or is not sufficient
External corrosion of underground structures manifests itself as either general
wall loss or localized corrosion. Industry experience has shown that underground
corrosion rates on bare unprotected pipe (i.e. no coating or CP) vary depending on
a number of factors including soil resistivity. Although the corrosion rates may
vary it is generally accepted that all soils are corrosive.

External corrosion damage which may start as localized pitting can interact to an
extent that the load bearing capability of the pipeline is decreased and a failure
may result. When doing predictions and engineering assessments of external
corrosion on carbon steel underground structures, the failure mode should be
considered in the consequence analysis.
(1) A holiday is a break in the coating system that exposes the bare metal to the
environment
(2) Disbondment is a failure of the bond between the coating and the steel pipe.
Disbondments allow water to migrate under the coating.
(3) Shielding is the prevention or diversion of cathodic protection current from its
intended path. There must be a continuous electrolytic path between the protected
pipe and the anodes. Disbonded coating may create a holiday as well as shield the
cathodic protection current.

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2.2 Soil Types

Soil pH, salinity, moisture content, resistivity, and microbes all affect corrosivity
where bare steel is exposed.

The soil resistivity at different areas on a pipeline will vary based on moisture
content and mineral composition. Table 2-1 summarizes the effect of different soil
types/resistivity on typical external corrosion rates. The corrosion rates identified
in Table 2-1 are for bare steel and no cathodic protection.

Table 2-1: Soil Resistivity Effect on Corrosion Rates

SOIL RESISTIVITY SOIL TYPE MOISTURE CORROSION

(ohm-cm) (mm/yr)

<500 Muskeg/sloughs/free Always wet Very corrosive

water accumulations > 1.0

500 - 2000 Loams/clays Mainly wet Corrosive to

moderately corrosive
0.5 – 1.0
2000 - 10000 Gravels, sandy Mainly dry Mildly corrosive
0.2 - 0.5

>10000 Arid, sandy Always dry Non-corrosive

< 0.2

Source: Modified from Corrosion Basics—An Introduction, NACE Press

2.3 Plant Applied Protective Coatings

Coatings perform two distinct functions. They provide a physical corrosion

barrier between the steel structure and the surrounding environment. Coatings
also reduce the amount of cathodic protection current required by lowering the
amount of metal which directly contacts the soil.

Coating technology has changed over time, which has resulted in the use of many
different types of coating systems, including but not limited to the following:
1) Fusion Bond Epoxy (FBE)
• Epoxy coating consisting of resins, curing agents, catalysts, accelerators,
etc.

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 • Excellent adhesion and resistance to soil stress, gouging and abrasion. Does
not shield cathodic protection current (i.e. fails safe)

2) Abrasion Resistant Fusion Bond Epoxy (Dual Power – DPS)

• Several layers of FBE, or FBE overcoated with a liquid epoxy, to provide
improved abrasion resistance
• Often used for horizontal directional drill (HDD) sections

3) Three (3) Layer Extruded Polyethylene

• Product consists of three layers; an FBE primer, a co-polymeric adhesive,
and a extruded polyethylene outer sheath

4) Two (2) Layer Extruded Polyethylene (i.e. YJ-1, Yellow Jacket)

• Rubber modified asphalt adhesive covered by an extrudes polyethylene
outer sheath

5) Thermally insulated Pipeline coatings such as:

• Polyurethane foam applied direct to pipe, polyethylene tape or extruded
polyethylene outer jacket – outdated
• Primer, polyethylene tape anti corrosion barrier, polyurethane foam,
extruded polyethylene outer jacket
• Primer, polyethylene tape anti corrosion barrier, polyurethane foam,
polyethylene tape outer jacket - outdated
• Two layer extruded polyethylene anti-corrosion barrier, polyurethane foam,
extruded polyethylene outer jacket - outdated
• Fusion bond epoxy anti-corrosion barrier, polyurethane foam, extruded
polyethylene outer jacket
• Three layer extruded polyethylene anti-corrosion barrier, polyurethane
foam, extruded polyethylene outer jacket

6) Polyethylene Tape (solid film backing)

• Primer, butyl rubber or similar adhesive, and polyethylene solid film
backing applied in a spiral wrap
• Poor adhesion, soil stress resistance. Low operating temperature.

7) Coal-tar enamel and asphalt mastics

• 1950-60’s technology no longer in use. Coal tar pipe coatings can contain
kraft paper layers, asbestos, or fiberglass layers to improve their
performance
• Care must be taken when working with coal tar coatings to avoid asbestos
hazards

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2.3.1 Thermally Insulated Pipelines

Coating systems, which provide thermal insulation, are widely used on upstream
pipelines that transport wet gas. The thermal insulation helps prevent hydrates
from forming. Typically a thermally insulated pipe system will include an anti
corrosion barrier on the pipe (ie. Polyethylene tape or FBE applied directly to the
steel surface), a layer of polyurethane foam (typically 2” thick), and a
polyethylene outer jacket coating.

The outer jacket coating is meant to prevent water ingress into the insulation as
well as to provide mechanical protection to the insulation. The outer jacket can,
for a number of reasons, be damaged and not completely effective. The
polyurethane foam material used for the insulation is not water resistant.
Therefore, it cannot be relied upon to protect uncoated steel. If water does reach
the pipe surface the anti-corrosion barrier is meant to prevent corrosion. In the
past, some thermally insulated pipelines were installed without an anti corrosion
barrier. Due to serious problems with external corrosion the current recommended
industry practice is to always apply an anti-corrosion barrier coating.

At the field joints, the insulation system is commonly provided by the use of half
shells. Gaps along the edges of the half-shells can allow the easy ingress of water.
An alternative approach involves the use of field-molding the girth weld
insulation, using a portable mould. The molded insulation fills the girth-weld
insulation cavity better than half-shells and adds an additional moisture seal. The
field molding process is highly recommended and leads to a much lower risk of
external corrosion.

For insulated pipelines, cathodic protection is believed to have very limited

benefit. This is due to the multiple layers of dielectric material that tend to shield
the protective current. Insulated pipelines rely solely on the integrity of the
external outer jacket coating, and the anti-corrosion barrier, to prevent external
corrosion.

2.3.2 Field Applied Protective Coatings

It is important to ensure that the joint coating material used is compatible with the
plant applied pipe coating material. An industry recommended practice is to select
joint coating that closely matches the performance characteristics of the plant
applied protective coating.

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Recommended Practice for the Mitigation of External
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 The most common field joint coating systems used for upstream gathering system
pipelines are:
• Heat shrink sleeves
• Polyehylene tape wrap
• Hand applied liquid epoxy
Heat shrink sleeves applied in the field to pipeline girth welds are either two-layer
or three-layer systems depending on what type of plant applied coating is used. If
the pipe is coated with a two-layer extruded polyethylene system the sleeve will
typically be a two-layer sleeve to match. Wrap-around style sleeves are superior
in performance. The use of older tube style sleeves is not recommended as they
tend to get contaminated before they can be shrunk down.

Polyethylene tapes can be applied by hand wrapping, or by using portable hand

wrapping equipment. The key to successful application relies on tape selection,
surface preparation and proper application. Soil stresses tend to damage tapes
especially on large diameter pipelines.

Woven Geotextile tapes are also available. Similar to polyethylene tape but with
superior soil stress resistance. These generally require the use of a hand wrapping
machines.

Hand applied two part liquid epoxies are typically used for fusion bond epoxy
pipelines as their performance characteristics closely match the FBE material.

Irregular shapes are often encountered on pipelines. These include shop bends, 45
deg elbows, 90 deg elbows, tees, weld-o-lets, repair sleeves, etc. Shrink sleeves or
tape coatings are not designed to coat such irregular shapes, and have lead to
corrosion problems in service. Irregular shapes should be coated with Petrolatum
tapes or other conformable coatings specifically meant for the task. Liquid epoxy
may also be used for the same purpose.

2.3.3 Installation Quality for Field Applied Coatings

Field applied coatings used for coating weld joints, fittings, risers, or for making
repairs to damaged coatings, are an important part of any coating system. The
field application of pipeline coatings is always challenging. These coatings are
applied outside in non-ideal weather conditions and in difficult terrain. However,
if the quality of the work is not comparable to the plant applied coating corrosion
problems, often referred to as joint corrosion, will result.

CSA Z662 requires that field applied coatings be applied in accordance with
documented procedures and an appropriate quality program. Coatings must also
be inspected prior to backfill. The sole use of coating manufacturer’s installation
guides does not adequately cover the above requirement. It is important that
owner companies develop specific coating application standards, specifications,

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Recommended Practice for the Mitigation of External
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 or procedures to make clear the minimum requirements for field applied coatings.
Such standards should consist of the following elements.

• List of Approved Coatings – suitable coatings selected to be compatible with

the plant applied coating are described by manufacturer and product name

• Contractor Supervision and Crew Size - a coating crew foreman responsible

for quality is important. The number of workers in a coating crew must be
sufficient to ensure quality and the required productivity.

• Application Crew Training – The workers must be trained on how to proper

apply protective coatings

• Minimum List of Tools and Equipment – specialized tools and equipment are
needed to do the work properly
• Storage and Handling Requirements – most coating materials should not be
frozen, or otherwise contaminated prior to use

• Surface Preparation – the level of surface preparation is crucial for achieving a

bond to the pipe. Grit blasting helps improve adhesion for all coatings and is
mandatory for some types of coatings.

• Pre-Heating – pre-heating is crucial form most types of pipeline coatings

• Application Requirements – application procedures should meet or exceed the

coating manufacturers minimum requirements

• Inspection – CSA Z662 requires that coating work be inspected. Inspection

may include item such as grit blast profile, hardness (cure), peel tests for
shrink sleeves, etc. Poor inspection, or a lack of inspection, is a common
aspect of joint corrosion.

Common barriers to obtaining good quality field applied coatings are lack of
worker supervision, poor training of the workers that are applying the coatings,
and a lack of proper coating inspection. Addressing these issues will improve the
long term performance of any coating system and help avoid disbonded and
shielding joint coatings.

2.3.4 Coating Degradation – Heat Damage, Disbondment & Blistering

Excessive heat can cause pipe coatings to soften, flow, or become cracked and
brittle. The result will be a disbonded and ineffective coating.

Soil stresses from due to backfill weight, soil-induced shear stress applied to the
coating due to thermal expansion, pipe settlement or soil settlement, can cause
disbondment or wrinkling of the coating.

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Recommended Practice for the Mitigation of External
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 Excessive CP current can also cause blisters in FBE coating, especially in hot and
wet soil environments. The locally increased pH and/or hydrogen molecules being
liberated at a holiday in the coating may cause the coating to disbond around a
holiday.

2.3.5 Coating Degradation - UV Damage

Cracking or embrittlement of coatings can occur due to prolonged ultraviolet

exposure prior to burial. This can happen if coated pipe is stored outside for
prolonged periods. Ultraviolet exposure of fusion bond epoxy coatings may result
in chalking and should be evaluated with the manufacturer prior to use. This can
also occur at locations where the pipe coating comes above ground but it not
protected from the elements.

2.3.6 Shielding of Cathodic Protection Current

The shielding of cathodic protection current is a common problem that can lead to
external corrosion damage and pipeline failures. Coatings with high dielectric
strength such as extruded polyethylene, shrink sleeves, and polyethylene tape may
lead to the shielding of cathodic protection current if damaged or disbonded.

Improving the quality of the application work can reduce the affects of disbonded
and shielding pipe coatings. Alternatively non-shielding (i.e. fail safe) coatings
such as FBE can be used, especially at high consequence areas such as
waterways, populated areas, environmentally sensitive areas, etc.

Most over the line survey techniques will not reliably detect the presence of
shielding coatings. In-line inspection and repair is the best way reduce corrosion
failures if disbonded coatings and CP shielding are present.

2.4 Contributing Factors

Table 2-2 describes the most common contributors, causes and effects of external
corrosion of pipelines. The table also contains corresponding industry accepted
mitigation methods used to reduce external corrosion.

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Recommended Practice for the Mitigation of External
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 Table 2-2: Contributing Factors and Mitigation of External Corrosion

Contributor Cause/Source Effect Mitigation

Excess • Coating failure • Water ingress • Reduce operating

operating temperature below
temperature • Coating disbondment • cathodic shielding limit of coating and
mastic

• Select coating
system with
temperature greater
than operating
temperature

Pipe • Excess operating • Coating damage • Proper pipeline

movement/soil temperature design
stress • Water ingress
• Operating temperature • Coating selection
variation • cathodic shielding that meets the
design
• Improper support requirements

Ground • Unstable soils • Coating damage • Route selection

movement/soil
stress • Freeze thaw cycles • Water ingress • Soil stabilization

• cathodic shielding • Coating selection

Improper • Rock damage • Coating damage • Proper construction

handling and practices
backfill • Water ingress
• Coating selection
• cathodic shielding

Poor joint • Poor joint coating • disbonded coating • proper design and
coating selection / engineering
Incompatible pipe and • water ingress
joint coating • application
• cathodic shielding standards or
• Improper application of specifcations
joint coating
• trained personnel
• Inadequate personnel
training • construction QC

• Limited supervision or • coatings inspection

inspection of work

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Recommended Practice for the Mitigation of External
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 Contributor Cause/Source Effect Mitigation
See NACE RP0303 Field Applied Heat Shrinkable Sleeves For Pipelines;
Application, Performance, Quality Control

Insulation • pipelines without a • water can enter at • ensure coating

corrosion barrier holidays and follow the system includes
between pipe and pipe wall anti-corrosion
insulation barrier
• water can enter joint
• Poor joint coating area • Follow written
quality that allows coating standards
water ingress • outer coating and or specification to
insulation will shield ensure quality work
cathodic protection done on joint
coatings

• Injection mould
foam at joint rather
than half shells

• Employ qualified
coating inspectors
to ensure quality of
work

Concrete • pipelines with out • water ingress • Coating must be

weights and adequate coating with
anchor blocks in the concrete portion
• damaged coating
designed with
• Cathodic shielding by consideration for
the concrete anchor
• coat pipe prior to
pouring concrete

• inspect coating
prior to installing
anchor

Externally • these are not • water ingress • install 100% holiday

weight-coated corrosion barriers free corrosion
pipe, and rock • cathodic shielding barrier applied
shielding directly to pipe

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 Contributor Cause/Source Effect Mitigation
Cased • casing in contact with • Cathodic shielding by • install non metallic
Crossings carrier pipe casing centralizers

• damaged coating • Insufficient cathodic • ensure coating is

protection 100% holiday free

• keep water out of

casing

Bored • coating damaged • water ingress • install 100% holiday

Crossings – during installation free corrosion
no casing • cathodic shielding by barrier
protective coatings
used as rock shields • apply cathodic
protection

Soil to Air • Damaged coating • Coating UV • proper coating

Interface degradation selection
(Risers) • Lack of coating
• Coating mechanical • install coating
damage above interface

• water ingress • inspection and

maintenance
• unreliable CP due to
intermittent electrolyte • mechanical
shielding

Cathodic • cathodic protection • external corrosion at • perform CP system

protection system operating coating defects survey and adjust
insufficient below NACE RP0169
criteria

Cathodic • foreign cathodic • Improper cathodic • Properly design

interference protection systems protection cathodic protection
system
• AC power lines
• Proper survey and
maintenance

Excess CP • Improperly operated • Possible coating • Perform CP system

system damage survey and adjust

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Recommended Practice for the Mitigation of External
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3 Recommended Practices

Table 3-1 describes the recommended practices for mitigation of external

corrosion during the design and construction phase of a piepline’s lifecycle.

Table 3-2 describes the recommended practices for the mitigation of external
corrosion during the operating phase of a pipeline lifecyle.

Table 3-1: Recommended Practices – Design and Construction

Element Recommended Benefit Comments

Practice

Coating – • Select coating system • Prevent disbondment • monitor operating

Plant Applied with design and cathodic shielding conditions to
temperature prevent exceeding
exceeding operating • Minimize cathodic design
temperature protection current specifications
needed to prevent
• Coating selection external corrosion
should consider type
of soil (water, sand,
clay, rock)

Coating – • Select coating system • Prevents water • cathodic shielding

Plant Applied that includes an anti- ingress to pipe may occur due to
Thermally corrosion barrier surface the insulation
Insulated Pipe between pipe and
insulation • cannot holiday
check outer coating,
• Protect install outer therefore corrosion
jacket coating system barrier must be
in rocky soils 100% holiday free.

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Recommended Practice for the Mitigation of External
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 Element Recommended Benefit Comments
Practice
Coating – • select a joint coating • prevents water • quality control is
Field Applied system that considers ingress essential
at Joints the current and future
operating conditions • ensures coating • applicators must be
system integrity trained
• select a joint coating
system that is • applicator must be
compatible with the using the correct
pipe coating system equipment and
written procedures
• select a joint coating
system appropriate for • Coating inspection
the field construction to ensure quality
environment and prevent joint
corrosion
• use proper surface
preparation as
recommended by the
coating manufacturer

• Develop coating
application standards
or specifications

Joint type • if joints other than butt • ensures electrical • Verify by periodic
welds (i.e. zap-lok) continuity necessary system surveys
are used consider the for CP system to
effects on cathodic function along the full
protection length of the pipeline

Cathodic • Install cathodic • Protects pipe against • Design in

Protection protection system corrosion at coating accordance with
holidays or damage NACE RP0169

• Use proper electrical

isolation to avoid
current drainage to
surface facilities and
well casings

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Recommended Practice for the Mitigation of External
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 Element Recommended
Practice
Inspection • Install or provide
Capability capability for
inspection tool
launching and
receiving
• Use consistent line
diameter and wall
thickness.
• Use piggable valves,
flanges, and fittings
Table 3-2: Recommended Practices – Operating
Element Recommended
Practice
Corrosion • Understand what type
Assessment of coatings exist in a
gathering system
• Evaluate operating
temperature against
coating system design
• Assess potential for
cathodic shielding
• Re-assess CP system
operation subsequent
to a line failure or
system addition
CP system • Perform annual survey
maintenance to verify sufficient CP
current
• Check all insulating
kits/joints
• Check for interference
• Check rectifiers
periodically and record
outputs
June 2009
Recommended Practice for the Mitigation of External
Corrosion on Buried Pipeline Systems
Benefit Comments
• Internal inspection • Consideration
using intelligent pigs is should be given to
the most effective the design of bends,
method for confirming tees, and risers to
overall pipeline allow for passage of
integrity inspection tools
• Proper design allows
for pipeline inspection
without costly
modifications or
downtime
Benefit Comments
• Understand and • Refer to CSA Z662
document design and Clause 9 –
operating parameters Corrosion Control
• Ensures reliability of • regulatory
CP system requirement
• Enables proof of • need to include
regulatory compliance deactivated,
discontinued, or
suspended lines
• only abandoned
lines should have
cathodic protection
disconnected
Page 15
 Element Recommended Benefit Comments
Practice
Note: ensure all personnel are trained and hold the required certification for
the work being performed.
Inspection • Develop an inspection • Provides assurance • Refer to Section 7
Program strategy that the corrosion for Corrosion
mitigation program is Inspection
• Utilize root cause effective Techniques
analysis results to
modify corrosion • Allows for corrosion • Refer to CSA Z662
mitigation and mitigation program Clause 9 –
inspection programs adjustments in Corrosion Control
response to inspection
results

Repair and • Inspect to determine • Prevents multiple • Refer to Section 7

Rehabilitation extent and severity of failures on the same for Corrosion
damage prior to pipeline Inspection
carrying out repair or Techniques
rehabilitation • Prevents recurrence
of problem • Refer to Section 9
• Based on inspection for Repair and
results, use CSA Rehabilitation
Clause 10.9.2 to Techniques
determine extent and
type of repair required • Refer to CSA Z662
Clause 10.10 for
repair requirements

Failure • Recovery of an • To understand • Adjust corrosion

Analysis undisturbed sample of
the damaged pipeline
• Conduct a thorough
failure analysis
corrosion mechanisms mitigation program
detected during based on results of
inspections or as a failure analysis
result of a failure

• Use the results of

failure analysis to re-
assess CP system

• Measure pipe to soil

potential at failure site

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 Element Recommended Benefit Comments
Practice
Leak • Integrate a leak • Permits the detection • Refer to Section 8
Detection detection strategy into of leaks for Leak Detection
a Pipeline Operation Techniques
and Maintenance
Manual • Technique utilized
depends on access
and ground
conditions

Management • Integrate an MOC • Ensures that change • Unmanaged change

of Change procedure into a does not impact the has resulted in
Pipeline Operation integrity of the pipeline many pipeline
and Maintenance system failures
Manual
• Understand and • Refer to Section 10
• Maintain records of document design and for Pipeline Integrity
pipeline operation and operating parameters Management
maintenance System

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Recommended Practice for the Mitigation of External
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4 Corrosion Mitigation Techniques

Protective coatings have a significant impact on the life cycle costs of a pipeline.
The success of preventing external corrosion is highly dependant on the choice of
coating and the quality of the field applied coating work. Table 4-1 describes
common techniques that should be considered for the mitigation of external
corrosion of pipelines once a pipeline is in operation.

Table 4-1: Corrosion Mitigation Techniques

Technique Description Comments

Cathodic • Design, install, operate, and • Regulatory requirement

Protection maintain CP system in accordance
with NACE RP 0169 • CP system require regular
maintenance
• Ensure rectifiers are checked
routinely to ensure they are
operating at the target current
output

• Reduce unnecessary rectifier down

time due to maintenance activities.

• Ensure annual CP surveys are

conducted

• React quickly to insulation

deficiencies, continuity bonding
issues, and other problems to
ensure CP are functioning properly

• Replace deplete groundbeds in a

timely fashion

• Upgrade CP system if more current

is need to provide the proper levels
of protection

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Recommended Practice for the Mitigation of External
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5 Corrosion Monitoring Techniques

Table 5-1 describes the most common techniques for monitoring corrosion and
operating conditions associated with external corrosion of pipelines.

Table 5-1: Corrosion Monitoring Techniques

Technique Description Comments

Production • Ongoing monitoring of fluid • Excess temperature may
Monitoring temperature damage the coating

Cathodic • Maintain, check, and operate CP • Regulatory requirement

Protection system in accordance with NACE
RP 0169

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Recommended Practice for the Mitigation of External
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6 Inspection Techniques

Table 6-1 describes common techniques that should be considered for the
detection of external corrosion and coating degradation of pipelines.

Table 6-1: Inspection Techniques

Options Technique Comments

CP • Close interval survey • Determines adequate protection
effectiveness level
survey • Annual system survey
• Detects interference

• May detect significant coating

problem areas

Coating • C – Scan Coating Conductance • Detailed coating evaluation

Integrity Survey techniques intended to identify
Survey areas of compromised coating
• ACVG (pin to pin) Coating survey
• May employ the NACE PR05202
Pipeline External Corrosion
Direct Assessment Methodology

In-Line • Magnetic flux leakage (MFL), • Effective method to accurately

Inspection ultrasonic and eddy current tools determine location and severity
are available. MFL is the most of corrosion
commonly used technique
• In-Line Inspection can find
internal and external corrosion
defects

• The tools are available as self

contained or tethered

• The pipeline must be designed

or modified to accommodate In-
Line Inspection

• May not be effective at risers

Note: Pressure testing alone is not recommended as a method to prove long term pipeline
integrity.

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Recommended Practice for the Mitigation of External
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7 Leak Detection Techniques

Table 7-1 describes common techniques that should be considered for the
detection of pipeline leaks caused by external corrosion. Proactive leak detection
can be an effective method of finding small leaks and mitigating the consequences
of a major product release or spill.

Table 7-1: Leak Detection Techniques

Technique Description Comments

H2S detection • H2S detection can be portable or • Permanent monitors are used at
permanent tools surface facilities.

Right-of-Way • Visual inspection by ground access • Indications include soil settlement,

(ROW) or aerial surveillance to look for gas bubbling, and water, soil, or
Surveillance indications of problems vegetation discoloration

• Can be used in combination with

infrared thermography and flame
ionization surveys

Production • Volume balancing or pressure • Changes in production volumes or

Monitoring monitoring to look for indications of pressure can indicate a pipeline
leaks failure

• This is a more effective tool for

finding large leaks and ruptures

Flame • Electronic instrumentation used to • Equipment is portable and used to

Ionization detect low concentrations of gas find small leaks
Survey

Infrared • Thermal imaging is used to detect • Need sufficient volume of escaping

Thermography temperature change on Right-of- gas to create an identifiable
Way due to escaping gas or temperature difference
produced water
• Normally completed using aerial
techniques

Odor Detection • Odorant detection using trained • Capable of detecting pinhole leaks
animals and patented odorants that may be otherwise non-
detectable

• This can only be used after the

system has been purged of fluids
and displaced with a special
odorant

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Recommended Practice for the Mitigation of External
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8 Repair and Rehabilitation Techniques

Table 8-1 describes common techniques used for repair and rehabilitation of
externally damaged pipelines.

Prior to the repair or rehabilitation of a pipeline the appropriate codes and

guidelines should be consulted, including:
• CSA Z662, Section 10.10 “Permanent and Temporary Repair
Methods”
When evaluating localized corrosion, the user is cautioned that in addition to the
assessment methods for internal pressure (hoop stress) calculations, consideration
must be given to the circumferential extent of corrosion that may affect the load
bearing properties where secondary stresses may be critical (e.g. bending loads,
thermal stresses, soil stresses).

Table 8-1: Repair and Rehabilitation Techniques

Technique Description Comments

Coating • Excavation, stripping or blasting • More suitable for localized areas
Replacement and re-coating of damage (e.g. joints) and areas
that do not require replacement

• May be possible to do without a

production outage

Pipe Section • Remove damaged section(s) and • When determining the quantity of
Replacements replace with new externally coated pipe to replace consider the
pipe. extent of corrosion and the
condition of the remaining
• Joint areas should be properly pipeline and joint areas
coated after the new repair section
is installed • Impact on pigging capabilities
must be considered (use same
pipe diameter and similar wall
thickness)

• For certain services,

consideration should be given to
the need for coating the inside of
the pipe with a corrosion inhibitor
prior to commissioning

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Recommended Practice for the Mitigation of External
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 Technique Description
Repair Sleeves • Reinforcement and pressure-
containing sleeves may be
acceptable for temporary or
permanent repairs of external
corrosion as per the limitations
stated in CSA Z662
Pipeline • In situations where it may be
Replacement difficult or uneconomic to prevent
continued external corrosion
damage (e.g. insulated pipelines,
badly disbonded coatings, damage
at joints) replacement of the
pipeline may be the best option
June 2009
Recommended Practice for the Mitigation of External
Corrosion on Buried Pipeline Systems
Comments
• For external corrosion it may be
possible in some circumstances
for the damaged section to
remain in the pipeline as per the
requirements in CSA Z662
Section 10
• Different repair sleeves are
available including composite,
weld-on and bolt-on types. The
sleeves must meet the
requirements of CSA Z662
Section 10
• Note: See above comments on
considerations for secondary
stresses when evaluating the use
of different types of repair
sleeves
• Consider need for pig and
inspection tool compatibility
• Refer to Section 4
“Recommended Practices ” in
this document for details
Page 23
9 Additional Resources

For more information on external corrosion of pipelines, pipeline coatings and cathodic
protection the reader should refer to the following organizations:
• NACE International

http://www.nace.org/

• European Federation of Corrosion (EFC):

http://www.efcweb.org/

• The American Society of Mechanical Engineers (ASME):

http://www.asme.org/catalog/

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Recommended Practice for the Mitigation of External
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