Corrosion Control in Gas Pipeline

Rehan Amjad
Dy. Chief Engineer SNGPL
• Mr. Rehan Amjad ------ M.Phill (Total Quality Management)
B.S.C Chemical Engineer.
(UNIVERSITY OF PUNJAB,LAHORE)

Deputy Chief Engineer (Corr Control),Lahore (D)

Experiences
• Paper industry
• Textile sector
• Pakistan ordinance factory
• SNGPL since 2005
Corrosion Control Center
Corrosion Control Lahore D
Corrosion Control Gujrat
Aditional assignments of QA,HSE,Maintenace
Quality Assurance Projects
 Contents
• What is pipe line?
• Gas pipeline
• Spread and scope of work of SNGPL
• Importance of Pipeline network integrity in Gas Distribution Company
• Why corrosion is huge threat to network integrity
• Methods to control corrosion in field
• Case studies
• Pipeline integrity surveys
• AC Current interference
• Stray currents generated from metro train and mitigation
 What is a Gas Pipeline

• Natural gas pipelines transport natural gas from stationary

facilities such as gas wells or import/export facilities, and
deliver to a variety of locations, such as homes or directly
to other export facilities.
• This process also involves three different types of
pipelines: gathering systems, transmission systems, and
distribution systems.
 Importance of Gas Pipeline Network
• Well, they run across multiple cross country lines to bring fuels
and feedstocks to a variety of consumers that include
homeowners, businesses, and power plants. In short, energy
from petroleum is used every day in varying capacities. It is
important to note that Pakistan has one of the largest network
of pipelines in the world. Therefore, they are extremely
integral to operations and functions of Energy Sector.
 SNGPL Gas Pipeline Network
• SNGPL transmission system extends from Sui in Baluchistan to Peshawar
in Khyber Pakhtunkhwa including whole Punjab and some area of Sindh
and Azad Kashmir comprising over 9,026 km of Transmission System
(Main lines & Loop lines).
• The distribution activities covering 5,284 main towns along with
adjoining villages in Punjab & Khyber Pakhtunkhwa are organized
through 16 Regional Offices. Distribution system consists of 142,998 km
of pipeline. SNGPL has over 7.22 million consumers comprising
Commercial, Domestic, General Industry, Fertilizer Power & Cement
Sectors. Annual gas sales to the consumers were 623,724 MMCF during
Jul 2019 - Jun 2020.
 Development project
• SNGPL had recently completed the largest ever pipeline
infrastructure Development project in the history of Pakistani
gas market involving approximately 1100 km pipelines of
diameters 16" to 42" along with installation of 35000 HP
compression for the receipt of additional 1200 MMCFD RLNG.
RLNG is being supplied to all categories of consumers including
Industrial, Power, Cement, CNG, Commercial and Domestic
throughout the year.
 VISION STATEMENT OF SNGPL
• To be the leading integrated natural gas provider in the region
seeking to improve the quality of life of our customers and
achieve maximum benefit for our stakeholders by providing an
uninterrupted and environment friendly energy resource.
 MISSION STATEMENT OF SNGPL
• A commitment to deliver natural gas to all door steps in our
chosen areas through continuous expansion of our network, by
optimally employing technological, human and organizational
resources, best practices and high ethical standards.
 TYPE OF PIPELINES IN SNGPL

• P.E(Polyethylene) Pipeline
• Mild Steel Pipeline

All high pressure Transmission pipelines and

Distribution Gas Mains in SNGPL are M.S
 Threats to MS/P.E Pipelines
• Terrorist attacks: are a major threat to our Transmission
Pipelines that are passing through areas where law and order
situation is not good
• Theft: from different consumers and non-consumers by
tapping our supply mains also damages the pipelines
• Third Party Damages: Other utility companies or private
builders can damage our pipelines during construction work
• Corrosion Leaks: Leaks due to corroded pipelines Associated
with M.S pipeline
 Corrosion

• Corrosion is defined as
Deterioration or destruction of material due
to its chemical interaction with environment.
 CORROSION BY DEFINITION

Corrosion is derived from Italian Word

CORRO-DARE which means CUT AWAY

Corrosion is the destruction of the metal by chemical

or electrochemical reaction with its environment in
which it is buried.

In case of pipeline electrochemical reaction occur between pipeline and soil which
brings drastic changes in the metal and it losses its metallic properties like tensile
strength, malleability & pliability.
 …. dust to dust

The fact is that the metal corrodes through sheer cussedness. They want to corrode. This
perverse desire stem from the fact that it is much more natural for a metal to exist in the form
of a compounds such as oxides contain less energy than metals and are therefore more
stable.
 Corrosion
 It’s a reverse of metallurgy.

 Any material when It is kept in a certain atmosphere there will be

potential difference between the material and the surroundings. To
complete the circuit ions of material comes to the solution.

 CORROSION RATE: Rate at which ions are coming out.

 Corrosion Management
• Pipeline Corrosion Management standard
• Reinforced concrete structures
• Bridges
• Tanks
• Well casings
• Distribution pipelines
• Oil and gas gathering pipelines
• Water/waste water
 What is Corrosion Management
• A comprehensive program for reducing
the effects of corrosion to an acceptable level
• NACE Mission Statement: Protecting people, assets
and the environment from the effects of corrosion
 What is Corrosion Management
• Corrosion management is an umbrella document that
ties together all of the various corrosion
activities
• Coatings surface preparation
• Cathodic protection monitoring and mitigation
• Materials selection
• SCC monitoring and mitigation
• Pipeline integrity assessment
 Corrosion Management Process
• The Pipeline Corrosion Management process provides a
common methodology for reducing the risks caused by
corrosion.
• The process continually improves the prevention and
mitigation safeguards against corrosion failure
• In addition, the process provides an effective and economical
approach to corrosion mitigation, assessment, and
remediation
 Pipeline Corrosion Management
• This standard applies to onshore carbon-steel pipelines
carrying natural gas and hazardous liquids.
• This standard addresses the following three corrosion (time-
dependent) threats identified in ASME B31.8S and API 1160

1. External Corrosion
2. Internal Corrosion
3. Stress-Corrosion Cracking (SCC).
 Pipeline Corrosion Management
• Pipeline Corrosion Management process begins in the design
phase for new construction
• The process entails a comprehensive due-diligence
for existing structures
• This document does not address threats other than
corrosion, such as third-party damage and outside
forces
 Pipeline Corrosion Management
• Identify threats
• Evaluate risk
• Determine and implement necessary mitigation
• Monitor effectiveness of mitigation
• Inspect and assess integrity
• Remediate
• Evaluate effectiveness of process
• Repeat
 Corrosion Management
• Corrosion management documents will provide
comprehensive processes for managing corrosion in
a diverse set of industries
• Acceptance and implementation of these documents
will improve public safety and protect assets and
the environment, furthering NACE Internationals
mission
Pipeline Integrity Management (PIM) System

Purpose
Pipeline Integrity Management System (PIMS) is the
software used to manage pipeline Integrity data. Previously
it was termed as ECDA (External Corrosion Direct
Assessment).
The Main objective of PIMS are:
• Safety
• Reliability
• Preventing incidents
• Maintaining operation License.
Pipeline Integrity Management (PIM) System

Procedure of PIMS Plan

There are many steps involved in PIMS. Planning is very crucial in
conducting the PIMS. The major steps are as below:
1. Aging of Pipeline Network
2. Coating of Pipeline (3LPE-Three Layer Polyethylene/Enamel/Cold Applied
Tape)
3. Location of Pipeline Network (Right of Way (ROW) availability)
4. CP Surveys (DCVG, CIP, SR, PSP)
5. After collecting CP surveys data, uploading of the data in the recommended
software for integrity analysis
6. For real time pipeline exposure conducting NDT on the identified bell holes
after PMIS.
 Pipeline Integrity Management (PIM) System

CP Surveys

1. DCVG (Direct Current Voltage gradient) technique is performed over the pipeline with special equipment to
detect and calculate the level & severity of the coating defects.

2. CIP (Close Interval Potential) is a series of structure-to-electrolyte direct current (DC) potential
measurements performed with special equipment at regular intervals to evaluate the level of polarization on
buried pipelines.

3. PSP (Pipe to Soil potential) is the potential difference measured between the buried pipeline ( or structure) and
soil in which it is buried by contacting the soil with a reference electrode.

4. SR (Soil resistivity) is a measure of how much the soil resists or conducts electric current.
 Pipeline Integrity Management (PIM) System
Constraints
• Skilled Staff
• Right of Way
• Special equipments
• Calibration of CP survey Equipments
• Isolation of the CP Network.

NDT (Non destructive Testing)

NDT is a testing and analysis technique used to evaluate the properties of a material, component, structure or system.
BELL HOLE INSPECTION
BELL HOLE INSPECTION
 Impact of Corrosion

• Cathodic Protection is essential for protection of

underground MS pipelines, the largest asset of our
organization. Without Cathodic Protection gas lines
corrode, leading to leakage and rupture, which may cause
1. Loss of gas LEADING to financial loss.
2. Disruption of gas supply.
3. Danger towards human safety.
 FACTORS EFFECTING PROTECTION AGAINST
CORROSION

• The factors causing low protection level of Network may be

categorized as under;
• Lines in sewerage drains
• Deteriorated Coating Condition
• Service Lines passing through drains
• Aging of Network
• Depth of Network
• Stray currents
 Mitigation of Corrosion

• There are different techniques used for mitigation of

Corrosion attack.
• In SNGPL we are using following Techniques for Corrosion
Prevention

1. Protective Coatings
2. Cathodic Protection
 Requirements for Corrosion
• Anode
Where current leaves the metal & enters electrolyte
- Corrodes (Oxidation)

• Cathode
Where current leaves electrolyte & returns to the
metal - Does not Corrode (Reduction)

• Metallic Path

• Electrolyte
Solution capable of conducting electricity due to
presence of ions – Water or Soil
 Protective Coatings

Following different Types of Pipeline Coatings are used:

• Epoxy Coal Tar. Coal tar epoxy (CTE) is a liquid epoxy

that has had some of the mineral fillers replaced
with semi-liquid coal tar pitch.
• Polyolefin Three-Layer Coatings.
• Epoxies With Fusion Bonding.
3LPE (Three-Layered Poly Ethylene) Coating

• Now a days most effective coating used is 3LPE (Three-Layered

Poly Ethylene) Coating.

• A three-layer extruded polyethylene coating is used for various

types of pipelines including sewer systems, water pipelines,
gas pipelines and other channels that are dangerous to water.
Polyethylene coatings have been in use to protect buried
pipelines from corroding since the 1950s. This type of coating
provides higher resistance to insulation than bitumen coatings.
3LPE (Three-Layered Poly Ethylene) Coating
• A three-layer extruded polyethylene coating can be applied through
sight extrusion and sleeve extrusion. These two methods of applying
polyethylene coating were introduced in the 1960s, replacing the
sintering technique. It was in the 1980s when 3LPE became very
prevalent in the industry.

• One advantage of this coating material is that it is ultra-adhesive, even

at room temperature. Also, it can be easily cut back as necessary by
having the pipelines heated. Furthermore, this material has a very
strong chemical resistance that makes it applicable even in the most
aggressive environments, including all forms of soil.
3LPE (Three-Layered Poly Ethylene) Coating

• The chemical resistance of this coating prevents its corrosion.

However, it should be noted that just like many materials, it is
also prone to some types of corrosion. Due to this, as early as
1974, testing has been required to determine the aging or
corrosion resistance of 3LPE. This is conducted by measuring
the temperature with the use of a thermometer at 140°F
(60°C). The measure of aging is the melt index, which is set at
an initial value of 25%. Over the years, more advanced testing
methods have been developed to determine the 3LPE's aging
and resistance to corrosion.
 Cathodic Protection

• Cathodic protection is a technique to control metallic corrosion, where electricity is

applied in an arrangement that makes the pipeline and structures to be protected
are made a cathode with respect to the ground.
• When a small pipeline or a hundred kilometer long pipeline is buried in the soil,
the moisture and oxygen in the soil works as the electrolyte. An anode and a
cathode is formed on the same interconnected pipeline, which also forms the
return path for the current.
• The lower the soil resistance (due to nature of soil), the higher will be the current
flow resulting in accelerated corrosion. Salt polluted ground and clay soils cause
greater corrosion when compared to gravel and sandy soils. If the gravel is
completely dry, then the need for Cathodic Protection and coatings may not arise.
In steel pipes, corrosion cells could result due to manganese, iron and other
contents. Even the replacement of a piece of pipe can result in anode formation
with respect to existing pipe.
 Cathodic Protection
• Every buried metal creates its own electrolyte solution potential. Thus a potential
difference (voltage) is created and maintained between the ground and the pipe
metal. This potential difference can be detected by connecting the negative wire of
a DC voltmeter to the metal, and the positive wire to a standard electrode of
copper sulfate connected electrically with the soil.

• When metals are connected electrically and buried in soil underground, they
spontaneously develop a galvanic cell. The metal that is higher in the galvanic
series will be anodic to the other metal lower in the series. An electrochemical
reaction corrodes the anode, while metal rendered cathodic is to be protected
from corrosion. Normally magnesium is used as a sacrificial anode with respect to
pipes and structures made of iron and steel, due to cost and stability
considerations. This sacrificial anode is buried in the ground and connected
electrically to the pipeline through low resistance copper wire. Multiple sacrificial
anodes are used in case a single anode is insufficient.
Sacrificial Anode Cathodic Protection (SACP)

• Sacrificial anodes are highly active metals that are used

to prevent a less active material surface from
corroding. In SACP application, the naturally occurring
electrochemical potentials of different metals are used
to provide protection. Sacrificial anodes are coupled to
the structure under protection and conventional
current flows from the anode to the structure as long
as the anode is more "active" than the structure. As the
current flows, all the corrosion occurs on the anode
which "sacrifices" itself in order to offer protection
from corrosion to the structure.
Sacrificial Anode Cathodic Protection (SACP)

Features and benefits of SACP:

• No independent source of electric power required

• Limited affects on neighboring structures
• Anode connections are also protected
• Correct material selection ensures no over-protection, thus
avoiding metal embrittlement and coating damage
• No possibility of plant damage due to incorrect connections
• Straightforward to install, operate and maintain
Impressed Current Cathodic Protection
• Cathodic Protection with a rectifier and impressed current can replace the
complicated multiple anode system, where the regular monitoring of
corrosion is mandatory. Converted direct current flows from the ground
bed to the piping structure and returns to ground.

• The system consists of a convertor/rectifier-transformer to convert the

supply voltage to the high current, low voltage DC power needed for
cathodic protection. An electric cable is connected to the buried pipeline
structure from the negative side of the convertor/rectifier instrument to
provide a return path for the flow of electricity. Variable voltage input is
provided to enable fine adjustment of the impressed current.
 Impressed Current System

Transformer Rectifier
(-) (+)

Groundbed
(Anodes)

Pipeline
(Structure)
Current
Flow
Impressed Current Cathodic Protection

• Impressed current cathodic protection (ICCP) has

the following advantages as compared to a
sacrificial anode system:
1. It can generate a higher impressed current when a
deteriorating coating is likely to accelerate corrosion.
2. It can take care of any changes in soil resistivity.
3. It can be adopted for coated as well as bare pipelines.
4. Pipeline structures of different sizes can be protected.
Cathodic Protection of SNGPL Network of Lahore
Region
• We have been operating 237 Nos. CP Stations in
Lahore Region with 2824 PSP points for evaluation
of our CP System. The current density for MS
Network is 2.61 mAmp/Sq. Meter.
C.P Station
 Challenges
• Interference from 660 kV MATIARI-LAHORE HVDC Transmission
Line.
• AC interference at 24” dia line running parallel to High Voltage
Transmission line.
• Ravi down Assembly Rehabilitation
• Stray Current interference from Lahore Orange Line Metro
Train
• Lines passing through sewerage man holes.
 660 KV HVDC TRANSMISSION LINE FROM MATIARI TO LAHORE
UNDERTAKEN BY NTDC

• Following activities are carried out at the Transmission lines to

assess the effect of the HVDC at the underground existing network
of the SNGPL pipelines pertaining to SMS-II Section-IV (MP-5, MP-
37.81, MP-41.41, MP-43.18 &MP-38.91),
• Demarcation of Pipeline locations parallel / crossing to HVDC
Transmission line.
• Gathered the coordinates by our own resources of the above
locations and marked on rout map.
• Installation of the Test Posts at 500 Mtr interval either site of
crossing point and at both ends parallel to the locations of the
HVDC Transmission line.
 660 KV HVDC TRANSMISSION LINE FROM MATIARI TO LAHORE
UNDERTAKEN BY NTDC

• During periodic monitoring, fluctuating potentials are observed at

MP 8.97Phool Nagar-DH line.
• Data collected by the data logger and analyzed for the further
action plan.
• To minimize fluctuating potentials, Zinc earthing anodes are
installed at 16” dia, 24” dia and 18” dia lines.
• Periodic monitoring is being carried out on weekly bases.
• To limit the effect of fault stray current, insulation of Valve
Assemblies at end points of the line segment under area of
influence is carried out.
 Stray Current interference from Lahore Orange
Line Metro Train
• Stray current is the current flowing on a structure that
is not part of the intended electrical circuit.
• Direct stray currents (D.C. stray current), in contrast to
alternating stray currents (A.C. stray current) have the
most pronounced corrosion effect on underground
structures, resulting in leaks
• Operation of Mass transit Metro Train System.

•Threat to underground MS pipelines.

•Plan of a Mass transit Train along SNGPL Pipeline

route.

•Coordination with Mass transit Project authorities.

Stray Currents Arising from DC Traction

Three-dimensional stray current profile in the subway system.

1——Catenary; 2——Train; 3——Rails; 4——Stray Current Collector Cable;
5——Ballast Bed; 6——Stray Current Control Mat; 7——Surrounding Soil;
8——Buried Pipe; 9——Anode Zone
 Case study
• In recent time, we have been conducting integrity
assessment surveys of different localities identified
by our field teams and Maintenance department.
The results for these integrity assessment surveys
carried out from Jul-21 to Dec-21 are as under;

Number of Localities with

Number of Localities Number of Localities with
Lines passing through
Surveyed Poor Coating Condition
sewerage

64 51 54
 Remedial Action Taken
• Pipeline Network rehabilitation
• Improved selection of material
• Close monitoring of water in line case
• UGLD (under ground gas leak detection)
 Pipeline integrity assessment tool in Distribution
• DCVG
• PCM
• UGLD
Under ground gas leak detection equipments, which are use
to detect leakage on pipeline and are very help full in
maintenance and repairs,
 Equipments in Use

Metrex-3 Methane Leak Detector

Inspectra Methane Leak Detector

Hi-Flow Sampler

Vehicle Mounted Gas Leak

Detector Technology:
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Laser Spectroscopy
 Equipment Details

Teams Equipment’s
Equipment Type Survey Technique
(Nos.) Principle
Sub Surface Gas
Hand held 41
Detection Survey
Laser Spectroscopy
Surface Gas Detection
Vehicle Mounted 02
Survey

• Carpet probes with external pump have been developed for

surface detection and increased survey progress.
• One hand held equipment has been converted into vehicle
mounted equipment by our engineers.

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