External Corrosion Direct Assessment (ECDA)

As described through NACE standard SP0502, External Corrosion Direct Assessment (ECDA) is a four turn-key process that covers the line through examination of places on the pipe where anomalies could form and thus corrode. This four step ECDA procedure which Alpha Pipeline Integrity Services strictly follows with NACE standard is:

Pre-Assessment Indirect Inspection Direct Examination Post Assessment

Below is an example of how Alpha implements ECDA on a various pipeline. Pre-Assessment The Pre-Assessment starts with a detailed Right-of-Way inspection. All details are noted (CP Readings, ROW conditions, AOCs). Indirect Assessment Methods :

Close interval survey (CIS) Direct current voltage gradient (DCVG) Alternating current voltage gradient (ACVG) Pipeline current mapper (PCM) C-scan Soil Resistivity

Direct examination:

Coating conditions Corrosion mapping and data collection Pipe defects and metal loss Remaining strength of the pipe Soil type, pH levels, depth Cathodic protection evaluation

Anomaly Verification Once the dig plan has been established and digs identified technicians using SubMeter GPS identified, Sub equipment return to the pipeline and stake the exact sites.

Technicians locate and document the defect found the Indirect Surveys by using Surveys.

The appropriate calculations are generated and repair calls are made made.

Post Assessment Once completed, all data is processed by Alphas engineers with the final report and recommendations. Click here to discuss your needs with a qualified Alpha associate.

Fact Sheet: External Corrosion Quick Facts:

Corrosion is the natural process that occurs when materials made from metal return to their original state through a chemical reaction known as oxidation. Corrosion of all types is one of the leading causes of pipeline leaks and ruptures. Improved technologies have led to better prevention, monitoring, detection, and mitigation of external pipeline corrosion even for old pipelines. New pipeline Integrity Management regulations will promote early identification of potentially externally corroded sections and their repair. Refer to other Fact Sheets for specific discussion of issues related to corrosion in general, internal corrosion, selective seam corrosion, and stress corrosion cracking.

What is external corrosion and why does it occur?

Corrosion is the deterioration of metal that results from a reaction with the environment which changes the iron contained in pipe to iron oxide (rust). For example, if your car develops a rust spot, that is corrosion of metal. The same process can occur in various forms on pipelines . As is the case with your car, there are effective methods for preventing and arresting corrosion damage to pipelines. External corrosion occurs due to environmental conditions on the outside of the pipe (e.g., from the natural chemical interaction between the exterior surface of the pipeline and the soil surrounding it). Typically, the exterior surface of a pipeline is coated in order to prevent the surrounding soil or other environmental condition from contacting the steel pipe, thus preventing the oxidation process. In addition, the oxidation process can be halted electrically on both bare pipelines as well as on pipelines that have been coated. When either or both of these protective measures break down, external corrosion can occur.
What are the risks from external corrosion?

External corrosion can result in the gradual reduction of the wall thickness of the pipe and a resulting loss of pipe strength. It can occur relatively evenly over an area of the pipe surface (sometimes referred to as General Corrosion) or in isolated spots on the pipe. This loss of pipe strength could result in leakage or rupture of the pipeline due to internal pressure stresses unless the corrosion is repaired, the affected pipeline section is replaced, or the operating pressure of the pipeline is reduced. External pipeline corrosion creates weaknesses at points in the pipe, which in turn makes the pipe more susceptible to third party damage, overpressure events, etc. (i.e., corrosion doesn't necessarily need to cause the leak or rupture itself to increase risk).

Pipeline failure rates from Corrosion

While data specific to external corrosion alone is not available, corrosion in all its various forms is one of the most prevalent causes of pipeline spills or failures. For the period 2002 through 2003, incidents attributable to corrosion have represented 25% of the incidents reported to OPS for both Natural Gas Transmission Pipelines and Hazardous Liquid Transmission Pipelines. Over this same period, approximately 1 percent of the incidents reported to OPS for Gas Distribution Pipelines were due to corrosion.
What is being done to prevent/mitigate external corrosion?

The steel pipe in modern pipeline systems is coated to protect it from external environmental conditions that can lead to corrosion. Modern manufacturing processes for steel pipe and coatings are subject to rigorous fabrication and installation standards and quality control to reduce the occurrence of defects that can lead to corrosion-induced failures. Operators use cathodic protection systems to protect pipes from external corrosion. One type of this system imposes a very low-voltage, direct electric current on the pipeline to oppose the natural corrosion currents at locations where pipe coating is damaged or missing. Another type system is to connect the pipeline to an anode ground that attracts the corrosion-causing current. This sacrificial anode attracts the current away from the iron in the pipe. The Office of Pipeline Safety has implemented new Pipeline Integrity Management (IM) regulations that require all pipeline operators to inspect and assess all of their pipelines that could affect areas of high consequence such as populated areas or environmentally sensitive areas. The operators are required to inspect and assess their pipelines for integrity issues, such as corrosion, and repair or replace affected pipe. By implementing the requirements of the regulations and through responsible maintenance programs, pipeline operators continuously inspect their pipelines for external corrosion damage.

External Corrosion: What more can be done?

Public : Be aware of pipelines located near you. Be observant for signs of pipeline damage, leakage, or security concerns. Report any concerns you have regarding pipeline safety to the pipeline operator immediately. Always respect the pipeline right-of-way. Do not dig or build on a pipeline right-of-way without first contacting the pipeline operator or your state one-call center. Industry : Pipeline operators and industry stakeholders can continue to develop and implement improved corrosion detection and prevention technologies. Operators must continue to implement corrosion protection effectively and strengthen pipeline integrity management programs. Operators must mitigate the effects of corrosion when it is detected. Regulators : OPS and state regulators must continue to inspect pipeline operators to ensure they effectively implement required integrity management and corrosion control programs to ensure that risks to pipelines are identified and mitigated at the earliest possible time. Better coordination is needed between local permitting agencies and pipeline operators to facilitate expeditious granting of permits when public safety is potentially threatened.

http://primis.phmsa.dot.gov/comm/FactSheets/FSExternalCorrosion.htm

External Corrosion Direct Assessment Corrpro is a world class provider of External Corrosion Direct Assessment (ECDA) related surveys and data analysis. Our Pipeline Services Division staff includes numerous personnel with more than 20 years experience in pipeline testing and integrity assessments. We have been the largest provider of these types of services in the United States for over 10 years. Corrpro's ECDA services include: Pre-Assessment Indirect Examination CIS Potential Surveys DCVG Surveys Electromagnetic Surveys ACVG Surveys Soil Studies Resistivity Surveys Depth of Cover Sub-Meter GPS Locating Direct Examination Excavate and Inspect Coating Evaluation Corrosion Measurements MIC Investigations Pipe Strength Calculations Root Cause Analysis Corrosion Rate Estimates Post Assessment http://www.corrpro.com/content/170/external-corrosion-direct-assessment-ecda.aspx

External Corrosion Direct Assessment (ECDA)

Municipalities have billions of dollars invested in their buried infrastructure systems. Inspection and maintenance of the infrastructure is a key asset management tool that municipalities use to protect this investment. Step 1: Pre-Assessment A collection of historic and current data to determine whether ECDA is feasible; defines areas on pipelines where ECDA can be used; and selects indirect inspection tools. Step 2: Indirect Inspection Above-ground inspections to identify and define the severity of coating faults and other anomalies, corrosive soil conditions and the status of the level of cathodic protection (if the pipeline is cathodically protected). Step 3: Direct Examination Analyse of the indirect inspection data to categorize the severity of the anomalies and to select locations along the pipeline for excavation and inspection. Step 4: Post-Assessment Post-Assessment covers the analyses of data collected from the three previous steps to assess the effectiveness of the ECDA process on the pipeline and to determine reassessment intervals.

Levelton Consultants has the capabilities to inspect and test municipal water systems using External Corrosion Direct Assessment (ECDA). ECDA is a four-step procedure requiring the integration of pre-assessment data; data from multiple indirect field inspections; and data from pipe external surface inspections conducted in accordance with NACE International Standard Practice SP0502-2008 Pipeline External Corrosion Direct Assessment Methodology.
http://www.levelton.com/materials/external-corrosion-direct-assessment-ecda/

Corrosion Service offers complete ECDA services, including accurate estimation of the extent of coating defects and corrosion activity, using a fast and efficient CIPS and DCVG integrated approach with no need to interrupt the survey or return to defect locations afterwards! External Corrosion Direct Assessment (ECDA) is a structured process used to evaluate buried onshore ferrous pipeline integrity. The ECDA goal is to enhance safety by managing the risk of pipeline corrosion failures while minimizing the cost required for excavations and repairs. ECDA may also be used when more established methods such as in-line inspection (ILI) and pressure testing are not possible or not practical. NACE Standard Recommended Practice on Pipeline External Corrosion Direct Assessment Methodology (RP05022002) describes the ECDA process as allowing ...the prediction of susceptible areas where corrosion activity has occurred, is occurring or may occur. Although ECDA field assessment techniques are well established, specialized field equipment and staff experienced in the collection, recording, and analysis of data are necessary to obtain reliable and meaningful results. Corrosion Service quickly embraced the new ECDA techniques and both our field and professional staff are well versed in their application. We are equipped with state-of-the-art equipment for surveys and the collection of data which is then analyzed by professional engineers with many years of pipeline corrosion prevention experience. The ECDA Process This four step process consists of: 1) Pre-Assessment; 2) Indirect Inspection; 3) Direct Examination; and 4) Post Assessment, which can be summarized as follows:

1. The Pre-Assessment step involves the collection and evaluation of historical data and pipeline characteristics. Based on this information, the feasibility of an ECDA application is determined and once affirmed, the pipeline is divided into regions with similar exposure and areas where the same indirect inspection tools may be used. 2. The Indirect Inspection step uses a combination of 2 or more above ground survey techniques such as close interval potential survey (CIPS), alternating current voltage gradient (ACVG), direct current voltage gradient (DCVG), AC attenuation for the identification of areas with corrosion activities or coating faults. The data is evaluated via systematic analysis and high-risk areas are identified for excavation. 3. The Direct Examination step covers the selection of sites to be excavated and the physical identification of defects requiring repair or replacement. 4. The Post Assessment step evaluates the previous 3 steps of the ECDA process and establishes a future assessment schedule.

Higher Efficiency and Lower Survey Costs Integrated CIPS/DCVG Survey Results Corrosion Service has developed an integrated indirect inspection technique merging both the CIPS and DCVG measurements. This integrated technique allows data acquisition of both CIPS and DCVG simultaneously. Higher efficiency and lower survey costs are achieved by merging both techniques. List of Projects > H3L Pipe-Type Cable (2004) > H1L (Spare) Pipe-Type Cable (2004-2005) > Transfer Line at Sault St. Marie (2004) > Panhandle Line (2004-2005)

DCVG Survey with Indication of Suspect Coating Holiday

> Leamington Line (2004-2005) > Brantford Line (2004-2005) > 21 Lines (In progress)

http://www.corrosionservice.com/ecda.htm

Failure Analysis

Metallurgical failure analysis is the process that determines reasons a metal component fails due to environmental conditions and/or mechanical stress. Analysis of a failed part can be done using destructive testing or non-destructive testing. Destructive testing involves removing a metal component from service and testing it in a laboratory. Non-destructive testing is a test method that allows certain physical properties of metal to be examined without taking the samples completely out of service.

Our professionals take the following steps when providing a failure analysis:

Research the history of the equipment/part Examine the equipment/part (visual examination including photos) Provide testing Catalog the evidence Plan of Action/report

Leveltons Physical Metallurgy Group has provided this service to many clients to determine the root cause and solution to the underlying problems to prevent future failures. Our current Laboratory Endorsements include:

BC Safety Authority Boiler and Pressure Vessel Testing Agency US Coast Guard Accepted Independent Laboratory Canadian Welding Bureau Certified Welding Inspection Organization and Metallurgical Laboratory

http://www.levelton.com/materials/failure-analysis/

Fact Sheet: External Corrosion Quick Facts:

Corrosion is the natural process that occurs when materials made from metal return to their original state through a chemical reaction known as oxidation. Corrosion of all types is one of the leading causes of pipeline leaks and ruptures. Improved technologies have led to better prevention, monitoring, detection, and mitigation of external pipeline corrosion even for old pipelines. New pipeline Integrity Management regulations will promote early identification of potentially externally corroded sections and their repair. Refer to other Fact Sheets for specific discussion of issues related to corrosion in general, internal corrosion, selective seam corrosion, and stress corrosion cracking.

What is external corrosion and why does it occur?

Corrosion is the deterioration of metal that results from a reaction with the environment which changes the iron contained in pipe to iron oxide (rust). For example, if your car develops a rust spot, that is corrosion of metal. The same process can occur in various forms on pipelines . As is the case with your car, there are effective methods for preventing and arresting corrosion damage to pipelines. External corrosion occurs due to environmental conditions on the outside of the pipe (e.g., from the natural chemical interaction between the exterior surface of the pipeline and the soil surrounding it). Typically, the exterior surface of a pipeline is coated in order to prevent the surrounding soil or other environmental condition from contacting the steel pipe, thus preventing

the oxidation process. In addition, the oxidation pr ocess can be halted electrically on both bare pipelines as well as on pipelines that have been coated. When either or both of these protective measures break down, external corrosion can occur.
What are the risks from external corrosion?

External corrosion can result in the gradual reduction of the wall thickness of the pipe and a resulting loss of pipe strength. It can occur relatively evenly over an area of the pipe surface (sometimes referred to as General Corrosion) or in isolated spots on the pip e. This loss of pipe strength could result in leakage or rupture of the pipeline due to internal pressure stresses unless the corrosion is repaired, the affected pipeline section is replaced, or the operating pressure of the pipeline is reduced. External pipeline corrosion creates weaknesses at points in the pipe, which in turn makes the pipe more susceptible to third party damage, overpressure events, etc. (i.e., corrosion doesn't necessarily need to cause the leak or rupture itself to increase risk).
Pipeline failure rates from Corrosion

While data specific to external corrosion alone is not available, corrosion in all its various forms is one of the most prevalent causes of pipeline spills or failures. For the period 2002 through 2003, incidents attributable to corrosion have represented 25% of the incidents reported to OPS for both Natural Gas Transmission Pipelines and Hazardous Liquid Transmission Pipelines. Over this same period, approximately 1 percent of the incidents reported to OPS for Gas Distribution Pipelines were due to corrosion.
What is being done to prevent/mitigate external corrosion?

The steel pipe in modern pipeline systems is coated to protect it from external environmental conditions that can lead to corrosion. Modern manufacturing processes for steel pipe and coatings are subject to rigorous fabrication and installation standards and quality control to reduce the occurrence of defects that can lead to corrosion-induced failures. Operators use cathodic protection systems to protect pipes from external corrosion. One type of this system imposes a very low-voltage, direct electric current on the pipeline to oppose the natural corrosion currents at locations where pipe coating is damaged or missing. Another type system is to connect the pipeline to an anode ground that attracts the corrosion-causing current. This sacrificial anode attracts the current away from the iron in the pipe. The Office of Pipeline Safety has implemented new Pipeline Integrity Management (IM) regulations that require all pipeline operators to inspect and assess all of their pipelines that could affect areas of high consequence such as populated areas or environmentally sensitive areas. The operators are required to inspect and assess their pipelines for integrity issues, such as corrosion, and repair or replace affected pipe. By implementing the requirements of the regulations and through responsible maintenance programs, pipeline operators continuously inspect their pipelines for external corrosion damage.

External Corrosion: What more can be done?

Public : Be aware of pipelines located near you. Be observant for signs of pipeline damage, leakage, or security concerns. Report any concerns you have regarding pipeline safety to the pipeline operator immediately. Always respect the pipeline right-of-way. Do not dig or build on a pipeline right-of-way without first contacting the pipeline operator or your state one-call center. Industry : Pipeline operators and industry stakeholders can continue to develop and implement improved corrosion detection and prevention technologies. Operators must continue to implement corrosion protection effectively and strengthen pipeline integrity management programs. Operators must mitigate the effects of corrosion when it is detected. Regulators : OPS and state regulators must continue to inspect pipeline operators to ensure they effectively implement required integrity management and corrosion control programs to ensure that risks to pipelines are identified and mitigated at the earliest possible time. Better coordination is needed between local permitting agencies and pipeline operators to facilitate expeditious granting of permits when public safety is potentially threatened.

Date of Revision: 12012011

http://primis.phmsa.dot.gov/comm/FactSheets/FSExternalCorrosion.htm