Table Of ContentP1:FCE/FEP P2:FCE
CE003-FM CE003-Peabody November16,2000 13:35 CharCount=0
PEABODY’S
CONTROL OF PIPELINE CORROSION
SECOND EDITION
A.W. PEABODY
Editedby
RONALD L. BIANCHETTI
NACEInternational
TheCorrosionSociety
1440SouthCreekDrive
Houston,Texas77084
i
P1:FCE/FEP P2:FCE
CE003-FM CE003-Peabody November16,2000 13:35 CharCount=0
NACEInternational
TheCorrosionSociety
(cid:176)
C 1967,2001byNACEInternational
SecondEdition2001. Allrightsreserved.
LibraryofCongressCatalogNumber99-80032
ISBN1-57590-092-0
PrintedintheUnitedStatesofAmerica. Allrightsreserved. Thisbook,orpartsthereof,
maynotbereproducedinanyformwithoutpermissionofthecopyrightowners.
Neither NACE International, its officers, directors, or members thereof accept any re-
sponsibilityfortheuseofthemethodsandmaterialsdiscussedherein. Theinformation
isadvisoryonlyandtheuseofthematerialsandmethodsissolelyattheriskoftheuser.
CoverillustrationbyMarkLewis,courtesyoftheEastBayMunicipalUtilityDistrict.
NACEPress:
DirectorofPublications:JeffLittleton
ManagerofNACEPress:NeilVaughan
NACEInternational
1440SouthCreekDrive
Houston,Texas77084
http:==www.nace.org
ii
P1:FCE/FEP P2:FCE
CE003-FM CE003-Peabody November16,2000 13:35 CharCount=0
Table of Contents
Preface v
AbouttheAuthor vii
Contributors ix
Chapter1 IntroductiontoCorrosion
JohnA.Beavers 1
Chapter2 PipelineCoatings
RichardN.Sloan 7
Chapter3 CathodicProtection—HowItWorks
JohnA.Beavers 21
Chapter4 CriteriaforCathodicProtection
JohnA.BeaversandKevinC.Garrity 49
Chapter5 SurveyMethodsandEvaluationTechniques
RonaldL.Bianchetti 65
Chapter6 Instrumentation
MarkLewis 101
Chapter7 GroundBedDesign
RonaldL.Bianchetti 131
Chapter8 ImpressedCurrentCathodicProtection
RonaldL.Bianchetti 157
iii
P1:FCE/FEP P2:FCE
CE003-FM CE003-Peabody November16,2000 13:35 CharCount=0
iv TableofContents
Chapter9 CathodicProtectionwithGalvanicAnodes
RonaldL.Bianchetti 177
Chapter10 CathodicProtectionwithOtherPowerSources
JohnA.Beavers 201
Chapter11 StrayCurrentCorrosion
MichaelJ.Szeliga 211
Chapter12 ConstructionPractices
RonaldL.Bianchetti 237
Chapter13 MaintenanceProcedures
RonaldL.Bianchetti 261
Chapter14 MicrobiologicallyInfluencedCorrosion
BrendaJ.LittleandPatriciaWagner 273
Chapter15 Economics
RonaldL.Bianchetti 285
Chapter16 FundamentalsofCorrosion
JohnA.Beavers 297
AppendixA NACEGlossaryofCorrosion-RelatedTerms 319
AppendixB AdditionalImportantInformationonUndergroundCorrosionControl 339
Index 341
P1:FCE/FEP P2:FCE
CE003-FM CE003-Peabody November16,2000 13:35 CharCount=0
Preface
Thisbookwasoriginallypublishedin1967bySamPeabodyandisthemostquotedand
useddocumentinthecorrosionindustryforpipelinecorrosioncontrolandtesting. When
theoriginalbookwaspublished,specificcriteriaforcathodicprotectionforunderground
pipelines were still under evaluation and consideration. Not until 1969 was the first
documentedstandardapprovedbyNACEInternationaloncriteriaRP0169. Thedepth
andvisionthatPeabodyincorporatedinthefirstversionofthebookhasstoodthetest
oftime.
Thisrevisedversionofthe1967bookisnotanattempttomakeradicalchangestothe
originaldocument. Muchoftheoriginaltextandconceptsremainintact. Weattempted,
however, to incorporate original traditional elements of the book with updates and
expanded discussions on equipment, testing techniques and criteria, coatings, survey
methods,anddataanalysis.
AnintegralpartofthisrevisionisaCD-ROMthatcontainsformulasofkeydesign
calculations, case examples of corrosion control designs which provide a set-by-step
overviewofhowtodesignvariouscomponentsofcathodicprotectionsystems,andan
electroniccopyoftherevisedbookedition.
AsdescribedinthePrefaceoftheoriginal1967edition,everyattempthasbeenmade
to check the accuracy of all statements and other data. However, it is unreasonable
to assume that everything in this book is accurate and exact. Any suggestions will be
consideredwhenfutureeditionsofthisbookareprepared.
v
P1:FCE/FEP P2:FCE
CE003-FM CE003-Peabody November16,2000 13:35 CharCount=0
About the Author
1915–1998
ThisupdatedversionofNACEInternational’sbooktitledControlofPipelineCorrosionis
dedicatedtothememoryofitsoriginalauthor,A.W.(Sam)Peabody. Sinceitspublication
in 1967, the book has been translated into at least seven different languages and is
consideredbymostasthedefinitiveworkonpipelinecorrosion.
Samreceivedhisbachelor’sdegreefromtheUniversityofMaineandpursuedgrad-
uatestudiesattheBrooklynPolytechnicInstituteinNewYork. HeworkedforEbasco
Services Inc. (no longer in existence) for over 40 years until his retirement in 1980 as
DirectorofCorrosionEngineering. HewasanactivememberofNACEsince1947. His
accomplishments,awards,andrecognitionsaretoomanytolisthere. Hisbiggestlegacy,
especiallytothoseofuswhohadtheprivilegeofworkingforandwithhim,isthathe
was the perfect example of “a gentleman and a scholar.” He was an excellent teacher
whoalwaysemphasizedprofessionalintegrity,aqualityheinstilledinsomany.
vii
P1:FCE/FEP P2:FCE
CE003-FM CE003-Peabody November29,2000 10:8 CharCount=0
Contributors
JohnA.Beavers
John A. Beavers is Vice President of Research at CC Technologies, a corrosion engineering
andresearchcompany. HereceivedB.S.andPh.D.degreesinmetallurgicalengineeringfrom
theUniversityofIllinoisatUrbana-Champaignin1973and1977, respectively. Dr. Beavers
has directed and contributed to numerous research programs on corrosion performance of
structuralmaterials.Theseprogramsincludedfailureanalyses,criticalliteraturereviews,and
laboratoryandfieldevaluationsofmetallicandnon-metallicmaterial.Dr.Beavershasutilized
state-of-the-artelectrochemical,surfaceanalytical,andmechanicaltechniquesfortheevalua-
tionofmaterialsperformance.Amajoremphasisofhisresearchhasbeenthemechanisticand
practicalaspectsofcorrosionandstresscorrosioncracking(SCC)onundergroundpipelines.
Dr.BeaversworkedatBattelleMemorialInstitutefrom1977to1987,wherehewasaSenior
ResearchLeaderintheCorrosionSection. HejoinedCCTechnologiesin1987.
Dr. Beavers has authored over 80 papers in the field of corrosion and has received two
U.S. Patents. An active member of NACE, he was Chairman of the Research in Progress
Symposiumin1994andofthePublicationsCommitteein1991and1992.
Editor’s Note: Sincere appreciation to John Beavers for investing a lot of time on a detailed and
productivereviewofthefinaldraftontheevebeforeprinting.
RonaldL.Bianchetti
Ronald L. Bianchetti is currently a Senior Engineer at East Bay Municipal Utility District
(EBMUD) in Oakland, California. He received a B.S. in engineering in 1975 from the
University of California, Davis and an MBA in 1981 from St. Mary’s College of California.
HeisaRegisteredProfessionalEngineerandhasover25yearsofexperience. Priortoholding
his current position, Mr. Bianchetti worked in the private sector as a consultant in the cor-
rosion industry from 1975 to 1992. His work includes planning, designing, testing, and the
construction management of cathodic protection systems for underground pipelines, tanks,
refineries,powerplants,andmarinestructures. HehasservedinNACEInternationalasPast
ix
P1:FCE/FEP P2:FCE
CE003-FM CE003-Peabody November29,2000 10:8 CharCount=0
x Contributors
Chairman of the Publications Committee, ad-hoc member to the Board of Directors, Past
WesternRegionChairmanandPastSectionChairoftheSanFranciscoSection.
Mr. Bianchettihaspublishedover30papersinthefieldofcorrosionandhasgivenhun-
dredsofpresentationsoncorrosionandcorrosioncontrol.
KevinC.Garrity,P.E.
Kevin C. Garrity, P.E., is currently Vice President of Engineering at CC Technologies, a cor-
rosion engineering and research company. He received a B.S. in electrical engineering in
1974fromthePolytechnicInstituteofBrooklyn. HeisaNACECertifiedCathodicProtection
Specialist and a Registered Professional Engineer in seven states. Mr. Garrity has 26 years
of experience in the design, installation, monitoring, and assessment of cathodic protection
systems for buried pipelines, underground storage tanks, concrete structures, and marine
structures. Mr. GarrityworkedatEbascoServicesfrom1974to1982,wherehewasaSenior
CorrosionEngineer,andatHarcoCorporationfrom1982to1989,wherehewasVicePresident
ofEngineering. HejoinedCCTechnologiesin1989.
In1996,Mr. GarrityreceivedtheColonelGeorgeW.CoxAwardforoutstandingcontribu-
tionstothefieldofundergroundcorrosioncontrol. Hehaspublishedmorethan20papersin
thefieldofcorrosioncontrol. Mr. GarritydeliveredtheplenarylectureatCorrosion’98.
MarkLewis
Mark Lewis is Assistant Corrosion Engineer at the East Bay Municipal Utility District
(EBMUD) in Oakland, California. He is a graduate of Kent State University and attended
Bethany College in West Virginia. He has worked in the cathodic protection and corrosion
engineeringfieldsince1980, bothwithintheUnitedStatesandinternationally. HeisaPast
ChairmanoftheSanFranciscoBayAreaSectionofNACEInternational.
Heistheauthorofseveraltechnicalandhistoricalarticlesoncathodicprotectionandhas
madenumerouspresentationsonthesubject.Mr.Lewishasapatentpendingforadistribution
systemrectifierdesign.
BrendaJ.Little
BrendaJ.Little,SeniorScientistforMarineMolecularProcessesattheNavalResearchLabora-
tory,hasaPh.D.inchemistryfromTulaneUniversityandaB.S.inbiologyandchemistryfrom
BaylorUniversity. SheisamemberoftheAmericanChemicalSocietyandtheNationalAs-
sociationofCorrosionEngineers(NACEInternational). SheisaNACEInternationalFellow
andtherecipientofa1999NACEInternationalTechnicalAchievementAward.
Dr. Little serves on the editorial board for Biofouling and is the author of one book, 20
bookchapters,andover80peer-reviewedjournalarticles.
P1:FCE/FEP P2:FCE
CE003-FM CE003-Peabody November29,2000 10:8 CharCount=0
Contributors xi
SteveMcKim
Since 1989, Steve McKim has been Vice President of American Construction & Supply, Inc.
Basedin Mill Valley, California, his company specializesincathodicprotectionconstruction
services.Mr. McKimpreviouslyworkedwithHarcoCorporationandChevronUSA.Hehas
beeninthecorrosionindustrysincehegraduatedfromtheUniversityofIllinoiswithaB.S.in
mechanicalengineeringin1983. HeisaPastChairmanoftheNACESanFranciscoBayArea
Section.
RichardN.Sloan
ThelateRichardSloan,wasanauthorityinthefieldofpipelinecoatings. Heworkedforover
45yearswithacompanythatwasfirstknownasHCPrice. (Thecompanychangeditsname
several times: HC Price, Ameron Price, Bredero Price, and Energy Coatings.) He attended
DrexelUniversityandgraduatedwithabachelor’sdegreeinIndustrialAdministration.
During his professional career, Richard Sloan taught various short courses in pipeline
coatings,andwasaspeakeratnumerousseminarsonthesubject. ThelateMr.Sloanwasan
activeandlong-standingmemberofNACE,AWWA,andWesternPipeliners.
MichaelJ.Szeliga
MichaelJ.Szeliga,P.E.,istheChiefEngineerforRussellCorrosionConsultants,Inc. Hehas
more than 23 years of experience in corrosion control engineering. Much of his work has
involved the analysis and control of stray current from DC-powered transit systems and
from impressed current cathodic protection systems. A Licensed Professional Engineer in
severalstatesandcertifiedbyNACEInternationalasaCorrosionSpecialistandaCathodic
Protection Specialist, Mr. Szeliga has been and is the principal corrosion consultant for the
design, construction, and maintenance of many light and heavy rail transit systems. He is
presently chairman of the NACE (05)024X Committee on Interference Problems Associated
withRailTransit. Mr. SzeligaisalsochairmanoftheASTMsubcommitteeonstraycurrent.
HehaseditedabookforNACEInternationaltitledStrayCurrentCorrosionandhaspub-
lishedseveralarticlesonthesubject.
PatriciaWagner
PatriciaWagnerretiredfromtheNavalResearchLaboratoryin1998after14yearsofextensive
experienceinmicrobiologicallyinfluencedcorrosion. Sheisthecoauthorofonebookandthe
authorofnumerousarticlesoncorrosion.
P1:GKW/SPH P2:GKW/UKS P3:GKW/UKS QC:GKW/UKS T1:GKW
CE003-01 CE003-Peabody November15,2000 10:33 CharCount=0
1
Chapter
Introduction to Corrosion
John A. Beavers
WHAT IS CORROSION?
One general definition of corrosion is the degradation of a material through environ-
mentalinteraction.Thisdefinitionencompassesallmaterials,bothnaturallyoccurring
and man-made and includes plastics, ceramics, and metals. This book focuses on the
corrosion of metals, with emphasis on corrosion of carbon and low-alloy steels used
inundergroundpipelines.Thisdefinitionofcorrosionbegsthequestion;whydomet-
als corrode? The answer lies in the field of thermodynamics, which tells whether a
process such as corrosion will occur. A second logical question is what is the rate
of corrosion or how long will a pipeline last? Corrosion kinetics can help provide an
answertothisquestion.BothtopicsarediscussedingreaterdetailinChapter16.Chap-
ter 1 contains an introduction to the subject of underground corrosion. A glossary of
terms is included in Appendix A of this book to help with the sometimes confusing
terminology.
A significant amount of energy is put into a metal when it is extracted from its
ores,placingitinahigh-energystate.Theseoresaretypicallyoxidesofthemetalsuch
as hematite (Fe O ) for steel or bauxite (Al O ¢H O) for aluminum. One principle of
2 3 2 3 2
thermodynamicsisthatamaterialalwaysseeksthelowestenergystate.Inotherwords,
mostmetalsarethermodynamicallyunstableandwilltendtoseekalowerenergystate,
whichisanoxideorsomeothercompound.Theprocessbywhichmetalsconverttothe
lower-energyoxidesiscalledcorrosion.
Corrosionofmostcommonengineeringmaterialsatnear-ambienttemperaturesoc-
cursinaqueous(water-containing)environmentsandiselectrochemicalinnature.The
aqueous environment is also referred to as the electrolyte and, in the case of under-
ground corrosion, is moist soil. The corrosion process involves the removal of elec-
trons(oxidation)ofthemetal[Equation(1)]andtheconsumptionofthoseelectronsby
someotherreductionreaction,suchasoxygenorwaterreduction[Equations(2)and(3),
1
