Atmospheric Corrosion - Jason Lozano

Atmospheric Inspection
Keeping it Consistent
NACE Twin Cities Section 10,000 Lakes
Pipeline Corrosion Control Seminar
February 4-5, 2020

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www.LSConsulting.com
• The purpose of this presentation is
to ensure that inspectors are
describing visual observations
made during assessments for
atmospheric corrosion in the same
manner.
• We all need to use the same
language.
Consistency is Critical
Insert relevant photo

3
If Jerry sees tool marks with rust
and rust at threads,
What one inspector sees,
all other inspectors should see as well
then Tony should be seeing tool marks
with rust and rust at threads as well.

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• Level of detail should ALWAYS be identified and agreed upon using the same
language.
• Asset ID and locations should ALWAYS be described in the same language.
• Asset conditions should ALWAYS be described in the same language.
• Pictures should ALWAYS be taken in the same manner using the same method.
• Quality of work from one inspector to the next should ALWAYS be consistent.
Inspection expectations should ALWAYS be surpassed

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Level of Detail

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Does the operator want
individual assets inspected?
(Verify with project manager and
supervisor)
Level of inspection detail should be clarified with the operator,
and all inspectors should be given clear instruction.
Does the operator want assets
grouped? If so, how? By line # or
segment, etc.? (Clarify)

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• The level of inspection detail is
crucial to know because it will
change how you identify assets.
• All inspectors working a project
MUST HAVE a complete
understanding of the level of detail
expected.
• It could be catastrophic for an
operator if each inspector used a
different level of detail. (Remember,
operators can be fined for
noncompliance.)
Important!

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Asset Identification

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• In a perfect world, the operator will
have all assets tagged already,
however in some cases this is not
what you will find in the field.
• Some assets will need to be
assigned an ID by the inspector
during the inspection.
ID Tags

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• MV-103 = Asset ID. MV meaning
(motorized valve or is it mainline
valve?)
• DB = Station ID
• 81 = Line number
• UDV = Function (In this case the
asset is a Unit Discharge Valve)
• 103 = The identifier number specific
to this particular valve
(Note: Tag also indicates the specific pump number
this valve is associated with)
Understanding the information on an asset tag

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In the event an asset does not have an asset ID tag,
an asset ID will have to be assigned

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• Location in relation to nearest
major asset (US for upstream DS
For downstream)
• Line number
• Nearest major asset ID
• Type of asset being identified (In
this instance, HV = Hand Valve)
Understanding information needed for proper asset
naming

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• UP= Unit pump
• TP= Transfer pumps
• BP= Booster pumps
• LNCR= Launcher
• RCVR= Receiver
• M= Meters
• FS= Flow sensors
• STR= Strainers
Types of major assets to name from
List below includes most (not all) major asset types to name from.
These asset types will almost always have an asset tag on them.
If an asset has an ID tag, it is ALWAYS a major asset.
• MV= Motorized valves
• HV= Hand valves
• PSV= Pressure safety valves
• PT= Pressure transmitter
• CK= Check valves
• PIT= Pressure indicating transmitter
• PRV= Pressure relief valves

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• PS= Pipe supports
• TZ= Transitions
• P= Pipes
• Secondary assets
Types of assets where it is NOT wise to name from:

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• It is extremely important to determine
the direction of flow. Without
understanding which direction the flow
is moving, it is impossible to relate an
asset’s location to another asset.
• This information needs to be accurate.
Even without drawings, an individual
should be able to determine a named
asset’s location by name alone.
• There are many different ways to tell
direction of flow by using one of the
many clues if you know where to look.
Determining the direction of flow

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Can you identify the direction of flow?

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Can you identify the direction of flow?

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• Naming an asset based on upstream
relation to other major assets limits the
number of potential names it can be
called making it easier for another
inspectors to remain consistent.
• Note: on occasion, you will have no
choice but to use the downstream
designation.
Whenever possible, give a name to an asset based on
US (upstream) location

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In some instances, you will not be able to name an
asset based on an upstream location

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What would you name this (TZ) transition?

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What would you name this transition?

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• On occasion you will find assets that
have flow in both directions. In this
case, you should name any assets you
are inspecting directionally from major
assets.
EXAMPLE: Name the HV in this picture
S-82-HV-125-HV
S= South
82= Line number
HV-125= The nearest major asset (in this
case, it’s right next to the tank)
HV= Asset type
Multi Directional Flow

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Asset Types

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• This next segment is based on the
assumption that the operator wants
all assets inspected and in detail.
• Not every project will require this
level of detailed inspection,
however each inspector should be
identifying assets in the same
manner should the operator
request it.

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This asset has an asset ID label
on it (PSV-123)
Similar assets but different names
This asset has no label and looks
similar to (PSV-123)

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If you look downstream of the asset, there
are no other major assets in line, therefore it
must be named off of an upstream asset.
This asset would be named DS-81-PSV-123-HV
Can you guess why?
Even though the asset is nearly identical
to the upstream PSV, it is not labeled so it
would be labeled as a hand valve.

27
This is a hand valve. It is operated by hand to
open and close. (label = HV) This IS NOT a
major asset because it has no label.
Assets that look different but are labeled the same
This is a hand valve. It is operated by hand
to open and close. (label = HV) This IS a
major asset because it has a label.

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Transition (TZ)
Other types of assets
Secondary Transition
(TZ-2)

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Galvanized support with 12” pipe
Supports
Note: It is extremely important to identify the type of support and diameter of the pipe it is
supporting.
Steel support with 12” pipe

30
PIG receiver (RCVR)
PIG Receiver and Launcher
Pig launcher (LNCR)

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Asset Conditions

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• As inspection is performed and assets
are evaluated, it is extremely important
that conditions are identified properly
and recorded using the same
descriptive language.
• Operators rely on quality reporting to
prioritize and facilitate repairs on the
assets we inspect therefore, all
inspectors should be clear on what they
are seeing and documenting
accordingly.
• The following section will cover
common conditions and appropriate
descriptions of those conditions.
Many conditions that may be present

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• Rust bleed is a common occurrence during
atmospheric inspection assessments.
• There are different levels of rust bleed so it is
important to note the degree.
• For the purpose of being consistent, rust
bleed should be graded as follows.
• Minor rust bleed should be used when there
is trace to a clearly visible amount present
• Moderate rust bleed should be used when a
significant percentage of the asset has bleed
present.
• Heavy rust bleed is to be used when the
majority of an asset is covered. (Can also be
representative of localized corrosion)
• Asset pictured has minor rust bleed.
Rust Bleed
Rust bleed develops when corrosion has begun at a specific point on an asset and is carried to other areas by moisture
leaving a staining or bleeding appearance.

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Moderate rust bleed
Levels of Rust Bleed
Heavy rust bleed

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• Disbondment occurs when the coating
separates from either the base
substrate or between layers of existing
coating.
• In this instance, the disbondment is
occurring between the coating and
base metal due to corrosion. As you can
see, there is a heavy layer of rust
forming on the base metal.
Disbondment

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Less obvious disbondment occurs when there is
poor adhesion between coating layers. This can be
caused by poor surface prep between coating layers
or non compatibility between coating types.
Other types and less obvious disbondment
Disbondment of coating due to poor initial
surface prep. (Note lack of corrosion)

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• Mechanical coating damage occurs when the
coated asset is struck by an object hard
enough to damage, chip, crack, scratch, or
cause disbondment.
• Tool marks are common as a form of
mechanical damage; however it can occur as
a result of striking anything against a cured
coating.
• In this photo, it appears as though tools may
have been struck against the coating in the
process of either loosening or tightening the
nuts and bolts. This is very common to find.
Even though there is no corrosion visible, it
is important to get good photos for the
operator. This type of damage is a kickoff
point of corrosion.
Mechanical Coating Damage

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Most of the time any mechanical damage
found will be in the form of tool marks.
Tool Marks
Tool marks are usually found on nuts
and bolts but can also be found on
pipe as well.

39
• Wrinkling tends to occur during the
curing process of coating that has been
applied.
• There are many factors that can
contribute to the cause of this however
most of those factors result in high
surface tension causing the wrinkling
that you see here.
Wrinkling

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• Some cracking is not very easy to see. In
this case the cracks have penetrated to
the substrate and moisture has
penetrated and corrosion has begun. If
there is no visible corrosion, it can be
difficult to see.
• Note: In this picture there is a
significant amount of checking all
around. No doubt that the checking
was a precursor to the cracks forming.
Cracking

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• Blisters can form as perfectly round
protrusions, or with some other
geometry.
• Blisters are caused by there being vapor
or liquid under a coating against the
substrate or in between coating layers
causing some level of disbondment.
• Blisters can be evaluated by ASTM
D714. This standard gives common
language in describing the frequency
and size of blisters.
Blisters

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• Chalking is when a coating is damaged
by UV radiation from sunlight.
Chalking

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• Mud cracking happens when inorganic
zinc coatings are applied too thick.
Mud Cracking

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• Sags occur when the coating is applied
too thick or the formulation is incorrect.
Sags

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• Pinholes can be caused by:
• Too much air in the coating
• Solvent entrapment
• Using incorrect solvent
Pinholes

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• Are sometimes also called cratering.
• Fisheyes are caused by contamination
on the substrate, usually grease or oil.
Fisheyes

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• How do we inspect coating under
insulation?
• Remove Insulation
• Install Inspection Ports
Coating Under Insulation

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• Problem and approach
• Statistical background
• Categorizing and quantifying assets
• Determination of risk and
confidence intervals
• Placement of ports
Overview

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Approach
Develop method to determine the number of corrosion under insulation (CUI)
ports required on a population of assets, to say to a specified level of confidence,
that statistically no corrosion is present on piping under insulation

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Approach
Develop method to determine the number of corrosion under insulation (CUI) inspection points required on a
population of assets, to say to a specified level of confidence, that no corrosion is present on piping under
insulation
Select statistical equation for determining population
sample size
Specify population(s)
Determine confidence interval for population(s)
Calculate required number of inspection locations
(sample size) to say no corrosion exists within
population(s), at the specified confidence interval

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Selection of Statistical Equation
• Slovin’s Formula
• Appropriate when nothing is known of the distribution or the parameters of
the population to be sampled
𝑛𝑛 =
𝑁𝑁
1+𝑁𝑁𝑒𝑒2
n=sample size
N=population size
e=error (1-confidence interval)

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• Slovin’s Formula presented graphically

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Slovin’s Formula represented via table

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• Population consists of a set of assets we
wish to investigate for corrosion and
install ports on
• How to quantify and categorize set of
assets to apply statistical formula to?
• Use these numbers for an example:
Determining the Populations

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• Filtered project documentation for
insulated assets
• Quantified based on asset type
• Elbows, tees, flanges, valves, linear feet
of straight pipe, supports
• Ensures all asset types, orientations and
geometries are considered for ports
• Allows for application of a higher
confidence interval to classes with
greater risk

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• Removable insulation
• When picking port locations, omit
removable insulation from asset
selection
Asset Total Removable Insulation
Piping (linear feet) 1503.2
Drainlines (6in and smaller) (linear feet) 417.1
Elbows (larger than 6") 223
Elbows (6" and smaller) 108
Tees (larger than 6") 115
Tees (6" and smaller) 108
Valves (flanged) (larger than 6") 169 x
Valves (flanged)(6" and smaller) 250 x
Valves (threaded/welded)(larger than 6") 0 x
Valves (threaded/welded)(6" and smaller) 21 x
Pressure Safety Device (larger than 6") 12 x
Pressure Safety Device (6" and smaller) 58 x
Blind Flanges (larger than 6") 25 x
Blind Flanges (6" and smaller) 159 x
Flanges (larger than 6") 520 x
Flanges (6" and smaller) 416 x
Pipe Supports (Hanger) (larger than 6") 0
Pipe Supports (Hanger) (6" and smaller) 5
Pipe Supports (larger than 6") 381
Pipe Supports (6" and smaller) 220
Olets 219 x
Nipples 1 x
Caps/Plugs 17 x
Air to Soil/Concrete Penetrators (larger than 6") 91
Air to Soil/Concrete Penetrators (6" and smaller) 0

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• Baseline of at least 80% confidence
established as requirement for all asset
classes (populations)
• Some assets may receive an elevated
confidence interval based on their:
• Asset type
• Material type
• Pipe Size
• Insulation penetration of a wall or floor
Determining the Confidence Interval

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• Determine highest risk descriptors, to
elevate certain populations to 90%
confidence interval
• Much of the decision making on what
was elevated to 90% may be based on
historical experience
• Need to be selective to keep port
numbers economical
Determining the Confidence Interval

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Calculation of Samples
• There were 223 elbows larger than 6” listed on the survey a few slides ago.
• We can see from the highlighted row on the table that for an 80% confidence level we
want to install 23 ports, and for a 90% confidence level we want to install 69 ports.

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• Use discretion to place the ports
throughout the area of interest
• Goals include
• Install in easily accessible locations
• Minimize need for scaffolding
• Spread out assets appropriately
• Select locations based on probability of
water
• Low sections of pipe
• Bottom of elbows
• 12 o’clock, 3 o’clock, 6 o’clock, and 9
o’clock positions
Selection of Ports

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Thank you!
Questions?

Atmospheric Corrosion - Jason Lozano

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