Tuesday, 15 May 2018: 15:50
Room 304 (Washington State Convention Center)
While corrosion protection of the exterior of natural gas pipeline has developed to be a routine process, including use of coatings and cathodic impressed current systems; the protection of the inside of the pipe is not as straightforward. This work explores the use of sacrificial metal coatings to protect the pipes inner surface. Coatings, applied by techniques including hot dip, electroplated, and thermally spray, were applied to one side of low carbon steel plates which were similar in composition to an API 5L pipeline steel. Coatings evaluated included Zn, alloys of Zn (95 Zn-5 Al, 85 Zn- 15 Al), Al, and an alloy of 95 Al- 5 Mg. Existing models suggest that any residual water, which often contains chlorides and CO2 from the gas, will be the primary contributors to any corrosion. Gravimetric corrosion tests were conducted in autoclaves to simulate the partial pressure of CO2 found in a natural gas pipeline. A test condition of; immersed samples in a 3 ½ wt. % NaCl brine, with a pressure of 300 kPa (45 psig) of CO2, and a temperature of 40 °C; was used. Tests of 168 h duration with, and without, a nonconductive masking of the steel substrate were conducted. For the tests where the steel surfaces were exposed, on the back side of the coated side of the steel test coupons, did not show significant corrosion after the tests with any of the sacrificial coatings. For the Zn, or Zn alloy, samples; a layer of ZnCO3 formed on coated and uncoated steel surfaces. The results indicated that for these conditions, the thermally sprayed coatings showed less weight loss than the hot dipped or electroplated coatings, and the Zn alloy with 15% Al had less weight loss than either the pure Zn or the Zn with 5 % Al. Visual examination indicated that while AlMg alloy successfully protected the uncoated steel from corrosion, it showed heavy corrosion including pitting in these conditions.