SUI NORTHERN GAS PIPELINES LIMITED

Summer Internship 2017

Corrosion Control Department

Haider Ali
7/1/2017

The consequences of corrosion are many and varied and the effects of these on the
safe, reliable and efficient operation of equipment or structures are often more
serious than the simple loss of a mass of metal. Failures of various kinds and the
need for expensive replacements may occur even though the amount of metal
destroyed is quite small. SNGPL Corrosion control department is committed to avoid
all such loses to sustain efficient uninterrupted transmission and distribution of
Natural gas in all areas of Pakistan.

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Summary
This internship report focuses on corrosion control in pipelines used for
transmission and distribution of Sui Northern Gas all over Pakistan. Transmission
lines extend from Sui gas well all the way to the north of Pakistan i.e. Peshawar.
The internship focuses on entertaining students with wide knowledge concerning the
steps taken to prevent corrosion and cure pipes which have been corroded.

The internship schedule included visit and detailed study of all the processes
carried out which are involved in maintaining pipelines at the corrosion control
center; transmission office and Regional office in Lahore.

The corrosion control center aims to fabricate new transformer rectifier units,
repair the defective T/R units and Instruments and production of coating outer wrap
products to meet in time requirement for customers. The center is highly committed
to establish a corrosion computer data bank based on the information collected
through field monitoring and surveys by site offices in transmission and distribution.
The CCC (corrosion control center) conducts underground gas leakage detection
surveys through laser based detectors on transmission and distribution network to
reduce the gas losses of SNGPL. The center conducts technical audits of cathodic
protection system to ensure efficient working of the system. Continually improving
the effectiveness of the quality management system and conducting periodic reviews
of the above mentioned policies for continuing stability of SNGPL is practiced.

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INTRODUCTION

Unprotected pipelines, whether buried in the ground, exposed to the atmosphere, or

submerged in water, are susceptible to corrosion. Without proper maintenance, every
pipeline system will eventually deteriorate. Corrosion can weaken the structural
integrity of a pipeline and make it an unsafe vehicle for transporting potentially
hazardous materials. However, technology exists to extend pipeline structural life
indefinitely if applied correctly and maintained consistently.

Four common methods used to control corrosion on pipelines are protective coatings
and linings, cathodic protection, materials selection, and inhibitors.

I. Coatings and linings are principal tools for defending against corrosion. They
are often applied in conjunction with cathodic protection systems to provide
the most cost-effective protection for pipelines.

II. Cathodic protection (CP) is a technology that uses direct electrical current to
counteract the normal external corrosion of a metal pipeline. CP is used where
all or part of a pipeline is buried underground or submerged in water. On new
pipelines, CP can help prevent corrosion from starting; on existing pipelines;
CP can help stop existing corrosion from getting worse.

III. Materials selection refers to the selection and use of corrosion-resistant

materials such as stainless steels, plastics, and special alloys to enhance the life
span of a structure such as a pipeline. Materials selection personnel must
consider the desired life span of the structure as well as the environment in
which the structure will exist.

IV. Corrosion inhibitors are substances that, when added to a particular

environment decreases the rate of attack of that environment on a material
such as metal or steel reinforced concrete. Corrosion inhibitors can extend the
life of pipelines, prevent system shutdowns and failures, and avoid product
contamination.

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Evaluating the environment in which a pipeline is or will be located is very important
to corrosion control, no matter which method or combination of methods is used.
Modifying the environment immediately surrounding a pipeline, such as reducing
moisture or improving drainage, can be a simple and effective way to reduce the
potential for corrosion.

Furthermore, using persons trained in corrosion control is crucial to the success of

any corrosion mitigation program. When pipeline operators assess risk, corrosion
control must be an integral part of their evaluation.

Corrosion control is an ongoing, dynamic process. The keys to effective corrosion

control of pipelines are quality design and installation of equipment, use of proper
technologies, and ongoing maintenance and monitoring by trained professionals. An
effective maintenance and monitoring program can be an operator’s best insurance
against preventable corrosion-related problems.

Effective corrosion control can extend the useful life of all pipelines. The increased
risk of pipeline failure far outweighs the costs associated with installing, monitoring,
and maintaining corrosion control systems. Preventing pipelines from deteriorating
and failing will save money, preserve the environment, and protect public safety.

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 TABLE OF CONTENTS

SR No Contents Page No

Summary ii

1 Introduction iii

2 CORROSION CONTROL CENTRE

2.1
 T/R Units Workshop 1

2.2
 Instrument Workshop 1

2.3
 GLD Section 5

2.4
 Material Testing laboratory 6

2.5
 Outer Wrap Plant 8

3 TRANSMISSION OFFICE
3.1
 Corrosion control activities pertaining to 8
transmission network
 Visit of SMS and valve assembly and
3.2
technical study of coating and cathodic 9
protection at above ground transmission
network
3.3  Visit of CP system 11

3.4  ECDA/DCVG/PSP etc. surveys 16

4 REGIONAL OFFICE LAHORE

4.1
 Corrosion control activities pertaining to 17
distribution network
4.2  Field survey of CP stations and PSP 18

5 Conclusion 19

6 Appendix 20

7 References 21

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CORROSION CONTROL CENTRE

T/R Units Workshop

Cathodic protection transformer rectifier units (also known as TR or TRU) are
used for Impressed Current Cathodic Protection (ICCP) Systems. These units are
purpose built and generally feature remote control monitoring capabilities and
current interrupters. Metallic structures are at risk of corrosion when submerged in
water or buried underground for extended periods of time.
SNGPL T/R Units workshop offer a range of services to help you protect your
critical assets and infrastructure from corrosion by maintaining uninterrupted
supply of working T/R units. Impressed current cathodic protection is a proven
system for effectively controlling corrosion on metallic structures.
Cathodic protection transformer rectifier units (also known as TR or TRU) are
used for Impressed Current Cathodic Protection (ICCP) systems. These units are
purpose-built and generally feature remote control monitoring capabilities and
current interrupters. The output of the transformer rectifier in the impressed current
cathodic protection system should be optimized to provide sufficient current to
protect pipelines.

Fig 1: Routine check of T/R unit in workshop by a SNGPL employee

The Benefits of Installing and Maintaining ICCP Systems
 Improved lifespan of metallic structures, equipment and marine vessels that are
subject to electrolysis i.e. pipes in case of SNGPL.
 Designed to provide consistent, reliable protection against electrolytic
corrosive damage.
 SNGPL T/R Units Workshop can design, supply and maintain ICCP
installations.
In addition to these benefits, T/R Units Workshop also adds value to workforce by
providing installation and
maintenance training for internees. The comprehensive training programs cover
how to
control and manage ICCP systems. SNGPL also trains staff on how to perform
thorough inspections and surveys so that they can identify opportunities to improve
pipeline protection and determine whether any adjustments need to be made in
order for an installation to be effective.

Instrument Workshop

High quality precise field test equipment’s used for cathodic protection are kept in
the instrument workshop. Some of them are the following:

 Pipeline locator
 Current calibrator ( Current source generator )
 Paint tester equipment
 Automatic transformer ratio tester
 Digital Earth tester
 Iron loss tester
 Digital Low Resistance OHM Meter
 Direct Current Voltage Gradient (DCVG)

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Fig 2: Some of the Instruments for use placed in SNGPL Instrument
Workshop.

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Pipeline locator

In the field of cathodic protection work, it is necessary to locate pipes in order to

locate interferences in the cathodic protection system. An electronic pipe locator is
used for this purpose. The main components of the locator are the
directional transmitter and the directional receiver. Each one of these units is
carried by an operator. The operators are usually about 30 feet apart. During actual
operation the transmitter sends out signals which travel along the pipeline. The
receiver, in turn, picks up these signals in varying intensities, depending on the
distance the operators are from the pipe. When both operators are directly over the
pipe, a maximum response is obtained in the phones and on the visual meter of the
receiver. Most pipe can be located easily and accurately in this manner.

Current calibrator (Current source generator )

It is a multifunction calibrator used to test and calibrate a variety of measuring

instruments. Offering a high level of accuracy for an affordable price, this easy-to-
use calibrator provides electrical (mA, mV, V and frequency in Hz) and
temperature (in °C or °F) output signals, making the calibrator useful in a wide
range of applications.

Paint tester equipment

The paint testeris a mobile device for the rapid and accurate determination of e.g.
paint gauge. This paint tester can detect all paints, paint and electroplated coatings
on iron / steel and varnish, paint, anodizing coatings on non-ferrous metals and
also anti-static steel accurately.

Automatic transformer ratio tester

It is used to measure the turns ratio, excitation current and polarity of

windings in single- and three-phase distribution and power transformers
(tested phase by phase), potential and current transformers, and tapped
transformers.

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Digital Earth tester

This is a robust installation tester LCD display. The installation tester offers, in
addition to the various measuring modes such as insulation resistance, grounding
resistance, loop impedance, voltage and low-impedance measurement.

Iron loss tester

Digital Iron Loss Tester is a handy instrument. It is very useful to find Watt loss of
electrical steel immediately. This is very simple and easy to use Instrument so,
anyone can operate it easily. Internationally accepted standard method of testing
for electrical steel sheet is Epstein frame method. However that method needs a
special size like 30mm x 305 mm and more than 250g weight. After testing, that
material will be useless.

Direct Current Voltage Gradient (DCVG)

Assuming that the buried pipeline is protected using Impressed Current

Cathodic Protection (ICCP - as are most pipelines with hazardous contents), then
any defects in the coating will result in electric current flowing from the
surrounding soil and into the pipe. These currents cause voltage gradients to be set
up in the soil, which can be measured using a voltmeter.

By looking at the direction of these gradients, the location of coating faults may be
identified. By plotting the direction of voltage gradients around a fault, the type
and nature of faults may be deduced. By measuring the localized soil potentials
with respect to remote earth, a measure of the effectiveness of the cathodic
protection may be calculated.

Specially designed DCVG meters are available, which have bespoke voltage
ranges, specially designed transient response, rugged cases and (usually) a center-
zero meter movement for ease of use. The NACE method requires the
measurements to be made using a pair of copper-copper (II) sulfate
electrodes rather than simple metallic probes. In addition, the cathodic protection is
switched on and off repeatedly using an electronic switch commonly referred to as
an interrupter. Thus, two voltage readings (the "on" and "off" potentials) are taken

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at each fault position. Counter-intuitively, it is actually the "off" potential which is
regarded as more indicative of the effectiveness of the CP applied to the pipeline.

Results of a DCVG survey often result in selecting locations to excavate pipelines,

which can be costly in urban areas. Collection of data and interpretation may be
performed by pipeline companies themselves or, more usually, by independent
specialists.

SNGPL follows the above mentioned NACE method during its DCVG Survey
of pipelines laid by SNGPL.

GLD Section

Pipeline leak detection is used to determine if and in some cases where a leak has
occurred in systems which contain liquids and gases. Methods of detection
include hydrostatic testing, infrared, and laser technology after pipeline erection
and leak detection during service.

Fig 3: Instrument used by SNGPL for Gas Leakage Detection.

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Material Testing laboratory

Gas pipelines are found across the globe. Pipelines can run above ground,
underground or they can be immersed in fresh or salt water. Coatings designed for
external pipeline applications must be engineered to withstand this wide variety of
environmental conditions. Soil stress, soil born chemicals and salt water present
formidable challenges to the performance of external pipeline coatings. External
coatings also need to be resistant to indigenous bacteria, other flora, waste water
and to the chemicals and solvents used in the processing of the hydrocarbons.
SNGPL Material testing laboratory is accomplished to test protective coatings.

Fig 4: Testing of coatings in Material Testing Laboratory at CCC.

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Currently Practiced Technology
There are currently four popular methods for coating pipelines:

1) Three-Layer PE (3LPE)/PP (3LPP)

PROS:
 Relatively low material cost

 Relatively low application cost

CONS:
 Requires application of flame to create adhesion

 Application of flame in pipeline environments has traditionally been the

cause of workplace fires and explosions

 Offers limited heat resistance

 Maximum 225°F – 250°F

 Lacks dimensional stability

 Offers borderline hardness

 Provides limited resistance to Sulfur, Amines, etc.

 Provides limited resistance to Oxygen and other oxidants

2) Fusion Bonded Epoxy (FBE)

PROS:
 Excellent chemical resistance

 Better dimensional stability – minimal hysteresis

CONS:
 Relatively Expensive

 Material expensive

 Pipe and coating must be heated to 250°F

 High labor requirement

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3) Coal Tar Enamel (CTE)
PROS:
 Extremely inexpensive

CONS:
 Minimum protection

 Highly Toxic and Flammable

4) Asphalt Enamel and Polyurethane (PUR)

PROS:
 Inexpensive

 Better than Coal Tar Enamel

 Decreased hysteresis

 Fast cure

CONS:
 Poor chemical resistance

 Severe temperature limitations

 No dimensional stability

Outer Wrap Plant

SNGPL CCC is currently not using its Outer Wrap Plant.

Recently it was used for cutting and packing of thermos glass.

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SMS ( SALES METERING STATION )

Fig 5: SMS Installed in Lahore.

There are six basic and essential processes being carried out at a sales metering
station.

I. Filtration
II. Regulation
III. Measurement
IV. Odor addition
V. Safety processes
VI. Cathodic Protection

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Each gas metering station branches off of the pipeline and is used to reduce
pressure and meter the gas to the various users. For the pressure reduction and
metering stations, the main equipment includes filters, heaters, pressure reducers
and regulators, and flow metering skids. In addition, each station is generally
equipped with drains for collection and disposal, instrument gas system and
storage tanks.

Filter Separators

Natural gas filter units are installed at each station to remove any entrained liquids
and solids from the gas stream. The filters may comprise cyclonic elements to
centrifuge particles and liquids to the sides of the enclosing pressure vessel. These
particles and liquids will then drop down for collection in a sump, which can be
drained periodically. A condensate tank is installed for atmospheric storage of any
liquids removed by the filter separator.

Flow Control

A control valve should be installed downstream of the meter run to control both the
flow through the meter and the delivery pressure. This valve will primarily operate
to limit the station throughput in order to prevent the incoming gas volume from
exceeding the meter capacity or the nominated volume but will also be equipped
with a pressure override. The control valve is generally controlled by a gas flow
computer (GFC) based upon set points provided by the gas control center.

The control valve will normally operate in the fully open position to minimize
pressure losses through the station and should have a positioner, position indicator
and position transmitter. The GFC would also monitor and control the facilities as
well as perform custody transfer quality measurement. The GFC communicates all
data to a central control console via the SCADA system.

At custody transfers, a gas chromatograph is generally used to determine the gas

composition for purposes of calculating the gas gross heating value. This data is
provided to the GFC for use in calculating the total gas heating value in the
metered gas. A gas sample is taken from a continuously flowing location on the
meter and regulator skid. The gas sample is secured at low pressure to minimize
lag time utilizing a self-regulating sample probe and routed to the gas
chromatograph and moisture analyzer. The moisture analyzer is provided to
measure the water content of the gas. Depending on sulphur content of the gas, a
sulphur analyzer may be required.

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Pressure Reduction And Regulation

The pressure-reduction system controls the supply pressure to the gas users at a
regulated value. Each system consists of at least two trains of pressure reduction –
one operating and the other standby. Each train will normally comprise two
regulator valves in series.

Metering System

The flow rate of the gas has to be measured at a number of locations for
the purpose of monitoring the performance of the pipeline system and more
particularly at places where custody transfer takes place. Depending on the
purpose for metering, whether for performance monitoring or for sales, the
measuring techniques used may vary according to the accuracy
demanded.

Cathodic Protection

It is typical to separate the cathodic protection systems of the pipeline and meter
station. This is normally done by installing insulation kits at the flange connections
at the meter skid. Buried piping within the meter station, either upstream or
downstream of the meter skid, should be cathodically protected from the associated
pipeline’s cathodic protection system.

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SAFETY ASPECTS
PREVENTION OF CORROSION CAUSED BY COOLING EFFECT

Currently SNGPL has not yet succeeded in preventing pipeline corrosion which is
cause by cooling effect on pipelines when pressure is reduced. In summers it
causes moisture on pipes while icing takes place in winters.

Fig 6: External Corrosion at SMS due to cooling effect.

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Automatic Shutdown Valve

An automatic shutdown valve is normally installed at the pipeline connection. This

valve should be remotely operated from the main operating system and equipped
with local pneumatic controls, a hydraulic manual override and open/close limit
switches.

Blow down of the meter station piping is accomplished by a vent stack located on
the station inlet piping and vents on the meter skid located downstream of the
meter and downstream of the flow control valve. Vent stacks may or may not
include silencers, depending on the noise levels at the closest noise sensitive area
(NSA).

Sound Pressure

Sound pressure levels at all service conditions should be considered. High noise
levels (generally defined at greater than 110 dB) can result in damage to regulators,
control valves, control valve accessories, instrumentation and downstream piping.
Following are standard measures that can be taken to reduce sound pressure levels
or to reduce the effects in the path:

 Install noise attenuating trim or diffusers on the regulator,

 Install heavy wall pipe,
 Install insulation,
 Install silencers,
 Bury the regulators.

Overpressure Protection

Stations do not require an overpressure relief device if a monitor regulator is

installed in series in each regulator run or if a monitor regulator is installed in
series with and common to all regulator runs.

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TYPES OF SURVERYS CONDUCTED AT SNGPL

 ECDA
 CIPS
 DCVG
 PSP

ECDA

The ECDA (External Corrosion Direct Assessment) is conducted in four steps:

1. Pre Assessment
2. Indirect Inspection
3. Direct Examination
4. Post Assessment

SNGPL strictly follows international standards to ensure pipeline safety during

conducting ECDA. It is elaborated using a flow chart diagram below.

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 1. Pre Assessment

The objectives of the pre assessment step are to determine whether ECDA is
feasible for pipelines to be examined, select indirect examination tools and identify
ECDA regions. The pre assessment step requires sufficient amount of data
collection, integration and analyses. The pre assessment step must be performed in
a comprehensive and thorough fashion.

2. Indirect Inspection

3. Direct Examination

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 4. Post Assessment

Post assessment step includes the following things:

Closed Interval Survey (CIS)

A method of measuring the potential between a pipe and Earth at regular intervals
along the SNGPL pipeline.

PIPE TO SOIL POTENTIAL (PSP)

Fig 7: SNGPL Engineer conducting PSP test at SMS.

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A pipe to soil potential survey is a technique used to measure the magnitude of
corrosion of pipelines and detect hot spots where the occurrence of corrosion is
severe.
The potential survey is based on recording pipe-to-soil potentials at regular
intervals over the pipeline with the reference electrode(s) located on the ground
surface. The higher the value of pipe-to-soil potential, the higher the magnitude of
corrosion.
The voltage potential (emf) generated between a buried pipe and its surrounding
soil, the result of electrolytic action and a cause of electrolytic corrosion of the
pipe.

A general idea of pipeline corrosion severity can be obtained from the average
pipe-to-soil potential. Newer pipelines generally exhibit a lower negative potential
than older and coated pipelines. For example, a new pipeline may show an average
potential of -1.65V when compared to a potential of -1.2V shown by an older
pipeline.
The changes in soil resistivity also induce potential differences. The surface
potential surveys are made to determine the anodic and cathodic areas on the pipe.

FIELD SURVERY OF CP STATION AND PSP TEST

Fig 8: SNGPL Technicians conducting TR routine check in DHA PHASE 5

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Fig 9: SNGPL Technicians conducting PSP test in DHA PHASE 5.

Fig 10: SNGPL Technicians checking TR in DHA PHASE 5.

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CONCLUSION

The gas delivery infrastructure is rapidly aging. Ensuring natural gas infrastructure
reliability is one of the critical needs for the energy sector. The largest component
of the natural gas infrastructure is the hundred miles far from delivery pipelines.
Therefore, the reliable and timely detection of failure of any part of the pipeline is
critical to ensure the reliability of the natural gas infrastructure.

The pipeline system is the most important part in media transport in order to
deliver fluid to another station. The weak maintenance and poor safety will
contribute to financial losses in term of fluid waste and environmental impacts.
There are many classifications of techniques to make it easier to show their
specific method and application. This reports discussion about gas leak detection in
pipeline system and maintain pipelines is what is being followed every day at
SNGPL though more experiments and simulation always need to be carried out to
get the fast result of leaking and estimation of their location and to maintain
quality.

Fig 11: The World needs more corrosion free pipelines like these

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APPENDIX

 CCC: Corrosion Control Centre

 CP: Cathodic Protection
 CIPS: Closed Interval Survey
 CTE: Coal Tar Enamel
 DCVG: Direct Current Voltage Gradient
 ECDA: External Corrosion Direct Assessment
 FBE: Fusion Bonded Epoxy
 GFC: Gas Flow Computer
 ICCP: Impressed Current Cathodic Protection
 NSA: Noise sensitive area
 NACE: NACE International, which was established in 1943 is a
professional organization for the corrosion control
 PSP: Pipe to soil potential
 PUR: Asphalt Enamel and Polyurethane
 SMS: Sales Metering Station
 SCADA: Supervisory control and data acquisition software
 T/R: Transformer Rectifier
 3 LPE: Three-Layer PE

REFERENCES

 https://www.nace.org/uploadedFiles/Corrosion_Central/Industries/SP050208
PHMSA.pdf
 http://www.cceng.com.au/product/cathodic-protection-transformer-rectifiers/
 https://pgjonline.com/2009/03/10/fundamentals-of-gas-pipeline-metering-
stations/
 https://www.fiorentini.com/ww/en/product/completesolutions/gas-
compressor-stations/prms
 https://www.masterbond.com/articles/chemical-and-heat-resistance-
protective-epoxy-coatings-oil-and-gas-pipelines
 http://iopscience.iop.org/article/10.1088/1757-899X/100/1/012013/pdf

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