The Progress of Corrosion Control

Strategy and Regulation in Several

Major Industrial Sectors in North

America National Center for Education and Research on Corrosion and Materials Performance

Inaugural Corrosion Forum September 20, 2012

Kevin C. Garrity, P.E.

NACE International President

Topics Covered

• North America Infrastructure Report Card

– Regulated Pipeline Infrastructure

– Regulated Nuclear Power Generation

– Semi-Regulated DoD Military Infrastructure

– Non-Regulated Bridge and Highway Infrastructure

• Path Forward “Are We Making Progress”?

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Examining Industry Parallelisms • Regulated Oil and Gas Industry

($8 Billion/year Cost of Corrosion) – Coatings and CP – Integrity Verification – Largely Successful

• Electric Power Generation ($5 Billion/year Cost of Corrosion) – Coatings and Marginal Use of CP – Limited Success Until Recently

• Defense Military Sector ($22.9 Billion/year Cost of Corrosion)

– Success is Now Apparent

• Reinforced Concrete Bridge Infrastructure ($29.3 Billion to Replace Deficient Bridges) – Corrosion Control Failed to Come to the Rescue

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Corrosion Control and Integrity Requirements

• Regulated Transmission and Distribution Pipelines – Established in 1971 and 1975 and re-

authorized by US Congress Every 4 years

• Nuclear Power Plants – Established in 2009

• DoD Facilities – Mandate for Development of Corrosion Policy

and Programs

• Bridge Infrastructure – Never mandated

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Regulated Pipeline Infrastructure

Reauthorization

• Congressional Hearings – In May CE NAPSR we were in a different place.

– IG/GAO and NTSB did not testify

• 6, 8, ?? Hearings with possibly more to come in Nov. – Deepwater Horizon

– Enbridge (Schauer)

– San Bruno

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Washington Criminal Charges Pipeline Rupture and Fire. Company Officials Sentenced to 6 months in prison. $80 million in civil penalties

Alaska Misdemeanor violation of the U.S. Federal Water Pollution Control Act March 2006 Prudhoe Bay pipeline release. $12 million Fine + 3 years’ probation.

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Pipeline Infrastructure

• Given the size of the infrastructure, we have an incredible safety record

• Accidents by tanker truck transport are considered more acceptable than by pipeline transport.

Vehicular “Accidents” happen every day -–Pipeline Accidents Don’t.

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Despite our Safety Record Notable Incidents have occurred in the Past

Few Years • San Bruno, California

• Allentown, Pennsylvania

• Philadelphia, Pennsylvania

• Others

– Michigan, Wisconsin, Illinois, Texas,Ohio

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Slide 11

San Bruno, CA September 2010

Slide 13

Slide 14

Allentown, PA February 2011

Slide 16

Now Questions are Being Asked on a Daily Basis

• Is our pipeline infrastructure too old and too tired?

• Is our aging infrastructure safe?

• Are we doing everything we can to ensure safety?

• Can we do more?

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Pipeline Accidents

• Usually caused by a unique set of circumstances

– Unfortunately the “stars are incorrectly aligned”.

– Suggests that we have a safe system.

– You still may be liable and certainly will be held accountable.

– Difficult to predict the unexpected.

• Rarely (If ever) the result of a systematic problem.

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Nuclear Power Generation

Nuclear Buried Pipe

Pilgrim

Vermont Yankee

Tritium Leaks into Groundwater Exceeding 20,000 pCi/L

Slide 20

NRC Issues Generic Aging Lessons Learned (GALL) Report, NUREG-

1801 Rev. 2

Slide 21

NEI 09-14 [rev 1]

“Guideline for the Management of Underground Piping and Tank Integrity”

•High Level of Accountability • Inspection Process to Provide “Reasonable Assurance” of Buried Pipe Leak Integrity •Aggressive Time Commitments for Implementation

Slide 22

NEI Strategic Partners

Identifies and Develops Technologies

Performs On-Site Compliance Audits

Slide 23

Buried Pipe Timeline

• 12/31/10 - Risk Ranking

• 6/30/11 - Inspection Plan in Place

• 12/31/11 - Procedures & Oversight In Place

• 6/30/12 - BPIG Inspections Start

• 6/30/13 - Condition Assessment of Piping With Radioactive Materials

• 12/31/13 - BPIG Asset Management Plan In Place

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Department of Defense Military Facilities and Equipment

History of Projects and Activities

• Large measure of success

• Combined savings & return on investment

• Life cycle cost avoidance - $billions

• ROI: 55:1

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Bridges and Highway Infrastructure

• 1998 Bridge Inventory

Cost of Corrosion Study

CONVENTIONAL

REINFORCED

CONCRETE

PRESTRESSED

CONCRETESTEEL OTHER TOTAL

Bridges in Inventory 235,151 107,666 200,202 40,395 583,414

Structurally Deficient 21,164 3,230 54,054 14,671 93,119

Percent Deficient 9 3 27 36 16

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No Regulations

• I-35 Bridge

– 13 Fatalities

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Corroding Bridges - What to Do About It?

• Many Options Exist

• Inspections

• Coatings

• Material Selection

• CP Alone or CP Combined With Other technologies are Options.

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Concrete R and D Impact

• Virtually Unparalleled Magnitude of R and D in Concrete Durability and Corrosion Control Methods (CP).

• No Other Industry Utilizing Corrosion Control Technology has seen as much R and D Effort.

And Yet Today There is still Skepticism.

One Must ask WHY???

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With No Regulations Where is the Incentive

• By 1989 275 Bridge Structures in the US and Canada had been Cathodically Protected – 840,000 Square Meters

• BY 2005 - 1000 Bridge Structures in the US and Canada had Coated Reinforcement – Today about 5,000.

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Why is this Important to the NACE Community?

• When regulatory oversight effectiveness is questioned, changes are often made.

• NACE International Standards, Education and Training and Technology Transfer is Key to the success of Technologically Driven Regulations and Oversight.

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Summary

• Corrosion Control Practices are Being Successfully Implemented and Managed in Several Industrial Sectors – Oil and Gas Pipelines – Nuclear Power Generation and Transmission

and Distribution – Military

• Regulations Help and NACE Plays a vital role. – Developing and Disseminating Technology and

Training

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Summary (Cont’d)

• Non Regulated Industries are Severely Lacking. – Bridges and Highway Infrastructure ($29 Billion). – Water and Wastewater Infrastructure ($35 Billion).

• Are We Making Progress? – Absolutely! – Tremendous Success in Oil and Gas, Defense and

Nuclear Power. – NACE International and its Worldwide Partnerships

are Stronger than Ever! – NACE International will continue to Focus on Core

Values based around Education, Training, Certification and Dissemination of Technology

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Thank You