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POLMAZ LIMITED
Introduction
Cathodic protection is a technique to control the corrosion of a metal surface by making it work
as a cathode of an electrochemical cell. Corrosion is an electrochemical process in which a
current leaves a structure at the anode site, passes through an electrolyte, and re-enters the
structure at the cathode site.
Galvanic system
A galvanic cathodic protection system makes use of the corrosive potentials for different metals.
Without cathodic protection, one area of the structure exists at a more negative potential than
another, and corrosion results. If, however, an object with much more negative potential, such as
a magnesium anode, is placed adjacent to the structure to be protected, such as a pipeline, and a
metallic insulated wire connection is installed between the object and the structure, the object
will become the anode and the entire structure will become the cathode.
Then the new object corrodes sacrificially to protect the structure. Thus, the galvanic cathodic
protection system is called a sacrificial anode cathodic protection system because the anode
corrodes sacrificially to protect the structure. Galvanic anodes are usually made of either
magnesium or zinc because of these metals higher potential compared to steel structures.
Today, galvanic or sacrificial anodes are made in various shapes using alloys of zinc, magnesium
and aluminium. The electrochemical potential, current capacity and consumption rate of these
alloys are superior for corrosion protection than iron.
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Galvanic anodes are designed and selected to have a more "active" voltage (i.e., a more negative
electrochemical potential) than the metal of the structure. For effective corrosion protection, the
potential of the steel surface is polarized or pushed - more negative until the surface has a
uniform potential. At that stage, the driving force for the corrosion reaction is halted. The
galvanic anode continues to corrode; consuming the anode material until eventually it must be
replaced.
The polarization is caused by the current flow from the anode to the cathode. The driving force
for the corrosion protection current flow is the difference in electrochemical potential between
the anode and the cathode.
In sacrificial anode systems the high energy electrons required for cathodic protection are
supplied by the corrosion of an active metal. Sacrificial anode systems depend on the differences
in corrosion potential that are established by the corrosion reactions that occur on different
metals or alloys.
For example, the natural corrosion potential of iron is about -0.550 volts in seawater. The natural
corrosion potential of zinc in seawater is about -1.2 volts. Thus if the two metals are electrically
connected, the corrosion of the zinc becomes a source of negative charge which prevents
corrosion of the iron.
The materials used for sacrificial anodes are either relatively pure active metals, such as zinc or
magnesium, or are magnesium or aluminum alloys that have been specifically developed for use
as sacrificial anodes. In applications where the anodes are buried, a special backfill material
surrounds the anode in order to insure that the anode will produce the desired output.
Sacrificial anodes are normally supplied with either lead wires or cast-in straps to facilitate their
connection to the structure being protected. The lead wires may be attached to the structure by
welding or mechanical connections. These should have a low resistance and should be insulated
to prevent increased resistance or damage due to corrosion. When anodes with cast-in straps are
used, the straps can either be welded directly to the structure or the straps can be used as
locations for attachment. A low resistance, mechanically adequate, attachment is required for
good protection and resistance to mechanical damage.
In the process of providing electrons for the cathodic protection of a less active metal the more
active metal corrodes. The more active metal - the anode - is sacrificed to protect the less active
metal the cathode. The amount of corrosion depends on the metal being used as an anode but is
directly proportional to the amount of current supplied.
Because the anodes in a galvanic cathodic protection system are sacrificial they must be
inspected periodically and replaced when consumed.
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For larger structures, galvanic anodes cannot economically deliver enough current to provide
complete protection. Impressed current cathodic protection (ICCP) systems use anodes
connected to a DC power source known as a cathodic protection rectifier. Anodes for ICCP
systems are tubular and solid rod shapes or continuous ribbons of various specialized materials.
These include high silicon cast iron, graphite, mixed metal oxide, platinum and niobium coated
wire and others.
A typical ICCP system for a pipeline would include an AC powered rectifier with a maximum
rated DC output of between 10 and 50 amperes and 50 volts. The positive DC output terminal is
connected via cables to the array of anodes buried in the ground and is known as the anode
ground bed. For many applications the anodes are installed in a 200 foot deep, 10-inch diameter
vertical hole and backfilled with conductive coke. Conductive coke is a material that improves
the performance and life of the anodes. A cable rated for the expected current output connects
the negative terminal of the rectifier to the pipeline. The operating output of the rectifier is
adjusted to the optimum level after conducting various tests including measurements of
electrochemical potential.
As in sacrificial anode systems, impressed current systems depend on a supply of high energy
electrons to stifle anodic reactions on a metal surface. In the case of an impressed current system
these high energy electrons are supplied by a rectifier.
Low energy electrons that are picked up at a non-reactive anode bed are given additional energy
by the action of a rectifier to be more energetic than the electrons that would be produced in the
corrosion reaction.
The energy for the electron energy pump action of the rectifier is provided by ordinary
alternating current. The effect of these electrons at the structure being protected is the same as
that derived from the sacrificial anode type of cathodic protection system. However, the anode
material serves only as a source of electrons and need not be consumed in providing protective
current.
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The materials used for impressed current cathodic protection can pass a current into the
environment without being consumed at a high rate. Graphite and high silicon cast iron are the
most commonly used impressed current cathodic protection anode materials; however, other
materials (such as magnetite, platinum, and newly developed ceramic materials) have been
successfully used.
For buried anodes, a backfill of carbonaceous material is used to surround the anode to decrease
the electrical resistance of the anode, to provide a uniform, low resistivity environment
surrounding the anode and to allow gasses produced at the anode surface to vent. In practice,
materials such as graphite are used for impressed current cathodic protection system anodes that
are slowly consumed.
Anodes in impressed current systems must be inspected and replaced if consumed or otherwise
damaged. As is the case for any electrical equipment, rectifiers used for impressed current
cathodic protection systems require preventative maintenance to insure proper operation.
POLMAZ LIMITED
BETWEEN ABOVE GROUND PIPE SECTION AND BELOW GROUND PIPE SECTION THE
ISOLATION JOINT IS USED TO PROVIDE ELECTRICAL DISCONTINUITY BETWEEN PROTECED AND
UNPROTECTED SECTIONS OF THE PIPELINE NETWORK, IN THE Cathodic PROTECTION SYSTEM,
THE BURIED PART OF THE PIPELINE IS THE SECTION THAT IS PROTECTED AGAINST CORROSION
CATHODICALLY. ABOVE GROUND PIPE SECTIONS ARE PROTECTED BY THE APPLICATION OF
EXTERNAL COATING AND THEREFORE ARE NOT CATHODICALLY PROTECTED. THIS MEANS
THAT THERE MUST BE AN ELECTRICAL DISCONTINUITY BETWEEN THESES SECTIONS, HENCE
THE PROVISION OF ISOLATION JOINT.
DESIGN CALCULATIONS
SOIL RESISTIVITY: 4000ohm-cm
CURRENT DENSITY: 11mA/m2
PIPELINE LENGTH: 11500m
PIPELINE DIAMETER: 0.2032m
a) DETERMINE CURRENT REQUIRED TO PROTECT THE PIPELINE:
CURRENT DEMAND:
DESIGN CALCULATIONS
I=i A
1. Calculate current required using the 8 Pipeline as a basis for the design.
Using metric units in metres:
Total Surface Area = dL
Therefore, d = 8 = 0.2032
L = 11500m
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7342.22 x 100 90
50
= 734.222m2
= 8,076.442mA
= 8.07644Amps
Wt = 1 x 8.076442 x 30
Wt = 242.29326kg
Therefore:
N = 242.29326
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N = 11.537
Therefore:
These numbers (12 Anodes) represent the minimum number of anodes to be used in the
impressed current deep well ground bed installation to protect the pipelines.
RN =
[( In 8L ) -1 + (2L x In 0.656N)]
2 NL
d
S
Where:
= 4000 ohm cm
L = 213.4cm
d = 20.3cm
S = 609.6cm
N = 12 Anodes [Minimum]
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POLMAZ LIMITED
RN =
[( In 8L ) -1 + (2L x In 0.656N)]
2 NL
d
S
RN =
4000
2 x 3.142 x 12 x 213.4
RN =
4000
[(In 84.0985) -1 + (0.70013 x In 7.872)]
16092.06
RN =
0.2485
RN =
0.2485
[(4.431988) -1 + (1.44458)]
RN =
0.2485
[3.431988 + 1.44458]
RN =
0.2485
[4.876568]
RN =
1.2118 Ohms
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Positive cable (Connection from transformer rectifier to deep well groundbed) (150m)
Rc = 0.4627 Ohms
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POLMAZ LIMITED
Current requirement being a critical part of design calculations for Cathodic Protection
Systems on existing structures is the amount of current required per square foot (called
current density) to change the structures surface potential to -0.85 volts. The current density
required to shift the potential indicates the structures surface condition.
(1.) Decrease the anode-to-earth resistance by increasing the anodes effective size.
(2.)Extend the system operational life by providing additional anode material.
(3.) Provide a uniform environment around the anode, minimizing deleterious localized
attack.
The carbonaceous backfill however, cannot be expected to increase the ground bed life
expectancy unless it is well compacted around the anodes.
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POLMAZ LIMITED
From the value of RT, the Transformer Rectifier System output voltage can also be calculated
from:
VREC = 1.5 x I x RT
VREC = Rectifier output voltage
I = Total protection current, Amps = 8.076Amps
RT = Total circuit resistance, ohms = 2 Volts
This value shall represent the maximum value to achieve cathodic protection
of -0.85volts DC. The actual value can be less than this value. Also, over the
life of the installation this value can change based on operational and
environmental conditions over time.
Therefore, the larger value shall be used to choose the needed output of the Transformer
Rectifier for the impressed current cathodic protection system.
Note:
Fundamentally, the 150% (1.5) is a factor to allow for aging of our normal rectifier stacks.
The impressed current cathodic protection system has been designed for a system life of 30 years
and the Cathodic Protection components shall comprise of the following:
` ONE UNIT OIL COOLED TRANSFORMER RECTIFIER (shall comply with IEC 146)
The rectifier shall be constructed using high current density selenium cells or silicon
diodes so arranged as to provide full wave rectification. The current rating of the diodes
shall be more than 1.25 times the maximum current rating of the rectifier and have a
minimum peak inverse voltage of 1200 V.
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For this pipeline, isolating joints shall be supplied and installed (welded) into the pipeline
length mono block. Before installation, the assembled isolating joint set shall be tested in
accordance with the procedure for isolating joints in line with pipeline acts and the
resistance shall be at least 1 M ohms. On the other hand Isolating Flange Kits can be
installed.
The welding and all necessary process of installing the isolation joints shall take a minimum of
2weeks and the lines will be placed out of service for this operation, as it is a major hot work.
BOND BOXES
(PDBB POISTIVE DISTRIBUTION BOND BOX)
(NDBB NEGATIVE DISTRIBUTION BOND BOX)
The junction boxes shall be either a 5-way or a 16-way type. The type shall be shown in
the completed installation as built drawing. The negative distribution and positive
distribution bond boxes are constructed standing beside the transformer rectifier. The
main supply cables from the positive and negative terminal of the TRR goes to the positive
distribution bond box and negative distribution bond box respectively. From the bond
boxes supply cables are then routed to the pipelines and anodes feeder cables.
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CABLES
All cables shall be No. 6 AWG copper cables, suitable for DC use and shall be double
insulated and sheathed to withstand the prevailing chemical and mechanical (soil)
conditions. The cables shall be NO.6 AWG stranded annealed copper cable with double
insulation having primary insulation layer of Kynar or Halar.
All negative cables (runs to the negative bond boxes and to the pipe lines) shall be black
outer sheathed. Unless otherwise specified by INDORAMA.
The positive cables shall be red and unless otherwise specified by the company
INDORAMA, the positive cable shall run the between transformer rectifier to the positive
distribution bond box and ground bed.
Cable entries to the transformer-rectifier are to be fitted with flame-proof glands and
cable shrouds and all cable are to be run in ducts through the transformer-rectifier plinth
into the ground. DC cable connections are to be made with sweated or crimped cable lugs.
TEST POINTS
Test points/posts shall be installed at locations along the pipeline right of way and at the
starting point of the pipelines within INDORAMA plant. The test post shall provide
sufficient room for the termination of test cables and for the installation of bonding
cables.
Generally, the test posts shall be located at intervals of 1 kilometer. The exact location
and type of test point installation shall be agreed with INDORAMA before any work
commences on the installation of a test point.
The test post shall be constructed from 3 or 4 diameter pipe and shall be about 1.4m long.
Measurement shall be taken with the cover in-place.
Stubs of 13mm reinforcing bar shall be welded to the bottom of the post to increase
anchorage and prevent rotation.
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To reduce vandalization of test posts, it shall be constructed from common pipe material
of low cost. Also the pipe base and support shall be installed within a concrete structure.
PLEASE FIND THE TOTAL COST FOR THE IMPRESSED CURRENT CATHODIC
PROTECTION SYSTEM IN THE COMMERCIAL.
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