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TOPICS TO BE COVERED

Cathodic Protection System Concepts


Sacrificial Anode System
Impressed Current System
Soil Resistivity, Line Current &
Potential Surveys
Rectifier System for Coated Lines
Groundbed Design & Installation
Operation & Maintenance of Cathodic Protection
System
Galvanic Anodes on Coated Line
Practical Demonstration
INTRODUCTION
In this presentation we will
Overview the causes of
corrosion and mitigation by use
of Cathodic Protection as they
apply to Well Casings AST
Bottoms, and Pipelines
The numerous plants and pipeline systems
that we are responsible for will be faced with
many issues relative to infrastructure
installation, upgrading and replacement. Of
concern is system integrity, to minimize
service disruptions and the risk of
environmental pollution, fire and safety
hazards resulting from spillage of flammable
products by leaking tank bottoms and buried
pipelines
In the management of large
infrastructure, the cost of corrosion
prevention is relatively small when
compared to the cost of total
replacement or substantial
rehabilitation. Therefore, the goal is to
prevent failures from occurring, thus,
extending the service life of the capital
plant.
This approach is preferred to a
program of failure management,
where service interruption, product
contamination, losses to personal
property and personal injury are all
possibilities. Although there are other
infrastructure failure mechanisms,
corrosion is a major factor in the
deterioration and failure of industrial
metallic infrastructure
It is clear that many of the decisions as to
how these funds should be allocated need
to be based on a clear understanding of the
corrosion exposure that exists on existing
and new infrastructure. Critical systems
cannot be installed and forgotten, but
instead must be constantly managed to
provide lower life cycle costs and ensure
that undesirable failures do not interrupt
operation
W CORROSION
H PROBLEMS
A AND THEIR
T SOLUTIONS
WE ALL KNOW THAT
CORROSION
IS
CORROSION IS RELENTLESS
CORROSION IS EXPENSIVE
CONSTANT
Every day, virtually everywhere on
earth, corrosion is at work 24 hours a
day. It is damaging our oil and gas
pipelines, power plants, storage tanks,
bridges, industrial facilities, reinforced
concrete structures virtually every
thing you can think of that is made of
metals.
IT IS COSTLY
This is a matter we will discuss
later on but for right now we
are all aware of the cost that
incurs in either repairing or
replacements as well as the
cost of protective measures we
adopt.
IT IS RELENTLESS
`
We all know that corrosion doesn't care what it is
eating away. Not long ago in the past, corrosion
awareness was minimal and most people thought
it is a natural phenomena and there is very little
we can do about it other than rely upon paints
and coatings. The situation has changed a lot and
people in industry are becoming more and more
aware of the damages that can result from
corrosion.
In retrospect
All of us whether we are:-
Owners
Managers
Engineers
Corrosion Workers
Consider corrosion as our worst enemy
CORROSION BEING OUR
ENEMY
NEVER UNDERESTIMATE
ITS POWER
Find out the weaknesses our enemy
Discover strategic weapons to fight it
When a study of corrosion is undertaken it may be natural
to think that corrosion is a simple single reaction and that
when understood it can be turned off like a spigot.

If cost and availability were not the factors, we could select


the very best materials and come close to doing just that.

But let us dismiss consideration of materials like gold and


platinum and think in terms of practical substances that
we can afford to use in our homes, industries, automobiles,
etc.
The best practical materials that we can think off
are: -
Iron and steel
Aluminum and copper alloys
Stainless steel and many other modern alloys

Using these materials we can design and build


engineering systems cost effectively.

Iron and steel are the materials which are


abundantly available and are comparatively very
cheap. That is the reason, these materials are the
back bone of industry.
Unfortunately, iron and steel are chemically very
unstable and are a challenge to corrosion
engineers.

Unless we find and use ways and means to protect


these materials, the results can be disastrous.

That's where the battle against corrosion begins

First of all let us define CORROSION


Websters Dictionary:
.the action or process of chemical change
.a gradual wearing away or alteration by a
chemical or electrochemical means,
essentially an oxidizing process
NACE Standard RP-0169
Deterioration of materials of
constructions, usually metals, that results
from a reaction with its environment
The definition I like is:
UNDESIRABLE destruction of METALS by
interaction with its environment
The word Undesirable suggest that the corrosion
of some metals is desirable under certain
conditions.
Can anyone in class name such metals whose
destruction under certain conations, would be
desirable?
MAGNESIUM, ZINC AND
ALUMINUM WHEN USED AS
GALVANIC ANODES

SCRAP IRON WHEN USED AS AN


ICCP ANODE
WHY DO METALS
CORRODE?

cor?
The fact that metals corrode should not be a matter
of surprise

Almost all metals should be expected to deteriorate


with time
Corrosion is as natural a phenomena as water
flowing downhill. Water is more stable at its lowest
level than any other elevated level.
Similarly, metals are more stable in their original
form than their refined form.
Just as water absorbs potential energy when
elevated, metals also absorb potential energy during
the refining process.
Millions and millions of years ago, metal
rested in peace underneath the earth in its
satisfied state, combined with other
oxidizing elements such as oxygen, hydroxyl,
sulfur etc. etc.
Then came along man, dug it up, mixed it
with lime and coke and subjected to
tremendous heat and separated it to almost
a pure metal which is its undesirable state.
A state where it does not want to remain
forever.
ORE TO METAL TO ORE CYCLE

ENERGY

ENERGY RELEASE
We can say it again that
unless we use ways and
means to prevent its
reformation back to rust,
we are corroding away
our plants infrastructure.
cost

Cost of Corrosion
Studies through out the world have shown that
Corrosion directly cost the national economy
approximately 4% of its GNP. In Pakistan this cost
could very well be in excess of 2 billion dollars
annually.
THE ABOVE LOSS OF MONEY INCLUDES
Plants and pipelines
Bridges
Automobiles
Sea going vessels
Building materials

Almost anything made of metals


THE MODES OF
CORROSION LOSSES ARE: -
Replacement Material costs
Labor costs
Product losses
Production losses
Clean-up cost due to spillage
Third party damage.
Loss of human life
NOW HOW CAN
WE MINIMIZE
THESE LOSSES?

how
1. Structures exposed to Atmosphere
Expensive alloys, Various kinds of
paints, epoxies coatings,
Galvanizing
2.Structures buried or submerged
Combination of coating and
Cathodic Protection
The use of coatings alone can reduce the
metal loss in tonnages but it will not prolong
the service life of equipment. This is
because no coating is perfect and there will
always remain bare areas in the shape of
pinholes and other minor defects.
In fact, you are better off without coating if
you do not intend to apply CP, because
corrosion then, instead of spreading
uniformly, will be concentrated at the
coating defects and time to failure will be
A recent example is several corrosion leaks in an LPG plant
within 10 months after commissioning.
The plant had a buried pipeline corridor just 500 feet long.
There were six lines ranging from 2 to 6. Coating was of
very good quality. No insulating flanges were provided to
isolate the buried sections of the lines from plants copper
grounding.
Consequently, these lines became anodic with respect to the
plants grounding system.
Pipe-to-soil potentials ranged between -300 to -400mV which
was significant proof that lines were undergoing anodic
reaction.
Soon after installing insulating flanges at both ends of this
corridor, the PSP steadily shifted to -600 to -700 mV which is
the normal natural potential of steel.
When a pipeline is buried, coating will begin to
deteriorate immediately after burial because
of
Debris in the trench
Growth of roots and shrubs
Abrasion because of line movement
Bacteria in soil
Aging with time
Unless we supplement protection
provided by the coatings with
cathodic protection accelerated
corrosion at coating defects will
occur.
Why combination of
cathodic protection
and coatings is
necessary?
The question sometimes asked is that if
we are protected by coatings then why
use cathodic protection or if we use
cathodic protection then why coatings?
The answer is, coatings are never
perfect and require protection
supplemented by cathodic protection.
The use of cathodic protection without
coatings can not be practical.
EXAMPLE: 12 20 KM LONG BARE
PIPELINE.
CD = 1mA/ft2
SA=20,600 SQFT
I = SA * CD/1000 = 206A
Linier resistance of pipe=0.382 ohms
Voltage drop in pipeline = 0.328*206 = 80 volts
With 1V required at far end, the drain point
voltage will have to be 81V..this is by far not
practical
CONSIDER THE SAME LINE WHICH IS
NOW WELL COATED
CD = 0.002 mA/ft2 (500 times less)
I = 0.4A (instead of 206A)

Voltage drop in pipe now will be = 0.382*0.4=0.15V


With 1V required at far end, the drain point voltage will
be 1.15V..This is practical
Line voltage drop

90

Voltage attenuation
Bare Pipeline
70

50
Volts

Bare Pipeline
30

10
Coated Pipeline

20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
-10
KM Frin drain point
A BRIEF HISTORY
OF CATHODIC
PROTECTION

History
In 1824 he found out
that by attaching zinc
plates to copper
cladding, the copper
corrosion was mitigated.
He stated that copper is
cathodically protected
Thus, Sir Humphrey
Davy became the
inventor of cathodic
protection and is known
as the father of cathodic
protection
In 1837, a French civil engineer (Sorel)
patented a process of coating steel by
dipping it in molten zinc metal. He named
the process Galvanizing.

In 1890s Thomas Edison tried to apply


ICCP onto ship hulls.

The commercial use of impressed current


systems appears to have begun in 1920s
And by 1945, this technique was well
adapted.
This enabled the rapidly expanding
oil and gas industry to benefit from
the use of thin wall pipes.
The increasing use of cathodic
protection in modern times began
from 1952 onward.
In Pakistan as I have been
told, Pakistan Oil Fields
Limited (POL) was the first
company to apply CP in
late1940s followed by SSGC
for the protection of their Gas
Transmission Lines beginning
from 1955.
CP is now being used on a
wide variety of immersed and
buried facilities and
infrastructure, as well as
reinforced concrete structures
all over the world
Although CP technology has
advanced a great deal since the
early application of it in 1824, it
still is not classified as a complete
science.
That may very well be the reason
for it to be classified as more of
an art than a science.
APPLICABILITY OF CATHODIC
PROTECTION
Pipelines
Ship Hulls
Storage Tank Bottoms
Jetties and Harbor Structures
Sheet Steel wharf heads, Tubular H beam Foundation
Piling
Offshore Platforms, Floating and Sub-sea Structures
Internals of large diameter pipelines
Storage Tank internals
Ships Tanks (Products or Ballast)
THE CATHODIC
PROTECTION PRINCIPLES

Understanding of the principles of


cathodic protection system is
based upon the understanding of
the corrosion process itself. So,
before going into CP, lets review
the corrosion process
Principles
The corrosion of metals is an
electrochemical process, which is associated
with the flow of DC current in a corrosion
cell.
Corrosion cell forms when two different
metals or two different areas of the same
metal are immersed in conductive medium
and are connected together. Corrosion cells
can also form on the same metal by
different caricaturists of the electrolyte.
Components of a corrosion cell are:
1- Anode
2- Cathode
3- Electrolyte
4- Metallic path
1-Anode
Anode is that part of the
corrosion cell which
discharges DC current into
the electrolyte
In a corrosion cell, anode is
more electronegative than the
cathode.
2-Cathode
Cathode is that part of the
corrosion cell which picks up
DC current from the
electrolyte.
In a corrosion cell, cathode is
more electropositive than the
anode.
3-Electrolyte
Any conductive medium
which permits ionic current
to move through its body
and which surrounds both,
the anode and the cathode
4-Metallic Path

Any metallic conductor which


permits electrons to flow through
its body and connects anode and
cathode together
1. Dissimilar metal cell
2. Oxygen concentration cell
3. Electrolytic concentration cell
4. Corrosion cell due to mechanical
forces
5. Corrosion cell due to concrete
embedding cell
DISSIMILAR METAL CELL
ILLUSTRATION

C S
O T
P E
P E
E I
R
-
+
DISSIMILAR METAL
CELL IN REAL
WORLD
STORAGE
TANK
GROUNDING
WIRE (BARE
COPPER)

CURRENT FLOW

ELECTRICAL GROUNDING
SYSTEM (COPPER)
OXYGEN OXYGEN
CONCENTRATION STARVATION

C
A A
T N
DIRECTION OF
H CURRENT FLOW O
O D
D E
E
+ -
IRON IRON

OXYGEN CONCENTRATION CELL


ANODE CATHODE ANODE

LOOSELY COMPACTED
COMPACTED
BACKFILLED SOIL
SOIL
SOIL

OXYGEN CONCENTRATION CELL ON A BURIED


PIPELINE
METAL ION CONCENTRATION CELL
(or Dissimilar Electrolytes)

C A

A N

T O

H D
CURRENT FLOW
O E

D
E

HIGH METAL ION LOW METAL ION


ELECTROLYTE ELECTROLYTE
-0.4 -0.6
MV
MV

LOW pH
HIGH pH
- +
LOW METAL IONS
HIGH METAL IONS

CATHODE PIPELINE ANODE


SOIL TYPE A SOIL TYPE B
DISSIMILAR ELECTROLYTE CELL
Cathodic Region due to
high oxygen adsorption

Anodic Region due


to low oxygen
adsorption
-
OXYGEN CONCENTRATION
CELL ON A REVOLVING DISC
Anodic Region due to low
metal ion concentration
(High Velocity)

Cathodic Region due to


high metal ion
concentration
(Low Velocity)
METAL ION
CONCENTRATION CELL ON
A REVOLVING DISC
Case-1 predominantly
applies to iron and other
metals more negative than
iron in the galvanic series.
Case-2 predominantly
applies to copper and other
metals more positive than CASE-1
copper in the galvanic
series.
The group of metals
between iron and copper
benefit from these two
opposing effects.
CASE-2
C A

A N

T O

H D
CURRENT FLOW
O E

D
E

ELECTROLYTE A ELECTROLYTE B

DIFFERENTIAL ELECTROLYTES
CORROSION CELL DUE TO
MECHANICAL FORCES

LOW SOIL STRESS (CATHODIC)

HIGH SOIL STRESS (ANODIC)


LOW SOIL STRESS
HIGH SOIL
CATHODE STRESS

ANODE

REAL WORLD EXAMPLE OF CORROSION


CELL DUE TO MECHANICAL FORCES
SECTION OF PIPE ENCASED IN
CONCRETE IS CATHODIC WITH RESPECT
TO ADJACENT SECTIONS

CONCRETE
PIPE PIPE
ANODIC ANODIC
CATHODIC
OLD PIPE/NEW PIPE CORROSION CELL

OLD PIPE CATHODIC

NEW PIPE
ANODIC
Polarization is a
phenomenon, which
tends to restrict or slow
down the rate of cell
reaction.

It is primarily due to
hydrogen film formation
on the surface of the
cathode. This does two
main things.
1. It reduces the surface area of the cathode
in direct contact with its surrounding.

2. It exhibits its own potential, which is in the


opposite direction of the cell voltage which the
corrosion cell function has to over come.
Both of these factors result in decrease in the
corrosion cell activity
Another factor that also
slows down the corrosion
cell activity, is the shift in
potential of the anode and
the cathode towards each
other, thus, reducing the net
driving potential of the cell
(Cell Voltage)
CORROSION CELL
POLARIZATION
Ea

EC

POLARIZED CELL VOLTAGE


INITIAL CELL
VOLTAGE

EA

Ec
B

MAX MIN
CORROSION
CURRENT
Cells driving voltage!
How is this voltage created?
Every metal when immersed in a
solution, exhibits a potential with
reference to a standard electrode.
This is called the natural or
corrosion potential of that electrode
NatP
Natural electrode potential of an
element is a relative value.

It is assigned to it by comparing
the potential of the pure metal in
a standard solution of its own ions
under standard laboratory
conditions against a standard
hydrogen electrode.
These potentials are in fact the
half-cell potentials of the metals.

2.74V

ZERO
REFERENCE

H
Mg
Cu
+.34V -2.4
ELECTRO MOTIVE SERIES OF METALS
METAL ION POTENTIAL
Potassium K+ -2.92
Barium Ba++ -2.90
Calcium Ca++ -2.87
Sodium Na+ -2.71
Magnesium Mg++ -2.40
Aluminum Al+++ -1.70
Zinc Zn++ -0.76
Chromium Cr++ -0.56
Iron Fe++ -0.44
Tin Sn++ -0.14
Copper Cu++ +0.34
Silver Ag+ +0.80
Platinum Pt++++ +0.86
Cold Au+ +1.50

POTENTIALS vs. SHE


Electromotive Series of Metals
Electromotive Force Series of Metals
In NeutralIn
Soils vs. Copper/Copper
Neutral Sulfate
Soil Reference to half-cell Sulfate
Copper/Copper

Metal Volts
Magnesium; Pure -1.75
Magnesium Alloy (6%Al,3%Zn) -1.60
Zinc -1.10
Aluminum Alloy (5% Zinc) -1.05
Pure Aluminum -0.80
Mild Steel (shiny) C -0.5 to -0.8
Mild Steel (rusted) Z
A -0.2 to 0.5
I
Cast Iron N
R -0.50
Lead C
B -0.50
Mild Steel in Concrete O -0.20
N
Copper, High Silicon Cast Iron -0.20
Carbon +0.30 - +0.40
FORMS
OF
CORROSION
Forms
FOUR MOST COMMON
FORMS OF CORROSION
ARE: -

1. Uniform corrosion
2. Pitting corrosion
3. Crevice corrosion
4. Galvanic corrosion
Uniform or General Corrosion
Attack proceeding evenly over the entire surface
or a large fraction of the entire surface.
General thinning until failure
High tonnage wasted
Easily measured and predicted
Uniform corrosion is relatively easily
measured and predicted, disastrous
failures are relatively rare. As
corrosion occurs uniformly over the
entire surface of the metal, it can be
practically controlled.This can be done
by cathodic protection, use of coatings
or paints, or simply by specifying a
corrosion allowance.
UNIFORM CORROSION
Pitting Corrosion
Pitting corrosion is a localized form of
corrosion by which cavities or "holes" are
produced in the material. Pitting is
considered to be more dangerous than
uniform corrosion because it is more
difficult to detect, predict and design
against. Corrosion products often cover the
pits. A small, narrow pit with minimal
overall metal loss can lead to the failure of
an entire engineering system.
PITTING CORROSION
Crevice Corrosion
Crevice corrosion is also a localized form of corrosion
usually associated with a stagnant solution on the
micro-environmental level. Such stagnant
microenvironments tend to occur in shielded areas
such as those formed under: -
Gaskets
Washers
insulation material
fastener heads
surface deposits
disbonded coatings
Threads
lap joints
clamps etc.
CREVICE CORROSION
Galvanic Corrosion
It occurs when two or more different
metals are immersed in an electrolyte and
are coupled together by a metallic path.
What is Cathodic Protection?
It is an electrochemical method of reducing or
eliminating the corrosion of a metal structure.
It requires flow of electrical current through the
electrolyte and onto the structure being protected.
Current may be provided by sacrificial anodes which
require no external DC power source or by ICCP
anodes in combination with external DC power source

DC CURRENT
CP?

PIPE ANODE
How does CP work?
C
A steel structure when buried or
immersed in soil or water develops P A
numerous corrosion cells which are I
formed by anodic (A) and cathodic
P C
(C) areas on its surface. The anodic
areas discharge current into the E
surrounding environment and A
corrode while the cathodic areas
pickup current from the
C
surrounding environment and do
not corrode. Furthermore, anodic
A
and cathodic areas keep changing
places
If, we now impress
sufficient current on the GROUNDBED

entire surface of the steel it


can be seen that all anodic
areas are suppressed and the
entire steel surface is
receiving unidirectional
current from soil which, is - - T/R
+

being supplied by an earth -


connection called anode.
This is the basic principle of
cathodic protection
Benefits of Cathodic
Protection
Without the application of
cathodic protection, the pipeline
leak frequency is known to rise
exponentially. Occurrence of first
leak is a signal that trouble is
knocking on the door.
Cumulative Leak Chart

1000

500 Leaks

No CP Applied CP Iinadequate
100 104 Leaks

Adequate Protection
11 Leaks Achieved
10

4 Leaks

1
0 2 4 6 8 10 12 14 16

Years
Actual case history of a gas distribution system in downtown
Houston

1930-1942: 142 Corrosion Leaks (12 yr)

1942-1974: Four small Leaks (32 yr)


Cathodic protection does not eliminate
corrosion. It does however, stops corrosion
of the structure being protected and
transfers the corrosion to another location
which is a man made anode.
CORROSION ANODE
PIPE

In discharging current to earth, the anode


material is subject to corrosion. It is
therefore, desirable to use such materials
which are consumed at a much lower rate.
COMPONENTS
OF CATHODIC
PROTECTION

Comp
IMPRESSED CURRENT
SYSTEM
1. DC Power Sources
2. AC Power Source in case of T/R
3. Anodes (consumable)
Anode

4. Anodes (Inert)
5 ANODE CABLE JUNCTION BOXES
6- CURRENT DISTRIBUTION BOXES
7- INTERFERENCE CONTROL BOXES
8- INSULATING FLANGES OR JOINTS
19- INSULATING SPOOLS IF THE
PROCESS FLOW IS CONDUCTIVE
THERMOELECTRIC
GENERATORS
Potential difference is created across
the terminals of a thermocouple when
heated. Current begins to flow as a
result of this potential difference.
These units are available from 15 to
550 watts with voltage ranging from
2.5V to 48V.
NODE CABLE JUNCTION
BOX
CURRENT DISTRIBUTION BOX

Current leads from different structures


To T/R Neg
MMO ICCP Anode Common size: dia. 25 x 1000 mm
Consumption rate = 5 to 8 mg/A/yr
At 8 amp/anode minimum 25 year life is achieved

metal coatings are usually expensive metal oxide like Ir, Ta, Ruthenium
Substrate of MMO anodes is usually
Titanium or Niobium.
Break down voltage of Titanium oxide is 9 to
11 volts (recommended 8V). When it is
imbedded in chloride free environment such
as tightly packed coke breeze in which case it
can be operated at as high as 100 volts. In
aqua solutions with high content of chlorides,
Niobium substrate is used. Its breakdown
voltage is 100V
PLATINIZED ANODES
The other inert anode is the Platinum
anodes. Thin film of platinum is
applied over Titanium or Niobium
substrate. The consumption of
platinum is 8 mg per amp per year
POLYMERIC CABLE ANODE
AS PER VENDOR;
MINIMUM 20 YEAR LIFE AT 16mA/LF
GALVANIC
ANODES
Magnesium or Zinc
packaged Sacrificial anodes

Available in various sizes

Open circuit potential of


magnesium ribbon is 1.5V
with reference to CSE

Open circuit potential of


zinc is 1.1 V with reference
to CSE
APPROXIMATE DATA FOR MAGNESIUM ANODE IN EARTH
Specific gravity 1. 94
Pounds per cubic foot 121
Theoretical Amp Hours per pound 1000
Theoretical pounds per amp per year 8.7
Current Efficiency percent 50 *
Actual amp-hours per pound 500 *
Actual pounds per amp per year 17.4 *
Open circuit potential in earth (w.r.t. CSE) standard alloy 1.5V
Open circuit potential in earth (w.r.t. CSE) high potential alloy 1.75V

Current efficiency varies with current density. Efficiency decreases when the
CD is 300 mA/sqft of bare metal and increases at lower current densities
Approximate data for zinc anode in earth
Specific gravity 7
Pounds per cubic foot 440
Theoretical amp hours per lbs 372 (1)
Theoretical pounds per amp per year 23.5
Current efficiency percent 90 (2)
Actual amp hours per pounds 335
Actual pounds per amp per year 26
Open circuit potential in earth (w.r.t. CSE) 1.1V

1-Zinc is special high grade which is 99.99 percent pure


2-The efficiency is constant at all current densities
Magnesium Ribbon Anodes dimensions as shown below
Zinc Ribbon is supplied in 2 forms (plus and Super) with different
standard dimensions
MAGNESIUM ANODE DATA
BARE METAL MAGNESIUM DIM PACKAGED TYPE

Ser H (in) W (in) L (in) Wt(lbs) Lg(in) Dia (in)

1 3 3 4.5 3 6.5 6 3S3

2 3 3 7.5 5 13.5 6 5S53

3 2 2 27 9 31 5 9S2

4 3 3 13.5 9 17 6 9S3

5 2 2 51 17 55 5 17S2

6 3 3 21.5 17 30 6 17S3

7 2 2 60 20 62.5 5 20S2

8 3 3 45 32 61 8 32S3

9 5 5 21 32 30 6 32S5

10 3 3 60 40 64 6 40S3

11 5 5 31 48 34 8 48S5

12 4 4 60 60 64 6.75 60S4
Zinc Ribbon (Super)
Consumption rate is 23lbs/A/yr
Weight per LF=2.4lbs

3/8

5/8
5/8
ZINC ANODE DATA

BARE METAL DIM PACKAGED TYPE

Ser H (in) W (in) L (in) Wt(lbs) Lg(in) Dia (in)

1 1.4 1.4 9 5 15 5 HZ5

2 1.4 1.4 24 12 30 5 HZ12

3 1.4 1.4 36 18 42 5 HZ18

4 1.4 1.4 60 30 66 5 HZ30

5 2 2 30 30 36 5 HZ30

6 2 2 45 45 51 5 HZ45

7 2 2 60 60 66 5 HZ60
INSULATING FLANGESW
INSULATING KIT
INSULATING SPOOL L=RA/p Where,
R=5 ohms (to be achieved)
A= cross sectional area of
CURRENT DRAIN pipe (cm)
CABLE
p = Resistivity of fluid in
L (cm) pipe in ohm-cm

FLANGES WITH
FLANGES INSULATION KIT
WITHOUT INTERNALLY
INSULATION COATED PIPE

If resistivity of fluid is not known then divide 650000/TDS (ppm) get an


estimate of fluid resistivity
ELECTRO-
CHEMISTRY
(Chemical reactions
accompanied with flow of
electric current)
As a result of cathodic protection, chemical
changes occur in soil in the vicinity of
cathode which are beneficial in the
protection of steel
1. Formation of Hydroxides of Calcium and
Magnesium.
2. Generation of Hydrogen gas which adheres
like an insulating film on the surface of the
cathode.
3. Oxidation and reduction reactions
Oxidation
Cathodic Area
This is loss of
electrons at the
anodic surface due
to which iron
atoms are
converted into ions
which are detached
from the iron body
Anodic Area
and enter into
electrolyte.
IN CHEMICAL LANGUAGE

Fe Fe++ + 2e
(Iron Iron ion + 2e)
Fe++ + 2(OH)- Fe (OH) 2
Reduction
e-
This reaction takes e-
place at the cathodic
site where excess
electrons neutralize
the hydrogen ions to
hydrogen atoms
which forms
hydrogen gas.
IN CHEMICAL LANGUAGE

2e + 2H H2 (gas molecule)
Other reactions that also occur are
2H2O + 2e- H2 + 2OH-
O2 + 2H2O + 4e- - 4OH-
Both, the oxidation and reduction
reactions are simultaneous and are
manifested by the flow of DC
current in a corrosion cell (ionic
movement).

PIPE CURRENT FLOW ANODE


Oxidation
reaction
Reduction
reaction
CORROSION RATES OF
METALS
Corrosion rate of any metal depends on
the properties of that metal and quantity
of current passage per unit time
W = Z*I*t (I = Current (A), t = time (s))
Z = Am / V (Z = Electrochemical Equivalent, g/C)
Atomic Mass: Fe=56, Al=27, Zn=65, Mg=24
Valence (V): Fe=2, 3; Al = 3; Mg & Zn = 2
e = F * Z (e = gm eq. mass; F = 96500 C)
Amp = C/s
Corrosion being an
electrochemical
phenomenon we need to
define current in
electrochemical language as
current per time unit.
The definition of current that most of us are familiar with is
the Ohms Law which states

I=E/R
In the electrochemical language, the DC current is defined
as that quantity of current which when passed through a
solution of Silver Nitrate (AgNO3) in accordance with
certain specifications, will deposit silver at the rate of
0.001118 grams per second.

This quantity of current is called a coulomb or one


ampere-second

Quantity of current and time is linked together as a unit


Most commonly used units

Ampere second (Coulomb)


Ampere hour
Ampere year
Faradays Laws

Faradays laws are very


important in the understanding
of the effects of current on
corrosion of metals
Faradays first law

This law states that, if a reaction takes place at the


surface of a metal as a result of the passage of current,
the quantity of material liberated by the flow of current
at that surface is directly proportional to the quantity of
electricity which has passed and is independent of other
factors, such as voltage, temperature, size of electrode,
etc.

In other words, according to this law, the same amount


of silver will be deposited by 1 amp in 30 sec. as by 2
amp in 15 sec. or by 3 amps in 10 sec.
Faradays second law

This law gives numerical relation between the quantity of


electricity passed through the cells and the quantity of
material liberated at the surfaces of the electrodes.

It specifies that the quantities of material liberated at two


or more electrodes by the same quantity of electricity, are
proportional to the equivalent weights of the substances
concerned.

Equivalent weight is defined as the atomic weight divided


by the valance of the substance.
- +

By any given amount of current if silver looses x grams in weight


then by the same amount of current copper will loose x times the
ratio of equivalent weights of copper and silver.
For Example:

Equivalent weight of copper is 31.75 and that of


silver is 107.88.

The ratio of Copper/Silver is 0.294

So, if silver looses 5gm then by the same amount


of current copper will loose
5 x 0.294 or 1.47 gm
Earlier it was said that one coulomb of electricity
displaces 0.001118 grams of silver. We can now find out
how many coulombs are required to displace one
equivalent weight of silver or 107.88 grams.

To get that number we simply divide 107.88 by 0.001118


and the answer is 96,493. This number is named
Faraday who discovered this number and is rounded off
to 96,500 coulombs.

This then, may be considered as a unit quantity of


electricity necessary to make a unit change of valence in
any atom. In other words, one faraday will displace one
equivalent weight of any metal.
The equivalent weight of iron being 27.92, the weight of iron
displaced by one Faraday will be 27.92 gm.

A corrosion Engineer feels more comfortable when he speaks


of weight loss of metals in terms of Lbs/Amp-year

Here is how we can convert the above weight loss to Lbs/Amp-


yr

27.92 gm = 0.061 lbs


96500 ampere-seconds = 0.00306 Amp-yr

So the corrosion rate of iron is


0.061 lbs/0.00306 amp-yr = 20.1 lbs/amp-yr
Instead of using the Faradays constant, there is a 2nd
method by which we can determine the corrosion rate
of any metal.

If you recall, the second law states that the corrosion


rates will be in direct proportion to the equivalent
weights. We will now determine the corrosion rate of
silver for example.

Ratio of silver to iron = 107.88/27.92 = 3.865


Corrosion rate of iron = 20.1 lbs/A-yr
Corrosion rate of silver = 20.1 *3.865
=77.7 lbs/amp-yr
Chemical equivalent series (From corrosion
handbook)
Metal Atomic Weight Valence Lbs. Per/ amp/yr
Aluminum 26.97 3 6.48
Copper 63.57 1 45.89
Gold 197.2 1 142.08
Iron 55.84 2 20.12
Lead 207.21 2 74.64
Magnesium 24.32 2 8.76
Silver 107.88 1 77.72
Tin 118.7 2 42.76
Zinc 63.38 2 22.83
Carbon 12.1 4 2.16
CP SYSTEM DESIGNS

Design Considerations
Selection of type of system
Galvanic System
ICCP System
CP Des
Cathodic Protection Design
Considerations
When a pipeline or a terminal facility is built, it represents a
huge capital investment. If we do not safeguard this investment,
we may expect corrosion failures which may result in: -

Loss of product
Loss of production
Damage repair cost
Spillage clean-up costs
Third party damage cost
Possibility of loss of human life
To safe guard the investment against corrosion damage,
coating is used as the primary barrier between the
structures and its environment. But this corrosion
prevention method does not guarantee 100% protection.
On the contrary, this method may accelerate time to
failure of an engineering system if used alone.

This is because coatings cannot be 100% defect free, they


do not provide complete protection coverage. Therefore,
a small percentage of the total surface area that remains
bare will experience concentrated corrosion and may
result in hole-through in a very short period of time. We
therefore must supplement protection by the use of
Cathodic protection
Having decided on installing CP, we need
to select the type of CP System which
should be most cost effective
There are two distinct types of CP systems
available to use each of which has some
advantages and some disadvantages.
These systems are : -
a) Galvanic system
b) Impressed current system (ICCP).
A GALVANIC SYSTEM
REQUIRES: -
Sacrificial Anodes
A conductor connecting the anode to
structure
Minimum Connection Resistance
Test and control Facility
IMPRESSED CURRENT SYSTEM
REQUIRES
Inert Anodes
DC Power Source
AC Power Source if T/R is used
Electrical connection between DC power
source and structure
Electrical connection between DC power
source and anodes
GALVANIC SYSTEM OR ICCP
A corrosion Engineer may select galvanic system if:-
Soil resistivity is reasonably low
Coating resistance is high
Total current demand is low
Otherwise, an ICCP system should be chosen
For estimating current demand, the table shown in the
next slide has proven extremely useful.
APPROPRIATE VALUES OF CURRENT
DENSITY
COATING QUALITY COATING RESISTANCE CD
OHMS/SQFT
(1) mA/sqft
(2)
(3)
Poor 10,000 0.06

Fair to Good 25,000 0.025

Good 50,000 0.0125

Very good 100,000 0.006

Excellent 1,000,000 0.0003

Near Perfect Coating 5,000,000 0.00005


GALVANIC SYSTEM
DESIGN
DESIGN EXAMPLE
Pipe diameter = 12
Pipe length = 5 km
Coating resistance = 50,000 ohm/sqft
Applicable (CD) = 0.0125 mA/sqft.
Soil Resistivity as measured = 1000 ohm-cm
Total surface area (SA) = dL = 51,500 sqft
Total current = CD * SA =650 mA or 0.65A
NUMBER OF ANODES REQUIRED
Life of Mg anode = 0.116*Wt x Eff x Utf/I
If anode weight is 17 lbs then life of one anode
=0.116*17*.5*.85/0.65 = 1.3yr

Number of anodes for 20yr life = 20/1.3 = 15


anodes
Consider installing 3 groups; 5 anodes per
group: Current per group = 0.65/3 = 0.217A
Resistance of a group of vertical anodes is calculated
using the equation:

0.159 p ln 8L 2L
- 1+ ln0.656N
NL d S
p = Soil Resistivity (1000)
N=Number of anodes = 5:
L= Length of anode = 48.3cm (20 inch)
d= Diameter of anode = 16.5cm: (6.5 inch)
S= Spacing = 152.4 cm (5 feet)

GBR = 1.46 ohms


Current output of one anode group is I=E/R

E= 1.75V - 0.9V = 0.85 V


Therefore I= 0.85/1.46 = 0.58A (one group)
Or, 0.58 * 3 = 1.74A (three groups)
Since we need only 0.65 amps, system life will
be shortened unless we use resistor control and
limit the current output to design current value.
(0.217A per group of anodes)
COST ANALYSIS GALVANIC VS ICCP
GALVANIC SYSTEM COST
Cost of 15 anodes = Rs. 100,000
Cost of 3 T/S = Rs. 120,000
Installation cost = Rs. 70,000
Total = Rs. 290,000
ICCP SYSTEM COST
Rectifier cost = Rs. 250,000
Cost of anodes = Rs. 100,000
Cost of materials = Rs. 100,000
Installation cost = Rs. 100,000
Total =Rs. 550,000
TYPICAL INSTALLATION

GRADE LEVEL
CADWELD
CONNECTIONS
GALVANIC ANODE BACKFILL
MG ANODES
75% Gypsum
20% Bentonite
5% Sodium Sulfate

ZINC ANODES
50% Gypsum
50% Bentonite
ADVANTAGE OF BACKFILL
1. It provides uniform environment for the anode
which results in its uniform consumption
2. It decreases anode to earth resistance
3. It retains moisture and thus low anode to earth
resistance is maintained
4. It acts as a depolarizing agent
Advantages of galvanic system
1. Low initial (when current demand is low)
2. uniform current
3. Virtually maintenance free
4. Over protection is minimized
5. Interference is negligible
6. No extra land procurement required
Disadvantages of galvanic system
1. High cost per ampere basis
2. Not adjustable to compensate for
increase in the current demand
3. Not cost effective where current
demand is high
4. May not be effective in soil resistivities
over 5000 ohm-cm
IMPRESSED CURRENT
SYSTEMS
Impressed current systems are of
two different types: -
1. Remote Ground Bed
2. Close Ground Beds

Remote ground bed systems are used for the


protection of long cross country pipelines
Close ground bed systems are used for CP of
congested pipeline systems.
REMOTE
When an anode discharges current it sets up earth gradient field.
How far from anode will this field spread is a function of current
and soil resistivity.
When current is picked up by a pipeline, it also creates earth
gradient field in the vicinity of pipe.
If these two earth gradient fields do not overlap each other, the
anode is said to be electrically remote from the structure being
protected.

GROUND BED
PIPE

VOLTAGE GRADIENT

CURRENT
REMOTE GROUND GROUND BED
BED SYSTEM REMOTE

POS. CABLE

NEG CABLE

VOLTAGE
GRADIENT

ZERO RESISTANCE T/R


EARTH T/R

PIPELINE
ICCP Advantages

1. Can be designed for 20 or more years of


service life
2. Have no soil resistivity restrictions
3. Current demands are not restrictive
4. Cheaper in cost per ampere basis
5. Adjustable to meet increased current
requirement
6. Spread of protection is only limited by
the internal resistance of pipe metal
ICCP Disadvantages

1. High initial cost


2. High maintenance cost
3. High operational cost
4. Can interfere with foreign pipelines
5. Requires land procurement
DESIGN
EXAMPLES
EXAMPLE-1
(NEW FACILITY)
ICCP USING
REMOTE GROUND
BEDS
(20 year design life using ICCP)
Pipe 8 dia. 50 km long
Coating Resistance 10,000 ohm/ft2
Soil resistivity = 5000 ohm-cm
SA = 350,000 ft2
CD = 0.06 mA/ ft2
Total required current = SA x CD =21A
Having calculated the current requirement (21A), we need to
check to see whether or not 50km protection spread will be
achieved. This is done by the use of voltage attenuation
calculation.
With the given perimeters, computerized attenuation
calculation generated the curve shown below
Voltage Attenuation Profile

1.500
Neg.Volts

1.000

0.500
-0.850V min.
0.000
-9E-15 6 11 17 22 28 33 39 44 50
Distance in Km
From the attenuation curve, it is obvious
that using the calculated current, only
25km is protected by installing the CP
system at one end of the line.

SOLUTION
1- Install the CP system at the midpoint of
line or
2- Install two smaller units at each end of
the line
GROUND BED DESIGN
Anode 2 x 60 High silicon chromium (SiCrFe)
cast iron 44 lbs
Anode is packaged in coke filled canister 8 x 84
Consumption rate =1 lb/amp-yr.
Life of a single anode at 10A
= 44 lb/(10A* 1 lbs) = 4.4 yr
Minimum Number of anodes required = 20/4.4
=4.5 say 5 anodes.
Resistance of a group of 5 anodes = 5.4
ohms
Power source min voltage
I * ( Rg +Rs )+Back emf
= 10*5.4+.003+2 = 56 V
Recommended Power Source is 60V
30A
COST COMPARISON ICCP VS GALVANIC

Approximate cost of ICCP


T/R = 800.000 (2 units)
Anodes = 256.000 (10 anodes)
Other material = 100,000 (Test post, wires and cable)
Installation = 200,000
Total =1.356,000
Galvanic System
Number of anodes required to provide 20A for 20 years service life
would be 477.
Cost of anodes = 3,300,000
Cost of 46 T/S = 1,920,000
Installation cost = 200,000
Total Material = 5,420,000
EXAMPLE-2
ICCP SYSTEM FOR AN EXISTING
PIPELINE.

Instead of estimating the current requirement for


protection, the actual required current is determined by
current requirement test. This test will be described later
on.
Rest of the calculations are as shown in the previous
example.
CLOSE OR
DISTRIBUTED
GROUND BED
SYSTEM
EXAMPLE
(NEW FACILITY)
ICCP USING CLOSE
DISTRIBUTED ANODES
For protection of Plant Piping where numerous buried
structures are present close ground bed system is used. This is
because of the shielding effect, a remote ground bed will not be
effective in this situation.

An anode discharging current into the earth develops an


influence area by shifting the potential of earth to more positive
value with respect to remote earth. Protection of pipe is
achieved by adding this shift in potential to the natural
potential of pipe

For example, natural potential of pipe is -500 mV. 2amps


current discharge shift the earth potential 15FT feet from the
anode by 400 mV in the positive direction. The pipe potential
becomes -900mV. Influence area extends 30ft along the pipe
DISTRIBUTED GROUND BED DESIGN REQUIRES
THE FOLLOWING DETERMINATIONS:

1. Soil Resistivity
2. Anode type and maximum allowable current
per anode (2A)
3. Spread of protection per anode determined
by either current drain test or Rudenberg
equation.
0.038 Ip ( y + y 2+ x 2 )
Vx = log10
Pi y x
X = Distance from anode
Vx = Voltage change at distance X
Y = Length of anode
EXAMPLE
Two lines in parallel. Length 600 feet. Soil 500 ohm-cm
Spread of protection from one anode as per
Rudenberg Equation=15+15 =30 ft
Ground Bed Gradient
1000
900
800
Millivolts

700
600
500
400
300
200
100
0
1
7
12
18
23
29
34
40
45
51
Distance from Ground Bed (feet)

30 feet

15 ft
15 ft 15 ft 15 ft
Total number of anodes = 600/30 = 20
Total current = 40A
Resistance of one anode in 500 ohm-cm soil = 1.5 ohm
Cable resistance to farthest anode = 0.15 ohm
Total Resistance of one anode = 1.65 ohm
Power Source rating = E=RI+ back emf (2V) = 3.3V
Recommended power source rating = 5V-60A min.
Life of each anode weighing 44 lbs with consumption
rate of 1 lbs per amp-yr = 22 years
SUMMARY
Corrosion control is essential to the efficient long-term
performance of capitalized infrastructure in the oil and
gas industry. Once a corrosion control program is
undertaken, the economic benefits become apparent.
Elimination of many pipeline failures and corrosion
related equipment failures reduce maintenance costs,
and ensures un-interrupted product delivery to the
customer. Basic survey techniques and methods to
identify and mitigate the corrosion processes in the oil
and gas industry is presented in the technician level
section that follows
END OF ADVANCE LEVEL
TecLev
The importance of regular monitoring cannot be over
emphasized. Often, once a cathodic protection
system has been designed and constructed, owners
begin to believe that their troubles are over. System
designer usually provides an operating manual
giving certain guidelines for monitoring and unless
the persons responsible for monitoring are not
sufficiently trained, the results can be drastic.
An oil producing company in Northern Pakistan began
experiencing corrosion problems on a facility only 5
years old. Potentials had routinely been monitored by
in-house electricians and reported each month to the
engineering manager who felt relieved by simply
viewing the results, which seemingly had always met the
minimum criterion of protection. It was only after leaks
had begun to spring that the company called in a CP
consultant who found that 90% of the buried pipelines
were inadequately protected. Excessive soil IR drops
and the influence of ground bed gradients had mostly
been responsible for producing erroneous data falsely
indicating adequate protection.
Ideally every foot on the structure should be
monitored. This however, is not practical.
Therefore, only locations where CP test
station exist or where the structure is
physically accessible are monitored
routinely.
CIPS is recommended once each year
Recognize factors which can affect the
validity of the monitored data.
1. Half-cell to earth contact resistance
2. Meter negative to structure contact
resistance
3. Half-cell near a ground bed
4. Half-cell over another protected line
5. Stability of half-cell
COPPER SULFATE REFERENCE ELECTRODE
ELECTROLYTE
Decrease in concentration
Contamination
TEMPERATURE effect
Positive shift of 0.9mV/deg C (0.5mv/deg F)
Example

At 40 deg C -860mV measured = 842 at 20 deg C


LIGHT
Shift of -50 mV have been observed from shaded to bright sun
shining on the reference electrodes transparent window
Crite

Criteria of Protection
When a steel structure is placed under cathodic
protection there must be some means to verify
the adequacy of protection afforded.

NACE standard RP0169 has established three


different criteria which are.
Minimum Limit

1) 100mV Polarization
2) 850 mV PSP with CP current interrupted
3) 850 mV PSP with CP current applied (not
reliable in high resistivity soils)
Generally practiced maximum limit
Maximum Limit (Ferrous metals)
NACE has not specified any maximum PSP value
Different schools of thoughts exist on current-off potential
limits

Maximum Limit (Amphpoteric Metals)


-100mV Shit
Al = 1150mV
Pb = 450mV
Equip

Basic Equipment Used in routing CP


monitoring
1- High impedance DC volt meter

2- Saturated Copper/Copper Sulfate Electrode

3- Clamp-on-Ammeter
A TYPICAL VOLTMETER

L.C. Display
Various Function
0.005
Buttons

Selector Switch

AMPS

A mA - + Positive Terminal

Common Terminal
Tong Tester for current measurement
The important requirement of the meter
is its high input impedance. When
potential measurements are made, some
amount of current flows through the
internal circuit of the meter causing
internal IR drop error.
Because of this error, the measured value
is less than the actual value.
EXAMPLE-1 VM

Meter internal resistance: 100 ohm/V B C


If the external resistance is 5 ohms then the
Correction factor = 100+5/100 = 1.05
D
Suppose actual PSP = 850mV A
Meter will read 850/1.05 = 810
EXAMPLE-2
Meter internal resistance: 10 meg-ohm/V
External resistance is same as in example-1
Correction factor = 10,000,000+5/10,000,000 = 1.000001
Meter will read 850/1.000001 = 850
REFERENCE
CELL
A reference electrode is a stable half-cell,
which is used to measure the potential of
other electrodes (a buried pipeline for
instance). The desirable properties of a
standard reference electrode are: -

Easily maintainable
Easy to use in field work and/or
laboratory work
Does not polarize when measuring
potential of another electrode
Resists contamination when in use
Portability
A TYPICAL REFERENCE ELECTRODE

The most
commonly used
reference
electrode is the
copper sulfate
half-cell
CARE OF INSTRUMENTS
VOLTMETER
Before use, check accuracy by comparing against a
known good instrument or a standard voltage cell.

CLAMP-ON-AMMETER
Compare instrument against a suitable shunt.

IF IN ERROR
Calibrate
HALF-CELL:The half-cell
should be checked for accuracy
prior to commencing each
survey.
This is done simply by
comparing the half-cell in use
against an unused (new) half-
cell.
HALF=CELL CALIBRATION METHOD

A mA - +

+ -

FIELD HALF CELL SHOP HALF CELL


If the field half-cell is found to be in
error (5 mV or more +/-) then: -
Dump out the solution
Clean copper rod using sand paper
Refill half-cell tube with fresh saturated copper
sulfate solution.
Re-check field half-cell against shop half-cell
If still in error, change the porous wooden plug
The frequency of monitoring
differs with each pipeline or
plant operator. Monitoring is
categorized as: -

1.Routine Monitoring
2.Detailed Monitoring
ROUTINE MONITORING
Frequency 1 to 3 months

1. Ground beds/DC Power Sources


2. PSP at all test posts
3. Isolation Joints
DETAILED MONITORING

1. All items routinely done


2. DC Power Source Efficiency
3. Interference testing
4. CIPS with current interruption
GROUND
BEDS
Monitoring & data
management
TYPICAL ANODE CABLE JUNCTION BOX
GROUNDBED DATA
MANAGEMENT
ANODE SHUNT I/mV mV DROP CURRENT
NO RATING ACROSS AMPS
SHUNT

1 50mV-10A 0.2 5.O 1.00

2 50mV-10A 0.2 4.6 0.92

3 50mV-10A 0.2 4.4 0.88

4 50mV-10A 0.2 4.7 0.94

5 50mV-10A 0.2 4.3 0.86

6 50mV-10A 0.2 5.O 1.00


GROUND BED OPERATING RECORD

YEAR GB T/R VOLTAGE CIRCUIT


CURRENT AVERAGE RESISTANCE
AVERAGE (E) (E/I)
(I)
1 5 3 0.6

2 5 3 0.6

3 5.5 4 0.7

4 5.5 4 0.7

5 5.5 4 0.7

6 6 5 0.8

7 6 6 1.0

8 6 8 1.3

9 6 10 2.2
GB Resistance plot

5.0
RESISTANCE

6.6 TIMES THE


4.0 INITIAL RESISTANCE
OHMS

3.0

2.0

1.0

0.0
1 2 3 4 5 6 7 8 9 10

TIME IN YEARS
TRANSFORMER/RECTIFIERS
(T/R)
Monitoring and data management
ELECTRICAL MEASUREMENTS
1. DC Current & Voltage (Panel meter)
2. DC Current across shunt & Voltage across
terminals
3. AC Voltage (Circuit Breaker)
4. AC Current at Circuit Breaker
PHYSICAL CHECK OF T/R
1. T/R case temperature
2. DC terminal temperature & Tightness
3. Earth connection tightness
4. Silica Gel Condition (Color)
5. Oil level & condition
6. General condition (dusty or clean)
UNIT NO------- LOCATION-----------------------------------------
STRUCTURE PROTECTED----------------------------------------
DATE-----------

DC OUTPUT 5A -3V
(PANEL METERS)
DC OUTPUT 4.8A 3,2V
(ACTUAL)
AC INPUT 380V 0.3A
(BREAKER)
CASE TEMP NORMAL

TERM. TEMP WARM

ELEC. CONN. TIGHT

SILICA GELL BLUE

EARTH CONN OK

OIL LEVEL OK

CONDITION DUSTY
PSP
Importance of
minimizing IR drop
error
INSTRUMENT

+ -

TEST LEADS

2 1

3
-
1 0.850mV
2 0.900mV
3 0.800mV
STRUCTURE

mV

-930

-935

-939

-964

-1004

ANODE -1109
ACTUAL CASE HISTORY

5V
GRADE LEVEL

3.3V

2.0V

0.9V

SOIL RESISTIVITY = 10,000 OHM-CM


IR FREE PSP
1. Permanent Reference Electrode
2. Current Interruption
3. CP Coupon
Current interruption
requires electronic
switch which can be set
to operate at preset
on/off time cycle
AN OIL PROCESSING PLANT IN
NORTHERN PAKISTAN

INSTANT OFF PSP SURVEY


-m V w r t Cu/CuSO4

1650
1450
1250 Cur r ent On
1050 Instant of f
850
650
450
1 2 3 4 5 6 7 8 9 10

TEST POST NUMBERS


CHART-1
CIPS: INLET UNIT-1
Sh e e t 1 o f 4

1 400
NEG. MILLIVOLTS

1 300 Ar ea satur ated wi th many anodes


1 200
(Cu/Cuso4)

1 1 00
1 000
900 Mi ni mum Pr otecti on
800
Pon
700
Pof f
600
500
400
300
200
1 00 Paved Road
0
0 10 20 30 40 50 60 70 80 90 1 00 110 1 20 1 30 1 40 1 50 1 60 1 70 1 80 1 90 200

DISTANCE IN FEET
IR DROP EXAMPLE
A FERTILIZER PLANT IN SINDH
3500

CURRENT ON
3000 PSP

2500 INSTANT OFF PSP

2000
-m V

1500

1000

MINIMUM LIMIT (850Mv)


500

0
74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
CP TEST POSTS
Permanent reference electrodes are
usually provided at the time of
construction of the facility.
Experience has shown that they are
not as dependable as claimed by the
manufacturers.
Unless annually calibrated, they
cannot be depended upon.
Calibration is simple
PERMANENT CELL CALIBRATION
Turn off all DC Power Sources
Connect one terminal of VM to permacell and the other terminal
to portable reference contacting the earth. Measure the potential
difference. Keep this data along with polarity on records.

Suppose that the permacell is 20mV negative, the PSP with


reference to permacell is -890 the corrected value is:

(-890) + (-20) = -910


CP COUPONS
CP coupon is a piece of metal made
of the same material as the
pipeline.
It is usually 1 square cm to 3
square cm of bare surface area.
It is placed very close to the
pipeline and connected to that
pipeline in a test station with on/off
switch
CP COUPONS
ON/OFF SWITCH

TEST LEADS

GRADE LEVEL

PIPE
REFERENCE

COUPON

CP Coupons are commercially available. They require reference


cell placed close to it
Access tube filled with native soil
ON/OFF
SWITCH

GRADE LEVEL

`
PIPE

COUPON
CP COUPON POTENTIALS

1800

1600
ON
1400 OFF

1200

1000
-mV

800

600

400

200

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
TP NUMBERS
INTERFERENCE
Undesirable flow of
current in a structure
INTERFERENCE ON FOREIGN LINE

FOREIGN LINE

ACCELERATED CORROSION

ARROWS INDICATE
DIRECTION OF
CURRENT FLOW
PROTECTED LINE

GROUNDBED
- +
T/R
INTERFERENCE TESTING
Testing for detection of interference is done
by measurements of on/off potentials on the
foreign line while the protected line T/R is
interrupted.
If interference is present, potential shift on
the foreign line will be towards more negative
values each time current is turned off.
For mitigating
interference RHEOSTAT
0-5 OHM
an
interference
control
bonding
station is
installed.
Foreign line Protected line
Foreign pipeline

BOND ADJUSTMENT
Connect bond with full
Variable resistance of rheostat in
Resistance circuit
Bond
Check off potential on the
Protected foreign line
Pipeline
If interference is still
present, progressively
decrease resistance until
interference is completely
eliminated
SPECIALIZED
SURVEYS
PIPELINE
CURRENT
MEASUREMENT
AT CURRENT DRAIN POINT

T/R CURRENT = 10A


T/R IR BETWEEN 1 & 2= 5mV
IR BETWEEN 3 & 2=7mV
CURRENT 1to2 =5*10/12=4.2A
3-WIRE TS CURRENT 3to2 =7*10/12=5.8A

1 3

200 feet 200 feet


ANYWHERE ALONG THE LINE
SHUNT
12V
BATTERY

ON/OFF
SWITCH

mV

200 FEET

1-Measure mV between inner leads. Record value indicating polarity + or shown on the
meter
2- Energize current say 20 amps
3- Measure mV again between inner leads
4- Calculate delta mV and and determine span current per mV
5- Multiply span length by current per mV to obtain current flowing through span.
CALCULATION EXAMPLE
mV at zero current applied = 5mV with meter polarity
minus (mV1)
mV at 3 amp current applied = 2 mV with meter polarity
plus (mV2)
The resultant change is( mV1) (mV2) =( -5) (+2) =
7mV due to 3amp current
Current per mV=3/7= 0.43 amps
Span length is 200 feet and resultant change=7mV
Therefore the current flowing through 200 ft span is
200 * 0.43A = 86A
GROUND BED
RESISTANCE
TEST
GROUND BED CURRENT (I) = 50A
CURRENT ON mV = 7.5 R=E/1 = .005/50=0.1
INSTANT OFF mV = 2.5 OHMS

mV () = 7.5 2.5 =5mV or 0.005V (E)

mV

ANODE CABLE JB

REMOTE HALF-CELL

GROUND BED
PIPELINE COATING RESISTANCE
Almost all of the resistance of pipe to earth is
the coating resistance.
Therefore, the procedure for measuring the
coating resistance is identical to the previously
described procedure for ground bed
resistance

R=E/I REMOTE HALF-CELL

PIPELINE mV
CLOSE
INTER PSP
SURVEY
1. PROVIDES DETAILED
STATUS OF
PROTECTION
2. LOCATES COATING
DEFECTS
CIPS: FLOWLINE D6 SS
SHEET 1 OPF 2
SURVEY FROM WELL HEAD TO FENCE VALVE
1200

1100

1000
TEST STATION
M ILLIV OLTS

900

850
800

700
WELL HEAD TOWARDS
FENCE VALVE
600
0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210
DISTANCE IN FEET
SOIL
RESISTIVITY
SURVEYS
1. DC CURRENT METHOD
2. AC CURRENT METHOD
E1 = Current Off E2 = Current On
E = E2 - E1
R = E I
DC
S = Pin separation in feet METHOD
ohm-cm= 191.5 * R * S
P1 P2

AC C1 C2

SOIL RESISTIVITY
METER

METHOD

For S in cm R = Dial reading * multiplier


S = Pin separation in feet
=2RS ohm-cm= 191.5 * R * S
Spacing Multiplier
5-2. 5 1000
7-10 1500
10-5 2000
15-8 3000
20-11 4000

p= R * Multiplier
P1 P2

C1 C2

SOIL RESISTIVITY
METER

SOIL BOX
SOIL RESISTIVITY CLASSIFICATION

Resistivity Range Corrosion Intensity


Ohm-cm
<500 Aggressive
500 - 1000 Corrosive
1000 - 2000 Moderately
Corrosive
2000 - 10000 Mildly Corrosive
>10000 Negligible
TROUBLESHOOTING
IMPRESSED CURRENT SYSTEM

There are only two main things that can go


wrong in the system. These are (with AC power
switched on) : -
1- There is no DC voltage and no DC current
2- There is DC voltage but no DC current
In the first case check the AC fuses and circuit
breaker.If all OK then the fault is internal and
Electrical Maintenance Department should be
referred to.
In the second case, any one of the
following can be the cause of
failure: -
1. Main anode cable has failed
2. Main cathode cable has failed
3. Under ground anodes have failed
4. Cable connection to pipeline has failed
TYPICAL CP CIRCUIT

V A
T/R OUTPUT
T/R
+ - 50V 0A AJB
C
A B

D
NJB

PIPE
ANODES
MAIN ANODE CABLE
FAILURE
V A
T/R OUTPUT
T/R
+ - 50V 0A AJB
A B C

A TO GROUND 50v

<1v
D C TO GROUND
NJB

PIPE
ANODES
GROUND BED
FAILURE
V A
T/R OUTPUT
T/R
+ - 50V 0A AJB
B C
A

A TO GROUND 50V

C TO GROUND 50V
1V
D B TO GROUND
NJB D TO GROUND 1V

PIPE
ANODES
MAIN NEGATIVE CABLE
FAILURE
V A
T/R OUTPUT
T/R
+ - 50V 0A AJB
C
A B

B TO GROUND 50V

D TO GROUND <1V

D
NJB

PIPE
ANODES
CABLE CONNECTION
TO PIPE HAS FAILED
V A
T/R OUTPUT
T/R
+ - 50V 0A AJB
C
A B

B TO GROUND 50V

D TO GROUND 50V

D
NJB

PIPE
ANODES
Possibility often exists that even the best equipment may fail to
detect cable breaks accurately. For instance, if a buried cable
runs parallel to a pipeline or other buried cables for that matter,
the signal strength received will not drop appreciably even when
the operator reaches the fault area. If this happens, the location of
cable break can only be narrowed down by digging test holes as
shown in figure below

VM
TR
JB
A GRADE LEVEL
C
B CABLE
Fault (if V=<1V)
Fault if V=V at T/R
ISOLATING
JONTS
To determine effectiveness of joint
isolation
1. Shutdown CP Power source
2. Measure Potential on both sides of the joint
and record
3. Turn CP back on
4. Measure potentials again on both sides and
record
1. If the change in potentials on the unprotected side
equals the change in potentials on the protected side,
then the isolation is 100% defective.

CURRENT SIDE A SIDE B CONDITION


`
OFF 660 500

CURRENT 900 500 EFFECTIVE


ON
CURRENT 900 690 PARTIAL DEFECT
ON
CURRENT 900 900 DEAD SHORT
ON

VM

PROTECTED SIDE (A) UNPROTECTED SIDE (B)

A B
For a partially defective isolation, percentage of defect may be
estimated by the following equation.

%defect = E(unprotected side) * 100 E(protected side)

Example

Side A: POFF = 600 & PON = 900 then E =300


Side B: POFF = 500 & PON = 690 then E =190

% defect = 190 x 100 / 300 = 63.33%

Replacement of insulating kit is recommended when defect is


25% or more or the current loss is significant
A second test method is the use of
an instrument specially designed
for testing isolation joints.
Simply connect leads from the
two terminals provided to both
sides of the isolation joint.
A strong signal indicates good
isolation while weak signal is an
indication of defective isolation.
THE END

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